Plant Maintenance and Preventive Maintenance Procedures

By : Mudit M. Saxena
Dept. of Mech. Engg.
ITE, Indus University
Maintenance Policies and Preventive
Maintenance

INTRODUCTION
 Plant maintenance is an important service function of an
efficient production system.
 It helps in maintaining and increasing the operational
efficiency of plant facilities.
 Maintenance isthe procedure of finding the faults in any
equipment/Machine and also removal of fault.
 It may be before the breakdown or after the breakdown.
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By: Mudit M. Saxena, Dept. of Mech. Engg., ITE, Indus University

• Plant maintenance usually refers to the methods,
strategies, and practices used to keep an industrial
factory running efficiently. This can include anything
from regular checks of equipment to make sure they
are functioning properly.
• The general aim of plant maintenance is to create
aproductive working environment that is also safe for
workers.
INTRODUCTION
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By: Mudit M. Saxena, Dept. of Mech. Engg., ITE, Indus

MAINTENANCE OBJECTIVES
•To increasefunctionalreliability ofproductionfacilities.
•To maximizethe usefullifeoftheequipment.
•To maximizeproduction capacity from the givenequipment.
•To minimizethe total productioncost.
• To minimizethe frequencyofinterruption in productionby
reducing breakdowns.
•To enhancethe safetyofthemanpower.
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MAINTENANCE OBJECTIVE
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IMPORTANCE OF MAINTENANCE
 It helpsin identifythe cause of failure , e.g whether the
failure is due to design defect, or a wear out failure.
 It also helps in deciding the type of maintenance and
maintenance decision like replace and repair.
 It provides the necessary information regarding the life
and reliability of the equipment.
 With the help of this tool spare parts managementgot
initiated.
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DIFFERENT TYPE OFMAINTENANCE:
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PLANNED MAINTENANCE
In planned maintenance the maintenance action is carried
out with some fore thoughts, prior planning , record
keeping and control action.
These can be further classified as :-
• Preventive maintenance
• Corrective maintenance
• Predictive maintenance
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• Or the maintenance carried out at predetermined intervalsor accordingto
prescribed criteria andintended to reduce the probability offailure or the
degradationofthe functioningandthe effects limited.
• It hasthree types
• Running maintenance
• Scheduledmaintenance
• Shutdown maintenance
PREVENTIVE MAINTENANCE
• It is based upon the principle that ‘prevention is better than
cure’.
• 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.
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RUNNING MAINTENANCE:
Running maintenance which includes those maintenance
activities that are carried out while the machine or
equipment is running.
Example – lubrication, adjustment of nuts and screws,
tightening of loose nut and bolts.
10By: Mudit M. Saxena, Dept. of Mech. Engg., ITE, Indus University

