Maintenance of Machinery and Installation (Meng5311) : Adama Science and Technology University

Maintenance of Machinery and
Installation (MEng5311)
Adama Science and Technology University
School of Mechanical, Chemical and Materials Engineering
Department of Mechanical Engineering
03/06/2022 Prepared by Biftu H. and Kuba D.

Chapter 1
Introduction
1. Background of Maintenance
2. Objectives of Maintenance and Maintenance Engineering
3. Maintenance Functions
4. Classification Of Maintenance

CHAPTER OBJECTIVES
At the end of this chapter the student will be able to:
 Define maintenance
 Explain the needs of maintenance
 Identify the terms of maintenance
 Describe the main objective of
maintenance
 Discuss about maintenance function

Background
 Maintenance of equipment is still a challenge due to factors such as size,
cost, complexity, and competition
 Effective asset management and maintenance practices that will
positively influence critical success factors such as safety, product
quality, speed of innovation, price, profitability, and reliable delivery.
 Each year billions of dollars are spent on equipment maintenance around
the world
 Maintenance engineering is a discipline that assists in acquisition of
resources needed for maintenance, and provides policies and plans for
the use of resources in performing or accomplishing maintenance
Definition of Maintenance
• Maintenance engineering and maintenance have the same end
objective or goal (ready equipment/item at minimum cost)
• Maintenance:
– All actions appropriate for retaining an item/part/equipment
in, or restoring it to, a given condition.
• Maintenance engineering:
– The activity of equipment/item maintenance that develops
concepts, criteria, and technical requirements in conception
and acquisition phases to be used and maintained in a
current status during the operating phase to assure effective
maintenance support of equipment.
– is an analytical function as well as it is deliberate and
methodical

Maintenance Facts and Figures
 Each year U. S spent over $300 billion for maintenance,
 Approximately 80% of this is spent to correct the chronic failure
of machines, systems, and people.
 Maintenance cost the United Kingdom (UK) was approximately
£3000 million annually.
 The typical size of a plant maintenance group in a manufacturing
organization varied from 5 to 10% of the total operating force.
 The operation and maintenance budget request of the U.S.
Department of Defense for fiscal year 1997 was on the order of
$79 billion.
cont ..
 Annually, the U.S. Department of Defense spends around $12 billion for depot
maintenance of weapon systems and equipment: Navy (59%), Air Force (27%),
Army (13%), and others (1%).
 In 1968, it was estimated that better maintenance practices in the U.K. could have
saved approximately £300 million annually of lost production due to equipment
unavailability.

Maintenance management is the process of overseeing
maintenance resources so that the organization does not
experience downtime from broken equipment or waste money on
inefficient maintenance procedures.
Maintenance management software (MMS) programs can assist

with the process.
The primary objectives of maintenance management are to

schedule work efficiently, control costs and ensure regulatory
compliance.

Terms and definitions used in engineering maintenance
Maintenance:- All appropriate actions for retaining an

item/equipment in, or restoring it to, a given condition.
Maintenance engineering: The activity of equipment/item
maintenance that develops concepts, criteria, and technical
requirements in conceptional and acquisition/gaining phases to be
used and maintained in a current status during the operating phase to
assure effective maintenance support of equipment.
Preventive maintenance: All actions carried out on a planned,
periodic, and specific schedule to keep an` item/equipment in stated
working condition through the process of checking and
reconditioning.

