Breakdown and Preventive Maintenance

Necessity of Maintenance Management

Breakdown of one piece of equipment or component can hinder the performance of the entire production process, resulting in delays. Repairing a machine can be expensive once it break down Malfunctioning equipment may affect the quality of products. Scrap or wastage due to such equipment increases the production costs. During machine breakdown, workers become idle resulting in higher labor cost per unit of the product. Machine failure can even lead to accidents in some cases.

Objectives of Plant Maintenance

To maintain the machinery without any breakdown and to keep the plant in good working condition. To maintain the machinery and other facilities in good condition so that the maximum capacity can be operated without any interruption or hindrance.

Objectives of Plant Maintenance

Proper and periodic maintenance ensures the availability of the machines, buildings and services required by various departments of the factory for the performance of their functions at optimum level.

Importance of Maintenance
Plant maintenance has to be given primary consideration in production management because plant breakdown may cause the following problems.
Production time will lost Production has to be rescheduled More waste material due to sudden stoppage of process Failure to recover overheads Most over-time work Resorting to more subcontracting work Temporary work shortages

Duties and Responsibilities of Maintenance Department

A. B. C. D. E. F. G. H. Inspection & Supervision Engineering & Improvements Maintenance of the Plant Repairs & Replacement Overhaul of Plant Construction Jobs Disposal Clerical Works

Different Types of Maintenance

Planned Maintenance Breakdown Maintenance Scheduled Maintenance Preventive Maintenance Predictive Maintenance

Planned Maintenance
It is organised and carried out with forethought, control and records. It implies all means of examination of all means of repairing, lubricating, servicing and overhauling in order to ensure minimum down time in the long run.

 Planned maintenance intention is to carry out maintenance before it is actually needed.

Breakdown Maintenance (Corrective)

Under breakdown maintenance the repairs are undertaken after the equipment went out of order and it cannot function any longer. The production department informs the maintenance department to rectify the defect who find out and correct the repairs.

Scheduled Maintenance
Scheduled maintenance avoids breakdowns. It involves inspection, lubrication, repair and overhaul of certain equipments which if neglected can result in breakdown.

Preventive Maintenance
Preventive maintenance is a planned and scheduled system that tries to minimize the problems of breakdown maintenance.

Predictive Maintenance
It is a latest maintenance technique. It involves application of human senses or other sensitive instruments like
Audio Gauges Vibration Analysers Amplitude meters Pressure, temperature and resistance strain gauges

Preventive Maintenance
It is based on prevention is better than cure .The main purpose of preventive maintenance is to locate the sources of repair and to remove them before the breakdown occurs. It is undertaken on scheduled basis for retaining an equipment in a satisfactory operating condition. It includes periodic test, monitoring, servicing and inspection.

Preventive Maintenance Program consists following activities

Design and installation of equipment Continuous monitoring of plant and inspection of equipment to prevent break down before they occur. Repeated servicing, up keep and overhaul of equipment. Adequate lubrication, cleaning and painting of equipment

Important factors
Analyzing records Availability of skilled people Location of maintenance facility Planning and scheduling Application of work standards Effective Inventory Control
Total No. of Equipments Service Life of Parts Job Conditions Sources of Supply Delivery Period Efficiency of the purchasing department

Advantages of Good Preventive Maintenance Program

The production down time will be less The overtime pay will be very low for maintenance personnel on ordinary repairs and adjustments than breakdown repairs. We can keep less equipment needed in stand by and reduce the investment It reduces product rejects, wastages and ensures better quality control It minimizes maintenance costs of both labor and materials. It provides longer service life of plant equipment and building. Only required spares have to be maintained leading to minimum inventory. It provides safety for workers and protection for the plant leading to minimize accidents. It predicts major breakdowns.

Bathtub Curve
Wear Out Stage Infant Mortality or Early Failure stage Failure Rate

Useful Life or Adult Stage

Time