Maintenance and Installation of Machinery

(Meng 5231)

Chapter One
Introduction

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 OBJECTIVES

 At the end of this chapter the student will be able to:

– Define maintenance.
– Identify the terms of maintenance.
– Describe the main objective of maintenance.
– Identify types of maintenance.

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 Class activity
What is maintenance?

Why is maintenance ?

When is maintenance?

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 MAINTENANCE

 The term maintenance covers all activities undertaken

to keep equipment in a particular condition

 The term ‘Maintenance’ means to keep the equipment

in operational condition or repair it to its operational
mode.
 maintenance is a set of organised activities that are
carried out in order to keep an item in its best
operational condition with minimum cost acquired

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 MAINTENANCE TERMS AND DEFINITIONS

• Maintenance:
 All actions appropriate for retaining an
item/part/equipment in, or restoring it to, a given
condition
• Reliability:
 The probability that an item will perform its stated
function satisfactorily for the desired period when
used per the specified conditions.
• Maintainability:
 The probability that a failed item will be restored to
adequately working condition.
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 MAINTENANCE TERMS AND DEFINITIONS

• Overhaul:
 A comprehensive inspection and restoration
of an item or a piece of equipment to an
acceptable level at a durability time or usage
limit.
• Inspection:
 The qualitative observation of an item’s
performance or condition

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 OBJECTIVES OF MAINTENANCE

• The main objectives of maintenance are:

– To maximize the availability of plant, equipment
for productive utilization.
– To extend the lifespan of plant/equipment by
minimizing their wear and tear deterioration.
– To reduce the cost of lost production due to break
down.
– To ensure safety of personnel.
– To provide information on the cost and
effectiveness of maintenance.
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 Classification of Maintenance

Maintenance

Corrective Preventive
Maintenance Maintenance

Unplanned Planned
Indirect PM Direct PM

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 1.CORRECTIVE MAINTENANCE (CM)

 In this type, actions such as repair, replacement, or

restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.

 Corrective maintenance implies that repairs are

made after the equipment is failed or can not
perform its normal function anymore.

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 1.CORRECTIVE MAINTENANCE (CM)

 This type of maintenance is subdivided into three

types:
A. Remedial maintenance, which is a set of activities
that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.
 The way to carry out this type of corrective
maintenance is by taking the item to be corrected
out of the production line and replacing it with
reconditioned item

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 1.CORRECTIVE MAINTENANCE (CM)

B. Deferred maintenance, which is a set of corrective

maintenance activities that are not immediately initiated
after the occurrence of a failure but are delayed in such
a way that will not affect the production process.
C. Shutdown corrective maintenance, which is a set of
corrective maintenance activities that are performed
when the production line is in total stoppage situation

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• Corrective maintenance has several prerequisites in
order to be carried out effectively:

1. Accurate identification of incipient problems.

2. Effective planning which depends on the skills of the
planners, the availability of well developed
maintenance database about standard time to repair, a
complete repair procedures, and the required labour
skills, specific tools, parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair

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 Disadvantages of Corrective Maintenance

Breakdown generally occurs inappropriate times

leading to poor and hurried maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for
both workers and machines
Direct loss of profit
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 2.PREVENTIVE MAINTENANCE (PM)
 Preventive maintenance is the maintenance carried
out at predetermined intervals or according to
prescribed criteria and intended to reduce the
probability of failure or the degradation of the
functioning and the effects limited.

 It is a set of activities that are performed on plant

equipment, machinery, and systems before the
occurrence of a failure in order to protect them and
to prevent or eliminate any degradation in their
operating conditions.

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 It is good for those machines and facilities
which their failure would cause serious
production losses.

 Its aim is to maintain machines and facilities in

such a condition that breakdowns and
emergency repairs are minimised.

 Its activities include replacements,

adjustments, major overhauls, inspections
and lubrications.

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 Researchers subdivided preventive maintenance into
different kinds according to the nature of its activities:

 Routine maintenance which includes those

maintenance activities that are repetitive and
periodic in nature such as lubrication,
cleaning, and small adjustment.
 Running maintenance which includes those
maintenance activities that are carried out
while the machine or equipment is running
and they represent those activities that are
performed before the actual preventive
maintenance activities take place. 17
 Opportunity maintenance which is a set of
maintenance activities that are performed on a machine
or a facility when an unplanned opportunity exists
during the period of performing planned maintenance
activities to other machines or facilities.
 Window maintenance which is a set of activities that
are carried out when a machine or equipment is not
required for a definite period of time.
 Shutdown preventive maintenance, which is a set of
preventive maintenance activities that are carried out
when the production line is in total stoppage situation.
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 Lack of preventive maintenance leads to a large demand for:

1. Many forced stoppages (Non-planned)

2. Long time for fault detection
3. The machines are not working properly
4. Has a negative effect on product quality
5. Contributes towards impaired working environment
6. Creates safety risks
7. Reduces the return on capital
8. Increasing maintenance costs
9. Lowering the productivity, both directly and indirectly
10. Remedial maintenance

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 PREVENTIVE MAINTENANCE

• Prevent the need for corrective maintenance from

occurring (maintenance prevention);
• Identify the need for corrective maintenance early, so that
planning and scheduling of corrective maintenance can be
done
• Detailed cleaning of components
• Lubrication
• Accurate balancing and alignment of equipment
• Good operations practices of process and equipment
• Painting programs and other measures to prevent
corrosion and additional damages to equipment and
building structures.
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Thank you

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