Cont, …
Corrective maintenance: The unscheduled maintenance or repair to

return items/equipment to a defined state and carried out because
maintenance persons or users perceived deficiencies or failures
Predictive maintenance: The use of modern measurement and signal-
processing methods to accurately diagnose item/equipment condition
during operation.
Maintenance concept: A statement of the overall concept of the
item/product specification or policy that controls the type of maintenance
action to be employed for the item under consideration.
Maintenance plan: A document that outlines the management and
technical procedure to be employed to maintain an item; usually describes
facilities, tools, schedules, and resources.
Reliability:
03/06/2022
The probabilityPrepared
that byan item will perform its stated function
Biftu H. and Kuba D.
Cont, …
Maintainability: The probability that a failed item will be restored to

adequately working condition.
Active repair time: The component of downtime when repair persons
are active to effect a repair.
Mean time to repair (MTTR): A figure of merit depending on item
maintainability equal to the mean item repair time. In the case of
exponentially distributed times to repair, MTTR is the reciprocal of the
repair rate.
Overhaul: A comprehensive/complete inspection and restoration of an
item or a piece of equipment to an acceptable level at a durability time or
usage limit.

Cont, …
Quality: The degree to which an item, function, or process

satisfies requirements of customer and user.
Maintenance person: An individual who conducts
preventive maintenance and responds to a user’s service call
to a repair facility, and performs corrective maintenance on
an item. Also called custom engineer, service person,
technician, field engineer, mechanic, repair person, etc.
Inspection: The qualitative observation of an item’s
performance or condition.

Objectives of Maintenance
 Improve maintenance operations,
 Reduce the amount and frequency of maintenance,
 Reduce the effect of complexity,
 Reduce the maintenance skills required,
 Reduce the amount of supply support,
 Establish optimum frequency and extent of preventive maintenance

to be carried out,
 Improve and ensure maximum utilization of maintenance facilities,

and improve the maintenance organization.
 All over the world, industries have various ways to organize
maintenance activities, namely;
planned,
unplanned,
preventive,
corrective, or
predictive maintenance.
 The primary objective is arrived at achieving maximum plant

availability at minimum cost, that is: To prevent breakdown of
equipment,
Cont, …
 To prolong the life span of equipment,

 To restore equipment to acceptable condition with minimum
delay after an eventual breakdown.

Generally, the objectives of maintenance should be
consistent with and subordinate to production goals.
The relation between maintenance objectives and
production goals is reflected in the action of
 keeping production machines and facilities in the best
possible condition.
 Maximising production or increasing facilities
availability at the lowest cost and at the highest quality
and safety standards.
 Reducing breakdowns and emergency shutdowns.
 Optimising resources utilisation.
Prepared by Biftu H. and Kuba D. 03/06/2022

 Reducing downtime.
 Improving spares stock control.
 Improving equipment efficiency and reducing scrap
rate.
 Minimising energy usage.
 Optimising the useful life of equipment.
 Providing reliable cost and budgetary control.
 Identifying and implementing cost reductions.

PLANT
M Reducing Breakdowns
Maximising Production
A
I
Reducing Downtime
Minimising Energy Usage N
T
Optimising Useful Life of E Improving Equipment Efficiency
Equipment N
A
Providing Budgetary Control N Improving Inventory Control
C
Optimising Resource Utilisation E Implementing Cost Reduction
Figure 1: Objectives of Maintenance

Types of Maintenance
 Run to Failure Maintenance (RTF)

 Preventive Maintenance (PM)
 Corrective Maintenance (CM)
 Improvement Maintenance (IM)

 Predictive Maintenance (PdM)
 Reliability Cantered Maintenance (RCM)
 Total Productive Maintenance (TPM)

MAINTENANCE
PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)
EMERGENCY BREAKDOWN
PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE
STATISTICAL - CONDITION - DEFERRED REMEDIAL

ENGINEERING DESIGN - OUT
BASED BASED
SERVICES
Shutdown Maintenance
WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN

NITY PREVENTIVE IMPROVEMENT CORRECTIVE
Figure 2: Types of Maintenance

Run to Failure Maintenance (RTF)
• It is the oldest type of maintenance.
• The required repair, replacement, or restore action

performed on a machine or a facility after the
occurrence of a failure in order to bring this machine
or facility to at least its minimum acceptable
condition.

