Learning Technique and method to do maintenance Engineering and Preventive maintenance of manufacturing Plant

1. Maintenance Engineering
In Process Manufacturing
Coordinate predictive and preventative maintenance (PPM)
Manufacturing and Assembly Processes
SAQA US ID: 9890 NQF LEVEL 4
PREPARED & FACILATATE : MICHEL MAFOUMBA
Mechatronics Engineer
Robotic Automation and Maintenance Engineering

2. PURPOSE OF THE UNIT STANDARD
 understand know various types of
maintenance, especially predictive and
preventive maintenance and their roles in
the production processes of the company.
 They will be able to identify root causes of
problems, use various analytical techniques
to analyse the production process with
respect to maintenance, develop a
practical maintenance plan and make
recommendations that will increase the
synergy between production and
maintenance.
LEARNING ASSUMED TO BE IN PLACE AND
RECOGNITION OF PRIOR LEARNING
 Electro-Mechanical Winding
 Metal and Engineering Manufacturing Processes
 Manufacturing and Assembly Operations
Supervision
Maintenance in Manufacturing

3.  Explain the purpose of predictive and preventative maintenance.
 Identify root-causes of break-downs and identify solutions.
 The Bath-tub model is explained and the appropriate PPM strategies (counter
measures for each of the phases are discussed as part of the proactive
maintenance process and data on).
 Discuss the safety, health and environmental (SHE) factors in maintenance
 Explain the principles of production scheduling systems.
 Discuss the principles of maintenance scheduling.
Maintenance in Manufacturing

7. Types of maintenance
a. Run-to-failure (breakdown maintenance)
b. Preventive (scheduled) maintenance
c. Predictive maintenance (PdM)
d. Reliability-centered maintenance (RCM)
1. Reactive maintenance (breakdown
maintenance)
Also known as breakdown or run-to-failure, reactive maintenance is
pretty simple: fix things when they break. Since repairs are not
planned, it’s a good method to employ for equipment that is not
essential for operations or has a low cost

8. 2. Preventive maintenance (scheduled)
Also known as proactive maintenance, this method involves periodically taking assets offline and
inspecting or repairing them at predetermined intervals (usually time or event-based triggers).
The goal of this approach is to extend the useful life of an asset and prevent breakdowns from
occurring.
Many organizations employing preventive maintenance use CMMS software to trigger work
orders when a PM is due. This allows a facility to automate much of its scheduling efforts, which
is a key ingredient of this preventive approach. Because planning is done in advance, it’s much
easier to have the right parts and resources on hand to complete each task.

9. 3. Predictive maintenance (PdM)
Predictive maintenance (PdM) aims to predict failures before they happen so maintenance can
occur at just the right time. PdM uses data from machine sensors and smart technology to alert the
maintenance team when a piece of equipment is at risk of failing. For example, a sensor may use
vibration analysis to alert the maintenance team that a piece of equipment is at risk of failing, at
which point it will be taken offline, inspected, and repaired accordingly.

10. 4. Reliability-centred maintenance (RCM)
Reliability-centered maintenance (RCM) addresses the fact that failure is not always linear. RCM is
a highly-involved process that seeks to analyze all the possible failure modes for each piece of
equipment and customize a maintenance plan for each individual machine. The ultimate goal of
RCM is to increase equipment availability or reliability.

11. Maintenance management strategies comparison chart
Need a quick comparison of these four strategies? Check out the chart below for a quick
rundown of each approach.
Maintenance strategy comparison chart
Strategy Summary Cost to
Implement
Pros Cons
Reactive Fix it when it breaks Low Ideal for low-priority
equipment
Can lead to
runaway repair
costs
Preventive Maintenance on a
predetermined schedule
Average Best strategy to
implement without
expertise
Without
optimization, “PM
creep” can occur
Predictive Condition-based
monitoring triggering
work orders
High Timely and informed
monitoring. More
insight into causes of
breakdowns
Can be expensive
to set up
RCM Investigation of failure
modes to determine best
maintenance strategy
Highest If executed properly,
provides the most
efficient maintenance
schedule
Requires time,
skill and financial
resources to be
effective

16. Maintenance Documentation
• Electrical Information
• Mechanical Documentation
• Control System Documentation
• Operator Recording
Information
• Manufacturer Documentation

