UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
MAINTENANCE PRESENTATION –CHAPTER 12

4/28/2024 1
 GROUP MEMBERS

1. Yohanes Assefa GUR/02301/12

2. Yohannis Mossie GUR/00281/12
3. Molalign Tamirat GUR/00814/12
4. Tewuba Sileshi GUR/00080/12
5. Hailemichael Melkamu GUR/00882/12

4/28/2024 2
 CHAPTER 12
RECONDITIONING OF EQUIPMENT
CONTENT
• Reconditioning of Equipment
• Definition
• Reconditioning process
• Cost Analysis of Reconditioning
• Requirements for Reconditioning
Undertakings
• Infrastructure
• Technical Requirements
4/28/2024 3
 CHAPTER 12
Reconditioning of Equipment
Reconditioning of equipment plays a significant role in maintenance of
equipment, particularly in developing countries where increasing cost of new
equipment makes the acquisition of new equipment difficult.
The need for reconditioning arises from:-
 Aging machinery with rapidly decreasing
Reliability and high risk of failure
 Increasing and unaffordable cost of new equipment
 Insufficient capital
 Lack of adequate foreign exchange

4/28/2024 4
 12.1 Definition
Reconditioning is defined as a systematic planned activity designed to restore an
equipment to its original performance condition. This process involves repair to
certain problem areas in an equipment that may
include:
Grinding app scrapping
Removal of slackness due to wear
And replacement of certain parts

4/28/2024 5
 12.2 Reconditioning process
The process of reconditioning is similar to the manufacture of a new machine
and should be approached in a logical and scientific manner. Reconditioning
process involves the following activities:-
Inspection of component parts and
determining their residual life.
Heat treatment processes like annealing,
quenching and tempering to modify the
mechanical properties of materials
4/28/2024 6
 Replacement of all parts which have a residual

life less than some critical useful life and replacing

by matching parts. In many industrial applications
the critical residual life is 5 to 7 years .

 De-greasing and cleaning of

equipment parts.

4/28/2024 7
 Stripping of existing machine

component-wise.

 Inspection and repair of all

castings.

 Replacement of all mandatory

components.

 Load testing of machine to

specified standards.
4/28/2024 8
 Grinding of guide-ways and
hardening.
 Assembly and testing of all sub-
assemblies.

 Reassembling the machine and

achieving specified standards of
alignments.

 Repainting and change of name

plate where necessary.

4/28/2024 9
 EQUIPMENT REPLACEMENT
VS

RECONDITIONING

Maintenance management is often

faced with the dilemma of replacement

versus reconditioning of an existing

equipment.
• Rule of thumb that can be applied in

this case is.

4/28/2024 10
Some basic point related to equipment replacement

A. Parts which require a considerable degree of specialized skills and costly

processes are best replaced.

B. If the repair facility available is limited then replacement of certain

machines with technologically superior equipment must take precedence
over reconditioning .

C. If cheap and fast replacement parts are available, reconditioning is not a

right alternative.

4/28/2024 11
Some basic point related to equipment reconditioning

In general, maintenance management should resort to reconditioning

if the following situations arise.

A. Whenever the machine is imported, reconditioning is made

compulsory for saving foreign exchange as well as ensuring economy
in consumption of spare parts.

B. Supply of machines/spares is unreliable.

4/28/2024 12
C. Equipment/part manufacture is discontinued and hence no supply is
possible
D. Critical components like :shafts, gears, valves, pumps, etc. retain
dimensional and structural integrity so that the desire performance is attained
for maximum period of time before replacement becomes necessary due to
breakage. Such components even if they year out, they should be
reconditioned and reused as long as possible .

4/28/2024 13
E. Replacement of machine is costly and new machine introduces
compatibility problem with existing set-up.

F. Budget shortage for replacement.

G. Original equipment is a special purpose machine and cannot be

reordered.

H. Rejection of output, reworking and scrap is beyond predetermined level

I. Reconditioning of an equipment should be considered at the end of a

predetermined
4/28/2024 trouble-free operating life of equipment 14
12.3 Cost Analysis of Reconditioning
In general, some organizations consider that cost of reconditioning up to 30% of
the price of anew machine to be acceptable, where the reconditioning cost
should include:
 material
 labor
 depreciation and

 any other contracted service required in the reconditioning process.

This level is acceptable if there are no other adverse effects on the performance
of the4/28/2024
machine after reconditioning. 15
 The performance after reconditioning can be assessed through
trouble-free service hours after reconditioning
out-put rate
expected life of equipment after recondition

In cost analysis of reconditioning, the reconditioning process will be approved

only if a critical cost-benefit analysis favours reconditioning to replacement. In
performing cost-benefit analysis one to consider the cost of replacement versus
that of reconditioning.

4/28/2024 16
Replacement costs should include:
 spares cost
 Installation, service costs
 cost of ordering end transporting, labour, utilities, etc.
Reconditioning costs should include:
material
labour
depreciation
outside contracted services.

4/28/2024 17
Inhere, one thing should be noted which may not be quantified in terms of
dollars; and that is, the experience gained locally in the process of
reconditioning. Performing a reconditioning activity develops local capabilities
which leads to increased design and fabrication capability.

12.4 Requirements for Reconditioning Undertakings

There are two aspects to the requirements that must be fulfilled to undertake
a reconditioning action. These are the infrastructure and technical requirements.

4/28/2024 18
 12.4.1 Infrastructure

For proper reconditioning adequate infrastructure facilities must be available.

Include:
 reconditioning shop
 machines
 skilled manpower
 coordination between design, planning, purchase, inspection,
sales and engineering
 training of personnel

4/28/2024 19
 12.4.2 Technical Requirements:
For proper reconditioning of an equipment the technical level must be
corresponding with the practical aspect.

Involved engineers should be familiar with the design features of the equipment
which include:
equipment performance,
assemblies,
 components,
 lubrication system,
4/28/2024 20
material specifications, etc.
Adequate machine history should be available which includes
operating conditions,
 working shifts,
maintenance system,
frequency of breakdowns,etc.

4/28/2024 21
4/28/2024 22
 REVIEW - QUESTIONS ?
1. What is the purpose of reconditioning equipment?
a) To increase the resale value
b) To restore components to optimal working condition
c) To make the equipment look new
d) To replace old equipment with new ones
2. What is the first step in the reconditioning process?
a) Applying protective coatings
b) Assessing the condition of the component
c) Disassembling the equipment
d) Replacing damaged parts
4/28/2024 23
4/28/2024 24