Cont, …
• It is subdivided into two types:

– Emergency maintenance: it is carried out as fast
as possible in order to bring a failed machine or
facility to a safe and operationally efficient
condition.
– Breakdown maintenance: it is performed after
the occurrence of an advanced considered failure
for which advanced provision has been made in
the form of repair method, spares, materials,
labour and equipment.
Cont, …
• Disadvantages:
1. Its activities are expensive in terms of both direct and

indirect cost.
2. Using this type of maintenance, the occurrence of a failure
in a component can cause failures in other components in
the same equipment, which leads to low production
availability.
3. Its activities are very difficult to plan and schedule in

advance.

Cont, …
• This type of maintenance is useful in the following

situations:
1. The failure of a component in a system is unpredictable.
2. The cost of performing run to failure maintenance activities

is lower than performing other activities of other types of
maintenance.
3. The equipment failure priority is too low in order to include

the activities of preventing it within the planned
maintenance budget.

Preventive Maintenance (PM)
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.
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.
• The advantage of applying preventive maintenance
activities is to satisfy most of maintenance objectives.
Cont, …
The factors that affect the efficiency of this type of maintenance:
1. The need for an adequate number of staff in the maintenance

department in order to perform this type of maintenance.
2. The right choice of production equipment and machinery that
is suitable for the working environment and that can tolerate
the workload of this environment.
3. The required staff qualifications and skills, which can be
gained through training.
4. The support and commitment from executive management to
the PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.

Cont, …
 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.

Cont, …
 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.
 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. 03/06/2022
Prepared by Biftu H. and Kuba D.
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.
In the British Standard 3811:1993 Glossary of terms,

corrective maintenance is defined as
The maintenance carried out after recognition and intended

to put an item into a state in which it can perform a required
function.

Cont, …
This type of maintenance is subdivided into three types:
1. 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 or transferring its workload
to its redundancy.

Cont, …
2. 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.
3. Shutdown corrective maintenance, which is a set of

corrective maintenance activities that are performed
when the production line is in total stoppage situation.

Cont, …
• The main objectives of corrective maintenance are the

maximisation of the effectiveness of all critical plant
systems, the elimination of breakdowns, the elimination of
unnecessary repair, and the reduction of the deviations from
optimum operating conditions.
• The difference between corrective maintenance and

preventive maintenance is that for the corrective
maintenance, the failure should occur before any corrective
action is taken.
• Corrective maintenance is different from run to failure

maintenance in that its activities are planned and regularly
taken out to keep plant’s machines and equipment in
optimum operating condition.
Cont, …
• The way to perform corrective maintenance activities is by

conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.
In the fault elimination step several actions could be taken

such as adjusting, aligning, calibrating, reworking,
removing, replacing or renovation.

Cont, …
• 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.

Improvement Maintenance (IM)
• It aims at reducing or eliminating entirely the need for
maintenance.
• This type of maintenance is subdivided into three types as
follows:
1. Design-out maintenance which is a set of activities that

are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.
Cont, …
2. Engineering services which includes construction and

construction modification, removal and installation, and
rearrangement of facilities.
3. Shutdown improvement maintenance, which is a set of

improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.

Predictive Maintenance (PDM)
 Predictive maintenance is a set of activities that detect changes
in the physical condition of equipment (signs of failure) in
order to carry out the appropriate maintenance work for
maximising the service life of equipment without increasing
the risk of failure.
 It is classified into two kinds according to the methods of

detecting the signs of failure:
 Condition-based predictive maintenance
 Statistical-based predictive maintenance

Cont, …
 Condition-based predictive maintenance depends on

continuous or periodic condition monitoring equipment to
detect the signs of failure.
 Statistical-based predictive maintenance depends on

statistical data from the meticulous recording of the stoppages
of the in-plant items and components in order to develop
models for predicting failures.

