1-1 Corrective, Preventive, Predictive

MAINTENANCE MANAGEMENT
MODELS
ING. ORLANDO DIAZ PARRA
2016
Aplicable Models
CORRECTIVE MAINTENANCE. MC
They are actions to regain normal function of the equipment
PREVENTIVE MAINTENANCE.. MP
It is a philosophy to maintain equipment in optimum condition.
PREDICTIVE MAINTENANCE MPd
Uses technology to maintain.
TOTAL PRODUCTIVE MAI NTENANCE TPM
It is a maintenance strategy and a philosophy for life.
RELIABILITY CENTERED MAINTENANCERCM
It is a demanding strategy to equipment of last generation.
PROACTIVE MAINTENANCE
It requires the participation of everyone in the group from the designer, to the
operator.
CORRECTIVE MAINTENANCE
Consists of allowing an equipment to run to the point where it can not

play its role.
Presented the fault, the fault is corrected and returned to wait for
another failure occurs.
As a philosophy applicable to all plant equipment causes great losses to

not take into account production costs generated by the sudden
stoppage of the equipment, called "dead time"
Carry equipment to failure requires a thorough knowledge of this to

make an accurate and rapid diagnosis of the causes.
This gives rise to maintenance COWBOY.
The COWBOY maintenance in each
company was a typical magician who

solved all machine breakdowns,
without involving the operator in
the solution and without seeking the

real cause of the fault.
C-2
Corrective maintenance has some justification, so that is noticeable in

plants where the number of teams, after an analysis of critical
equipment, some may be selected to make corrective maintenance,
that is take them to failure.
The equipment is not part of a line or critical

point in the process
The machine not cause serious disruption to
production or maintenance.
The equipment is in a state of obsolescence
or disused.
The equipment has twin or redundant. (The
machine is in standby must be the most
reliable).
It's easy replacement by a new equipment for
cost and time.
C-3
Indifference or refusal to recognize the benefits of better management of
maintenance lead some companies to adopt, by default, this type of maintenance
since it is the one that requires less knowledge and organization with costly
consequences and unrewarding, as:
It requires more staff for maintenance activities.

continuous and prolonged shutdowns that threaten the production.
lost profits higher amounts.
Discomfort in personal conflict between production and maintenance.
Teams can be irreparably damaged.
It is difficult to talk about quality in maintenance management.
the appearance of people who believe themselves indispensable to the
maintenance operation is encouraged.
Maintenance activities can not be properly controlled and sometimes
operation only makes a report of "stop machine "
is not made no analysis of the causes of the shutdown or damage
The stop may cause damages environmental or human resource involvement
of unpredictable dimensions.
Take any other maintenance strategy, for good, organized and innovative that it is, does
not eliminate that failures and unplanned shutdowns occur, therefore, for the prompt
attention of these arrests are required::
A team specialized for quick and successful attention fault with knowledge of the
different types of equipment in the plant,
Proper management of this group, to coordinate and decide according to prioritize

the completion of work and study, analyze and determine the procedures and more
efficient working methods,
Good information and communication between the operating personnel and

maintenance for which are required to maintain ongoing training programs and staff
training,
Adequate provision of appropriate tools and equipment for repair personnel can
effectively play its role and
An adequate supply of spare parts and spare parts.
PREVENTIVE MAINTENANCE
Is the maintenance that runs the plant equipment in a planned and

scheduled in advance, based on periodic inspections duly established by
the nature of each machine and aimed at identifying possible defects that
may cause unscheduled stoppages or major damage affecting life useful of
the machines .
a good PM program is the heart of effective maintenance can prevent

equipment failures occur at a bad time because it can take a census
when the fault is about to occur and fix it before it causes damage.
PM inappropriate program can cause problems: whenever a team is
intervened is exposed to potential harm and is too expensive to
replace components prematurely.
They are advantages of PM:
The PM can plan ahead proactively, so that workloads can be

programmed.
Given the decline of unplanned downtime, overtime for

maintenance personnel can be reduced.
The demand for human and material resources can be adjusted

to what is strictly necessary.
By reducing intervention times, there is more time for

production and relations between staff are improved.
Due to the repetitive nature of PM procedures can be

improved and fine-tuned skills decreasing intervention times.
It can assure the existence of parts in stock, if the intervention

is anticipated replacement.
It can better ensure staff safety and detection of pollution

problems (sawtooth).
They are disadvantages of PM:

When you run a PM plan the following potential problems should be recognized and
minimized
Whenever you involved in a team there is a potential risk of failure through negligence,
ignorance, abuse or improper procedure.
New parts and consumables are more likely to be defective to those already in use
(probability of failure).
Parts replacement before failure occurs requires as many items because the life of the
element will end before taking him to the fault .
Initial costs are incurred before an inappropriate analysis that show an increase in the
value of maintenance, however, the medium term are considerably lower costs
incurred.
It requires the involvement of operating personnel to notify the PM potential failures.
PHILOSOPHY OF PM
TO PREVENT
DETECT THE
BEGINNING
DISCOVER HIDDEN
FAILURE
P-4
The most important elements of the PM are :
The most important element is the inspection whose objectives are

