MAINTENANCE

SACPL- HALOL
By- MILIND D. KHANDAVE
 Maintenance Definition
• 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.
• Activities of maintenance function could be
either repair or replacement activities, which are
necessary for an item to reach its acceptable
productivity condition and these activities, should
be carried out with a minimum possible cost.
 Maintenance History
1. In the period of pre-World War II, people thought
of maintenance as an added cost to the plant which
did not increase the value of finished product.

Therefore, the maintenance at that era was

restricted to fixing the unit when it breaks because
it was the cheapest alternative
 Maintenance History
2. During and after World War II at the time when
the advances of engineering and scientific
technology developed, people developed other
types of maintenance, which were much cheaper
such as preventive maintenance.

In addition, people in this era classified

maintenance as a function of the production
system
 Maintenance Objectives
• 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.
• Reducing downtime.
• Improving spares stock control
 Maintenance Objectives
• 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.
There are 9 types of
maintenance split between
Preventive Maintenance and
Corrective Maintenance.

Preventive Maintenance is done

before a failure occurs and consists
of maintenance types like:
Time Based Maintenance, Failure
Finding Maintenance, Risk Based
Maintenance, Condition Based
Maintenance and Predictive
Maintenance.

Corrective maintenance is done

after a failure has occurred either as
Deferred Corrective Maintenance or
as Emergency Maintenance. In the
rest of this article, I will discuss each
of these different types of
maintenance in detail:
Preventive Maintenance
(PM)
 Time Based Maintenance (TBM)
 Failure Finding Maintenance (FFM)
 Risk Based Maintenance (RBM)
 Condition Based Maintenance (CBM)
 Predictive Maintenance (PDM)
Corrective Maintenance
(CM)
 Deffered Corrective Maintenance
 Emergency
 
Preventive Maintenance
Preventive maintenance is aimed at catching and fixing problems
before they happen. It is most commonly carried out in the form of
regular inspections, usually occurring multiple times per year.
When you inspect a system or a piece of technology, carefully
check for all signs of wear, tear or imminent breakdown. Replace
damaged parts immediately. This will prevent having to go into
“crisis mode” if something breaks unexpectedly.

The primary benefit of preventive maintenance is that it can

eliminate unplanned shutdown time as you will ideally catch
problems before they occur.

.
Condition-Based
Maintenance
Condition-based maintenance is
sometimes considered to be a more
advanced alternative to preventive
maintenance. Rather than being inspected
according to a schedule, machines and
systems are carefully observed for changes
that could indicate upcoming failure.
With condition-based maintenance,
technicians observe the system running
and identify variables that could affect
functioning, like temperature, vibration
speed, power, the presence or absence of
moisture, and more.

Another strategy within condition-based

maintenance is predictive maintenance
HAINRICH DIAGRAM
Different Sections of Curve :
Bathtub curve is basically divided into three different sections.
Asset generally faces these three sections all over their lifetime.
Three different sections of bathtub curve are given below –

                                                                            
MTTF vs MTTR – Mean time to failure vs Mean time to repair
Mean time to failure typically measures the time in relation to a failure. Mean
time to repair measures how long to get a system back up and running. This makes
for an unfair comparison, as what is measured is very different.
Let’s take cars as an example. Let’s say your 2006 Honda CR-V gets into an
accident. MTTF could be calculated as the time from when the accident occurs to
the time you get a new car. MTTR would be the time from when the accident
occurs to the time the car is repaired. 
                                                                                                                                                          
                                                                                                                                    

Mean Time To Recovery

 measures the time between when the failure is first discovered
until the equipment returns to operation. So, in addition to repair time,
testing period, and return to normal operating condition, it captures failure notification time.
Although these terms are often used interchangeably,
they need to be more clearly defined when it comes to Service Level Agreements (SLAs)
and maintenance contracts so that all parties agree on exactly
what they mean and what they are measuring. 
MTTR values generally include the following stages:
1.An issue arises
2.The issue is detected
3.Technicians are notified
4.The issue is diagnosed
5.The issue is fixed
6.The system is reassembled
7.The system is restarted and tested
8.The system is made available for use
The 4 Types of MTTR
There are actually four different definitions of MTTR in use, which can make
it hard to be sure which one is being measured and reported on.
1.Mean Time to Repair (MTTR) is the most commonly used variation of
MTTR and measures the average time taken to repair a system, including
diagnosis, repair and testing. This is more often used for technical or
mechanical systems.
2.Mean Time to Recovery (or Mean Time to Restore) is like Mean Time to
Repair, as it represents the average time from system failure until it is fully
operational again. This metric may be used for online services or software.
3.Mean Time to Respond measures the time taken to repair a system,
from the moment you are notified, until it is completely fixed. This does not
include any time taken from the initial failure to when you are first alerted.
4.Mean Time to Resolve extends Mean Time to Repair, by including any
time taken to reduce the chances of the failure happening again. This
additional time may occur after the system is back online but is definitely
key to maximizing customer satisfaction.
A Formula for Calculating MTTR
So how do you go about calculating MTTR?
Because MTTR represents the average time taken to address an issue, it is
calculated by adding up all time spend on unscheduled or corrective
maintenance in a period, and then dividing this total by the number of
incidents in that period.
MTTR = Total corrective maintenance time
Number of repairs
Here’s an example.
Let’s say you have a very expensive piece of medical equipment that is
responsible for taking important pictures of healthcare patients.
Over the last year, it has broken down a total of five times. The time that
each repair took was (in hours), 3 hours, 6 hours, 4 hours, 5 hours and 7
hours respectively, making a total maintenance time of 25 hours.
So the MTTR for this piece of equipment is:
MTTR = 25 / 5 = 5 hours