19. Communicate equipment repair needs and preventive
maintenance needs to maintenance specialists.
Step 8: Make Final Checks
Competent troubleshooters always check to make sure
the trouble is actually cleared and the system is
functioning normally. They know too well how easy it is
to cause a new trouble while clearing an old one. They
also know how easy it is to leave something like a
setscrew loose, or something unplugged or out of
adjustment. Therefore, a final check of normal
operation is a necessary part of the troubleshooting
sequence
Step 9: Complete Paperwork
Troubleshooters are not immune to the bureaucratic plea
to "fill out those forms!" Even though paperwork is not
troubleshooting, it is part of the troubleshooters job.
Often, the history of a machine is recorded in an
equipment log. Dates of PMs, information about retrofit,
and parts that have been changed are recorded at the
time of service or repair
Step 10: Inform Area Supervision/Instruct Operators
Once the equipment is returned to service, the user
is informed of this fact. Often, operators are
instructed in the proper use or care of the
equipment or cautioned about peculiarities of the
system. Although this activity is not strictly part of
the troubleshooting procedure, it is important to
the continued proper functioning of the equipment

20. Maintenance Troubleshooting or Breakdown
Five-Step Troubleshooting Process consists of the following:
1. Verify that a problem actually exists.
2. Isolate the cause of the problem.
3. Correct the cause of the problem.
4. Verify that the problem has been corrected.
5. Follow up to prevent future problems.
Step 1: Verify That a Problem Actually Exists
• What are the operators indications of the trouble
• How did the operator discover the trouble
• What were the conditions at the time the trouble first occurred
• Is the trouble constant or intermittent
• Panel graphics
• Loop diagrams
• Piping and instrumentation diagrams
• Block diagrams
• Wiring diagrams
• Schematic diagrams Each of these examples is described briefly next.

21. A panel graphic is a graphic representation of the system that is mounted on an
equipment or system control panel. Although the panel is intended to provide the
operator with a big picture of the operations, it can be useful to the troubleshooter
during this step
Panel Graphic

22. Loop Diagram
A loop diagram is used to provide detailed mechanical information about a
process. This diagram does not give significant electrical or instrumentation
information. Figure 5 is an example of a loop diagram.

23. Piping and Instrumentation
Diagram
A piping and instrumentation diagram
(P&ID;) shows the functional layout of a
fluid system and its piping, valves, and
instrumentation as clearly and accurately
as possible. It is accurate to the extent
that all components are connected to
each other as shown in relation to flow
path orientation

24. Block Diagram
Block diagrams are the simplest of all electrical diagrams. A block diagram illustrates
the major components and electric or mechanical interrelations in block (square,
rectangular, or other geometric figure) form.

25. Schematic Diagram
Schematic diagrams (often just called
schematics) are drawings that show all
the components in their proper
electrical positions, but not necessarily
in their proper physical locations.
Schematic diagrams are very useful to
the technician troubleshooting an
electrical or electronic circuit

26. Maintenance Breakdown

27. The third step of the five-step troubleshooting process is
correcting the cause of the problem. This step involves
performance of the repair or other activity that
eliminates the problem
Correct the Cause of
the Problem

29. Step 4: Verify That the Problem
Has Been Corrected
Once the corrective action is taken, the troubleshooter should verify that the trouble
has been corrected. This usually involves rechecking the same indications that proved
there was a problem. This time though, the checks should prove that a problem does
not exist
• Check all indications that relate to the repaired area.
• Perform a valve/switch line-up check to validate the integrity of the
system.
• Using approved procedures, establish normal operating conditions and
check equipment performance.
• Check for abnormal operation of all inputs and outputs to the repaired
equipment

30. Follow Up to Prevent Future Problems
The final step in the five-step troubleshooting
process is to follow up to prevent future
problems. This step involves taking preventive
measures and recommend actions that could
help keep the equipment from failing. This may
include the following:
 Changing the preventive maintenance
schedule to help prevent failures.
 Recommend a different supplier if a
replacement component is unsatisfactory.
 Recommend procedure modifications that
may prevent future failures.
 Conduct operator/maintenance training to
raise awareness of the potential for
problems.
 Complete proper documentation and
troubleshooting log entries to aid in future
troubleshooting of similar problems.