SCHEDULED MAINTENANCE:
• Scheduled Maintenance is any variety of scheduled
maintenance to an object or item of equipment.
• Specifically, Planned Maintenance is a scheduled service visit
carried out by a competent and suitable agent, to ensure that
an item of equipment is operating correctly and to therefore
avoid any unscheduled breakdown and downtime.
• Good example of PM program is car maintenance. After so
many kilometers or miles oil should be changed, parts
renewed.
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SHUT DOWNMAINTENANCE:
• Which is a set of preventive maintenance activities
that are carried out when the production line is in
total stoppage situation.
• These are performed generally after three or six
months.
• These involves the inspection of plant items which
are known or suspected to occur.
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CORRECTIVE MAINTENANCE
• 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.
• It also include the different types of actions like typical
adjustment of redesign equipment.
• The difference between corrective maintenance and preventive
maintenance is that for the corrective maintenance, the failure
should occur before any corrective action is taken.
•It is of two types
1. Breakdown maintenance
2. Shutdown maintenance
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BREAKDOWN MAINTENANCE
• It is an emergency based policy in which the plant or
equipment is operated until it fails and then it is brought
back into running condition by repair.
• The maintenance staff locate any mechanical, electrical
or any other fault to correct it immediately.
• It is feasible for the small factories where
• There are few types of equipment.
• Machine and equipments are simple and does not require
any specialist.
• Where sudden failure does not cause any serious
financial loss.
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PREDICTIVE MAINTENANCE:
• As the names implies it involves the prediction of the
failure before it occurs, identifying the root cause for those
failures symptoms and eliminating those causes before
they result in extensive damage of the equipment.
• Type of maintenance performed continuously or at intervals
according to the requirements to diagnose and monitor a
condition or system. Also called condition based
maintenance.
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UNPLANNED MAINTENANCE:
• Maintenance action which is carried out without any fore
thoughts or prior planning is called unplanned
maintenance.
• Emergency maintenance is one of the example of
unplanned maintenance.
• In this type of maintenance the maintenance action is
executed with the help of all available maintenance
resources in least possible time, without any major time
lag.
• Examples are gas leakage in chemical plant, fire
hazards, breakdown of boiler, turbine etc.
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NATURE OF MAINTENANCEPROBLEM:
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GENERAL CLASSIFICATION MAINTENANCE PROBLEM.
Mechanical Failure
Worn out bushes and bearings and other moving parts.
Fatigue of machine members
Creep of material at high temp
Excessive forced vibration, misalignments etc.
Thermal Failure
Overheating of the component
Lack of lubrication
Inadequate of cooling
Electrical insulation failure
Chemical Failure
Highly corrosive fluids containing abrasive particles Failure of protective
linings like glass , rubber etc.
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CLASSIFICATION MAINTENANCE
PROBLEM BASED ON TIME SPAN:
• Short run production problem
Maintenance problem which are carried out in a sort period of time are
known as short run production system. It may be hourly, daily
,weekly and monthly.
Example:-
Hourly- inspection of correct lubricant, level of coolant, sharpness of
cutting tool.
Daily- cleaning of m/c, tightening of nuts, correct cooling,
inspection of various indicators, minor adjustment of parts.
Weekly- Major adjustment, lubrication, tightening of parts.
Monthly- checking for insulation, corrosion, safety guards,
checking of worn-out and distorted parts.
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PROCEDUREOF PREVENTIVEMAINTENANCE
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1. Job Identification By Preparing Of Facility Engineer
• The very first step of PMP is to prepare the facility
register which defines that what to be maintained.
2. Preparation of maintenance schedule
• In this step we prepare a maintenance schedule. It is simply
acomprehensive list of all the incident and their time of
incidence.
• It gives the useful information regarding the method, time and
place of maintenance work, besides it also provides secondary
information about maintenance man power requirement etc.
• It gives the various details regarding maintenance like what,
when, how, where.
PROCEDUREOF PREVENTIVEMAINTENANCE
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3. Preparation Of History Card
• It not only gives the useful information about the result
of maintenance events but also furnishes the essential
details regarding the uses of machines, free of failures
and failure modes.
4. Preparation of Job specification
• In this step the job specification is prepared. It is simply
adocument which provide the essential information regarding the
maintenance work to be done.
• In general practice these job details are specifications compiled
from maintenance schedules.
• They are a means of communicating the engineer’s requirement
to guide the workers.
• They are prepared separately for each job.
PROCEDURE OF PREVENTIVEMAINTENANCE
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5. PREPARATION OF MAINTENANCE PROGRAMMING
• It is a sequential list which allocates specific maintenance work to a
specific period.
• In order to apply the job specification, the maintenance programme is
generally prepared for long run when the machines/ equipment are to be
inspected.
• It is not a good practice because an industry can not prepare a long run
production well in advance since too many factors arise and they will
result into change in production and maintenance requirement.
• It presents a overall picture of present and future maintenance
commitments.
PROCEDURE OF PREVENTIVE MAINTENANCE
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6. PREPARATION OF WEEKLY/MONTHLY MAINTENANCE PROGRAMMES
• The next step under plant maintenance procedure is to
prepare the weekly/ Monthly maintenance programmes. The
maintenance programmes include the following topics.
1. Reconditioning or replacing the lubricating oil
2. Repairing and replacing worn out parts and tools etc
3. Checking all the electrical connections of the system
4. Checking the control system
5. Checking the performance of each parts.
6. Cleaning the interior parts like spark plugs, filters radiators,
crankcase, cylinders etc.
7. It will lie under the long run maintenance programmes.
PROCEDURE OF PREVENTIVEMAINTENANCE
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7. Preparing of inspection report
• This step is followed after the maintenance programme is
over. This is simply a document which furnishes the useful
information about the maintenance inspections which were
performed in the past.
8. Preparing of maintenance request
The next step under plant maintenance procedure is to preparation
of maintenance request. It is simply a document or various
maintenance suggestions and recommendation given by the
inspection report. Suggestions are the useful feedback
information that comes from users end workers.
PROCEDURE OF PREVENTIVE
MAINTENANCE
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9. Feedback Mechanism
• In the last step the application of corrective and control
actions are available on the basis of feedback mechanism.
These corrective actions should be applied to respective
plant facilities at the initial stage of maintenance planning
or design.
PROCEDURE OF PREVENTIVE
MAINTENANCE
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SCHEDULES OF PREVENTIVE MAINTENANCE:
• It is simply a comprehensive list of all the incident and their
time of incident. It gives the following useful information
regarding the maintenance work.
i. What is to be done or maintained?
ii. How is to be maintained?
iii. When is to be maintained?
Besides this it may also provide the secondary information
regarding the place of maintenance and maintenance
requirement.
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MAINTENANCE STRATEGY
• A maintenancestrategy definesthe rules for the sequenceof
plannedmaintenancework. It containsgeneral scheduling
information, andcantherefore be assignedto asmany
maintenancetask lists (PMtask lists) andmaintenanceplans as
required.Amaintenancestrategy containsmaintenance
packagesin whichthe followinginformation is defined:
• The cyclein whichthe individualwork shouldbe performed (for
example, everytwo months, every3,106.86 miles, every500
operating hours)
• Other datawhichaffectsscheduling
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STRUCTURE:
A maintenance strategy consists of:
• Strategy header: Name of the strategy,
• Scheduling parameters: Contain the scheduling data for
the respective maintenance
strategy, which influence the
scheduling of maintenance plans.
• Scheduling indicators
• Maintenance packages
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SCHEDULING INDICATORS
Within a maintenance strategy, you can use different
scheduling indicators to specify the type of scheduling you
require or to define a cycle set:
• Time-based (for example, every 30 days)
• Time-based by key date (for example, every 30 days on the
30th day of the month)
• Time-based by factory calendar (for example, every 30
working days)
• Performance-based (for example, every 50 operating hours)
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Maintenance Packages:
• Maintenance activitiesthat must be performed at a particular
date or point in time are combinedinto maintenance
packages