Cont, …
 The drawback of predictive maintenance is that it depends

heavily on information and the correct interpretation of the
information.
 Some researchers classified predictive maintenance as a type

of preventive maintenance.
 The main difference between preventive maintenance and

predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to
determine the actual mean time to failure whereas preventive
maintenance depends on industrial average life statistics.
Reliability centered maintenance (RCM)
 Reliability centered maintenance (RCM) is a process to ensure
that systems continue to do what their users require in their
present operating context.
 It is generally used to achieve improvements in fields such as the
establishment of safe minimum levels of maintenance.
 Successful implementation of RCM will lead to increase in cost
effectiveness, reliability, machine uptime, and a greater
understanding of the level of risk that the organization is
managing.
 Reliability centered maintenance is an engineering framework
that enables the definition of a complete maintenance regimen.
 It regards maintenance as the means to maintain the functions a
user may require of machinery in a defined operating context.

Cont, …
 As a discipline it enables machinery stakeholders to monitor,
assess, predict and generally understand the working of their
physical assets.
 This is embodied in the initial part of the RCM process
which is to identify the operating context of the machinery,
and write a Failure Mode Effects and Criticality Analysis
(FMECA).
 The second part of the analysis is to apply the "RCM logic",
which helps determine the appropriate maintenance tasks for
the identified failure modes in the FMECA.
 Once the logic is complete for all elements in the FMECA,
the resulting list of maintenance is "packaged", so that the
periodicities of the tasks are rationalized to be called up in
work packages; it is important not to destroy the applicability
of maintenance in this phase.
Cont, …
 Lastly, RCM is kept live throughout the "in-service" life of
machinery, where the effectiveness of the maintenance is
kept under constant review and adjusted in light of the
experience gained.
 RCM can be used to create a cost-effective maintenance

strategy to address dominant causes of equipment failure. It
is a systematic approach to defining a routine maintenance
program composed of cost-effective tasks that preserve
important functions.

Cont, …
 The important functions (of a piece of equipment) to preserve with
routine maintenance are identified, their dominant failure modes and
causes determined and the consequences of failure ascertained.
 Levels of criticality are assigned to the consequences of failure. Some
functions are not critical and are left to "run to failure" while other
functions must be preserved at all cost.
 Maintenance tasks are selected that address the dominant failure causes.
This process directly addresses maintenance preventable failures.
 Failures caused by unlikely events, non-predictable acts of nature, etc
will usually receive no action provided their risk (combination of severity
and frequency) is trivial (or at least tolerable).When the risk of such
failures is very high, RCM encourages (and sometimes mandates) the
user to consider changing something which will reduce the risk to a
tolerable level.

Cont, …
 The result is a maintenance program that focuses scarce
economic resources on those items that would cause the
most disruption if they were to fail.
 RCM emphasizes the use of Predictive Maintenance

(PdM) techniques in addition to traditional preventive
measures.

Total productive maintenance (TPM)
 Total productive maintenance (TPM) is a system of maintaining

and improving the integrity of production and quality systems
through the machines, equipment, processes, and employees that
add business value to an organization.
 TPM focuses on keeping all equipment in top working condition to

avoid breakdowns and delays in manufacturing processes.
 TPM also focuses on the total Participation of individuals from

top management to shop floor (lower employees).

Cont, …
 One of the main objectives of TPM is to increase the
productivity of plant and equipment with a modest investment in
maintenance.
 Total quality management (TQM) and

total productive maintenance (TPM) are considered as the key
operational activities of the quality management system.
 In order for TPM to be effective, the full support of the total
workforce is required.
 This should result in accomplishing the goal of TPM: "Enhance

the volume of the production, employee morale and job
satisfaction."