to prevent failures, detect the onset of a fault and discover hidden
faults.
The inspection must take a route which clearly point to inspection sites
and to see possible elements how wear, misalignments, erosions, cracks,
fissures, spills, overheating, etc.
The inspection should have a frequency that can be hourly, daily, weekly,
monthly, etc. depending on the stability, purpose and extent of use of
machinery.
Defined route and frequency of inspection, a format of report for the

report of anomalies is also required of production
Each team must have your resume, in which are indicated among other
things its identification code, its lifetime, reports of anomalies and
interventions.
The results of inspections and according to inspection frequencies,

originate work orders to be executed and whose fulfillment should leave
adequate records.
Depending on the volume of information to process a computer

system that supports and automatically generate work orders and feed
the resumes of each team will be very convenient for the MP.
En una fbrica sin MP:
PRODUCCION
1. Se atrasan los programas
2. Posibilidad de detenerse el proceso
productivo
3. Materia prima puede daarse.
PERSONAL
1. Desmoralizacin y malestar general
del personal
2. Oportunidad de saboteo.
3. Dificulta lograr incentivos.
ALMACEN Y BODEGAS
1. Muchas veces no hay el repuesto
2. Pedidos de emergencia
3. Conflictos al no poder satisfacer un
pedido.
VENTAS
1. No se cumplen entregas.
2. Conflictos con los clientes.
3. Desprestigio de la empresa.
MANTENIMIENTO
1. Personal trabaja bajo excesiva
presin.
2. El trabajo es deficiente.
3. Aumenta la cantidad de personas
involucradas.
4. Ms horas extras.
CONTABILIDAD Y FINANZAS
1. Los costos varan mucho.
2. Con frecuencia se descuadran los
presupuestos.
3. Dificultad para cuantificar los costos.
PREDICTIVE MAINTENANCE
It is the planned and scheduled maintenance according to TREND, STATE

OR CONDITION
This TREND is determined by recording operational variables, using different
technological devices and specialized software.
Vibration analysis
Analysis of used oils, gases and other fluids.
Analysis of current consumption in engines
Thermography
Monitoring process variables: pressure, temperature, concentration, time,
electric sequence, etc.
It is a indispensable part of the planning of maintenance and of the stop

strategies in the modern enterprice, whose more important advantages are:
In the long term it is cheaper, although requiring high initial investments.

substantially reduces glitches, given that the equipment condition is
monitored in real time.
Lowers costs of inspections, as it is known by monitoring the state of
much of the equipment.
Decreases the amount of necessary spare parts and repair time, because
you can make an exact schedule of what has to be involved.
The procedure is performed as a result of a trend analysis and not
fulfilling a period of time or of operation.
lower the cost of insurance of equipment
C-1
PROCESS PREDICTIVE MAINTENANCE

MONITORING
VARIABLES
TREND
ANALYSIS
COMPARISON
WITH
STANDARD
EQUIPMENT
CHECK AND
CONTROL
PLANNING
AND
EXECUTION
DECISION
MAKING
Maintenance is a combination of actions focused to increase the

continuous run of the equipment, extend the life of the equipment,
decrease cost and doing investment more profitable, increase the
productivity and quality of product, with the final purpose of prevent
loss.
Maintenance is, with frequency, the department that more staff employs
and represent until forty per cent of total cost of one company. Not
doubt that maintenance is one of the business areas in which can be
obtained significant increases in the company profits.

1-1 Corrective, Preventive, Predictive

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MAINTENANCE MANAGEMENT

They are actions to regain normal function of the equipment

It is a philosophy to maintain equipment in optimum condition.

PREDICTIVE MAINTENANCE MPd

Uses technology to maintain.

TOTAL PRODUCTIVE MAI NTENANCE TPM

It is a maintenance strategy and a philosophy for life.

RELIABILITY CENTERED MAINTENANCERCM

It is a demanding strategy to equipment of last generation.

Consists of allowing an equipment to run to the point where it can not

As a philosophy applicable to all plant equipment causes great losses to

Carry equipment to failure requires a thorough knowledge of this to

company was a typical magician who

without involving the operator in

the solution and without seeking the

Corrective maintenance has some justification, so that is noticeable in

The equipment is not part of a line or critical

It requires more staff for maintenance activities.

Proper management of this group, to coordinate and decide according to prioritize

Good information and communication between the operating personnel and

An adequate supply of spare parts and spare parts.

Is the maintenance that runs the plant equipment in a planned and

a good PM program is the heart of effective maintenance can prevent

They are advantages of PM:

The PM can plan ahead proactively, so that workloads can be

Given the decline of unplanned downtime, overtime for

The demand for human and material resources can be adjusted

By reducing intervention times, there is more time for

Due to the repetitive nature of PM procedures can be

It can assure the existence of parts in stock, if the intervention

It can better ensure staff safety and detection of pollution

They are disadvantages of PM:

It requires the involvement of operating personnel to notify the PM potential failures.

The most important elements of the PM are :

The most important element is the inspection whose objectives are

Defined route and frequency of inspection, a format of report for the

The results of inspections and according to inspection frequencies,

Depending on the volume of information to process a computer

It is the planned and scheduled maintenance according to TREND, STATE

It is a indispensable part of the planning of maintenance and of the stop

In the long term it is cheaper, although requiring high initial investments.

PROCESS PREDICTIVE MAINTENANCE

Maintenance is a combination of actions focused to increase the

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