TOTAL PRODUCTIVE
MAINTENANCE (TPM)
• Total productive maintenance (TPM) originated in Japan in
1971 as a method for improved machine availability through
better utilization of maintenance and production resources
• I t can be considered as the medical science of machines.
• Total Productive Maintenance (TPM) is a maintenance
program which involves a newly defined concept for
maintaining plants and equipment.
• The goal of the TPM program is to markedly increase
production while, at the same time, increasing employee
morale and job satisfaction.

• TPM brings maintenance into focus as a necessary
and vitally important part of the business.
• It is no longer regarded as a non-profit activity.
Down time for maintenance is scheduled as a part of
the manufacturing day and, in some cases, as an
integral part of the manufacturing process.
• The goal is to hold emergency and unscheduled
maintenance to a minimum.
TOTAL PRODUCTIVE
MAINTENANCE (TPM)
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WHY TPM
•TPM wasintroduced to achievethe following objectives.
Theimportant onesare listed below.
•Avoid wastagein aquicklychangingeconomicenvironment.
•Producing goodswithout reducing product quality.
•Reduce cost.
•Produce alowbatchquantity at the earliest possibletime.
•Goods sendto the customers must benon defective.
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CONCLUSION
• Today, with competition in industry at an all time high,
TPM may be the only thing that stands between
success and total failure for some companies.
• It has been proven to be a program that works. It can be
adapted to work not only in industrial plants, but in
construction, building maintenance, transportation, and
in a variety of other situations.
• If everyone involved in a TPM program does his or her
part, an unusually high rate of return compared to
resources invested may be expected.

ASSIGNMENT - 11
Q 1. What is plant maintenance ? What are its
objectives.
Q 2. What is the importance of maintenance ?
Q 3. Explain different types of maintenance.
Q 4. Explain the nature of maintenance problems.
Q 5. Explain the procedure of preventive maintenance.
Q 5. What are the scheduling indicators of maintenance.
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Plant Maintenance and Preventive Maintenance Procedures

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