Cont, …
 The main objective of TPM is to increase the
Overall Equipment Effectiveness (OEE) of plant equipment.
 TPM addresses the causes for accelerated deterioration while creating
the correct environment between operators and equipment to create
ownership.
 OEE has three factors which are multiplied to give one measure called
OEE:
OEE = Performance * Availability * Quality
 Each factor has two associated losses making 6 in total, these 6 losses
are as follows:
Performance = (1) running at reduced speed - (2) Minor Stops
Availability = (3) Breakdowns - (4) Product changeover
Quality = (5) Startup rejects - (6) Running rejects
 The objective finally is to identify then prioritize and eliminate the
causes of the losses. This is done by self-managing teams that problem
solve. Employing consultants to create this culture is common practice.
 The eight pillars of TPM are mostly focused on proactive and
preventative techniques for improving equipment reliability:
1. PROCESS AND MACHINE Improvement
2. Autonomous maintenance
3. Preventive/Planned Maintenance
4. Process Quality maintenance
5. Cost Deployment/ administrative work
6. Early Management of new Equipment
7. Training and Education
8. Safety sustain success and Health Environment

Figure 3: Pillars of TPM

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Maintenance of Machinery and

Department of Mechanical Engineering

03/06/2022 Prepared by Biftu H. and Kuba D.

03/06/2022 Prepared by Biftu H. and Kuba D.

03/06/2022 Prepared by Biftu H. and Kuba D.

03/06/2022 Prepared by Biftu H. and Kuba D.

03/06/2022 Prepared by Biftu H. and Kuba D.

Maintenance management software (MMS) programs can assist

The primary objectives of maintenance management are to

03/06/2022 Prepared by Biftu H. and Kuba D.

Maintenance:- All appropriate actions for retaining an

03/06/2022 Prepared by Biftu H. and Kuba D.

Corrective maintenance: The unscheduled maintenance or repair to

Maintainability: The probability that a failed item will be restored to

03/06/2022 Prepared by Biftu H. and Kuba D.

Quality: The degree to which an item, function, or process

03/06/2022 Prepared by Biftu H. and Kuba D.

 Reduce the amount and frequency of maintenance,

 Reduce the effect of complexity,

 Reduce the maintenance skills required,

 Reduce the amount of supply support,

 Establish optimum frequency and extent of preventive maintenance

 Improve and ensure maximum utilization of maintenance facilities,

 The primary objective is arrived at achieving maximum plant

 To prolong the life span of equipment,

03/06/2022 Prepared by Biftu H. and Kuba D.

Prepared by Biftu H. and Kuba D. 03/06/2022

Prepared by Biftu H. and Kuba D. 03/06/2022

Figure 1: Objectives of Maintenance

Prepared by Biftu H. and Kuba D. 03/06/2022

 Run to Failure Maintenance (RTF)

 Improvement Maintenance (IM)

 Total Productive Maintenance (TPM)

Prepared by Biftu H. and Kuba D. 03/06/2022

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

STATISTICAL - CONDITION - DEFERRED REMEDIAL

WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN

Figure 2: Types of Maintenance

• It is the oldest type of maintenance.

• The required repair, replacement, or restore action

Prepared by Biftu H. and Kuba D. 03/06/2022

• It is subdivided into two types:

1. Its activities are expensive in terms of both direct and

3. Its activities are very difficult to plan and schedule in

Prepared by Biftu H. and Kuba D. 03/06/2022

• This type of maintenance is useful in the following

1. The failure of a component in a system is unpredictable.

2. The cost of performing run to failure maintenance activities

3. The equipment failure priority is too low in order to include

Prepared by Biftu H. and Kuba D. 03/06/2022

The factors that affect the efficiency of this type of maintenance:

1. The need for an adequate number of staff in the maintenance

Prepared by Biftu H. and Kuba D. 03/06/2022

 It is good for those machines and facilities which

 Its aim is to maintain machines and facilities in such a

 Its activities include replacements, adjustments,

Prepared by Biftu H. and Kuba D. 03/06/2022

In the British Standard 3811:1993 Glossary of terms,

The maintenance carried out after recognition and intended

Prepared by Biftu H. and Kuba D. 03/06/2022

1. Remedial maintenance, which is a set of activities that

interrupting the continuity of the production process.

The way to carry out this type of corrective maintenance is by