THE TYPES OF MAINTENANCE


what they are & when to use them

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Preventive Corrective
Maintenance Maintenance
vs
before a failure after a failure
has occurred has occurred

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 The Types of Maintenance
Maintenance

Preventive Corrective
Maintenance Maintenance

Time Condition Risk

Failure Finding Predictive Deferred Emergency
Based Based Based

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“9 Types of Maintenance”
Time Based Maintenance
Considered Preventive Maintenance

Task Type Scheduled Overhaul / Replacement

Objective Restore or replace regardless of condition

Fixed time or usage interval

Interval
e.g. 1 month, 1,000hrs or 10,000 km

When to use Age related failure modes, compliance tasks

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Failure Finding Maintenance
Considered Preventive Maintenance

Task Type Functional Test

Objective Determine if hidden failure has occurred

Fixed time interval

Interval
(can be set based on risk assessment e.g. SIL)\

When to use Protective functions, hidden failure modes

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Condition Based Maintenance
Considered Preventive Maintenance

Task Type Measurement of condition

Restore or replace based on a measured condition

Objective
compared to a defined standard

Interval Fixed interval between condition assessments

Random failure modes

When to use
(i.e. those with constant probability of failure)

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 The P-F Curve

P = change in condition or performance

detected
smooth
running
further
degradation
Functional Performance

impending
failure
F = functional
failure

limited
functionality
PF Interval = lead time to failure

Time

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“9 Types of Maintenance”
Predictive Maintenance
Considered Preventive Maintenance

Task Type Calculation and extrapolation of parameters

Objective Determine if failure is imminent and intervention is required

Continuous online monitoring of parameters, intervention as

Interval
required

When to use Well understood failure modes with significant consequences

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Risk Based Maintenance
Considered Preventive Maintenance

Task Type Inspection or Test

Determine condition, conduct risk assessment and establish

Objective
when next inspection, test or intervention is required

Time based interval between tasks and scope of task is

Interval
based on risk assessment

Often used for pressurised equipment (vessels, piping etc.)

When to use
and can be used for pressure relief valves

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Deferred Maintenance
Considered Corrective Maintenance

Task Type Repair / Replace

Restore or replace following failure. Result of a Run to Failure

Objective
Strategy or an unplanned failure.

Not applicable, but intervention is deferred to allow for proper

Interval
planning & scheduling.

When to use As part of a Run-to-failure strategy

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Emergency Maintenance
Considered Corrective Maintenance

Task Type Repair / Replace

Objective Restore or replace following unplanned failure.

Immediate intervention required, breaks into the Frozen

Interval
Weekly Schedule

When to use Avoid

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 Comparison of Maintenance Types
Preventive Maintenance Corrective Maintenance

Maintenance Type Time Risk

Failure Finding Condition Based Predictive Deferred Emergency
Based Based
Maintenance Maintenance Maintenance Maintenance Maintenance
Maintenance Maintenance

Scheduled Calculation and

Measurement of Repair / Replace
Task Type Overhaul / Functional Test extrapolation of Inspection or Test Repair / Replace
condition
Replacement parameters

Determine
Restore or replace condition and Restore or replace
based on a Determine if failure conduct risk following failure. Restore or replace
Restore or replace Determine if measured is imminent and assessment to Result of a Run to following
Objective regardless of hidden failure has condition intervention is determine when Failure Strategy or unplanned failure.
condition occurred compared to a required next inspection, an unplanned
defined standard test or intervention failure.
is required.

Continuous online Time based Not applicable, but

Fixed time or Fixed time interval Fixed time interval monitoring of interval between intervention is Immediate
usage interval e.g. (can be set based for condition
Interval parameters, tasks and scope of deferred to allow intervention
1 month, 1,000hrs on risk assessment measurements / intervention as task is based on for proper planning required.
or 10,000 km e.g. SIL) inspections required risk assessment & scheduling.

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“9 Types of Maintenance”
 And what about

Planned vs Unplanned Maintenance?

or

Proactive vs Reactive Maintenance?

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Planned vs Unplanned Maintenance

This is all about whether you have

planned, i.e. properly prepared,
your maintenance such that
you can execute it efficiently.

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Planned Unplanned
Maintenance Maintenance
vs
Work that has been prepared Work that is executed
in advance by a planner. without advance preparation.

All preventive maintenance This should only be the most

should be planned maintenance urgent corrective maintenance
i.e. emergency maintenance.
Almost all of your corrective
maintenance should be planned Emergency maintenance
maintenance. should be < 2% of total
maintenance workload.

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Reactive vs Proactive Maintenance

This is really a differentiation

in maintenance culture.
Are you chasing failures
or continuously improving?

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Proactive Reactive
Maintenance Maintenance
vs
A maintenance culture that is A maintenance culture that is
focused on continuously dominated by failures.
improving.
The organisation is caught in a
Preventive maintenance is vicious cycle of equipment
executed on time. breakdowns.

Defects when detected are Firefighting is the norm. There is

eliminated. Improvements are no time for improvement.
made by all.

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