Basic Mechanical

Maintenance
By: Oyebola Oluyemi
Discussion

Introduction
What is Maintenance
Types of Maintenance
History of Maintenance
Total Productive Maintenance
Reactive vs Proactive
What is Maintenance
The work of keeping something in proper condition; upkeep

All activities involved in keeping a systems equipment in

working order

All actions or activities which have the objective of retaining

or restoring an item in or to a state in which it can perform its
required function

Maintenance can also be referred to as Capacity Assurance

 Type of Maintenance

Preventive Breakdown
Maintenance Maintenance

Maintenance

Predictive Reliability
Maintenance Centered
Maintenance
 History of Maintenance

19-- 1950 1960 1970 1980 1990

Breakdown Maintenance

Repairs or replacements performed after a machine has

failed to return it to its functional state following a malfunction
or shutdown
It can also be called Emergency or corrective maintenance
Wait until equipment fails and repair it. It could be planned or
unplanned

Advantages
Low initial cost
Requires fewer staff
No Planning needed
Disadvantages
Sporadic equipment
downtime
Interferes with planned work
Shorter life expectancy of
assets
Indirect costs
Inefficient use of resources
 Preventive Maintenance
Actions performed on a time - or machine-run-based schedule that detect, preclude,
or mitigate degradation of a component or system with the aim of sustaining or
extending its useful life through controlling degradation to an acceptable level
It is maintenance that is regularly performed on a piece of equipment to lessen the
likelihood of it failing
Routine inspection and servicing i.e. cleaning, inspection, oiling and re-tightening; to
keep facilities in good working condition
It is the same as planned, schedule, routine maintenance

Advantages Disadvantages
Extends the useful lifecycle Time consuming
of assets Costly due to more frequent
Enhances the performance parts change
of assets by increasing Labour intensive
uptime Requires maintenance
Reduced overtime costs planning
and more economical use
of maintenance workers
Predictive Maintenance

This is designed to help determine the condition of in-

service equipment in order to predict when
maintenance should be performed
This approach promises cost savings over routine or
time-based preventive maintenance, because tasks
are performed only when warranted
Reliability Centered Maintenance

a process used to determine the maintenance requirements of any

physical asset in its operating context
It is a process to ensure that assets continue to do what their
users require in their present operating context.
Prioritizing maintenance efforts based on equipments
importance to operations, its downtime cost in revenue and
customer loss, its impact on safety, and its cost of repair
Reliability Centered Maintenance

There are four principles that are critical for an RCM

program

The primary objective is to preserve system function

Identify failure modes that can affect the system

function

Prioritize the failure modes

Select applicable and effective tasks to control the

failure modes
 Reliability Centered Maintenance

Advantages Disadvantages

Can be the most efficient Can have significant startup

maintenance program costs associated with staff
Lowers costs by eliminating training and equipment needs
unnecessary equipment Savings potential is not readily
maintenance or system seen by management
overhauls
Minimizes the frequency of
overhauls
Reduces probability of sudden
equipment failures
Incorporates root cause
analysis
Increases component
reliability
Total Productive Maintenance (TPM)
This is a concept of Maintenance Management by which
many Industries in the world have improved their Productivity
and quality to the highest level and attained, Zero
Breakdown, Zero Defects in their Production Line
TPM is a holistic approach to equipment maintenance that
strives to achieve perfect production
No Breakdowns
No Small Stops or Slow Running
No Defects
No Accident
The major difference between TPM and other concepts is that
the operators are also made to involve in the maintenance
process. The concept of "I ( Production operators ) Operate,
You ( Maintenance department ) fix" is not followed
Total Productive Maintenance (TPM)
Benefit of TPM
Increase productivity and OPE ( Overall Plant Efficiency )
Rectify customer complaints
Reduce the manufacturing cost
Satisfy the customers needs ( Delivering the right
quantity at the right time, in the required quality)
Reduce accidents
Keep the work place clean, neat and attractive
The workers get a feeling of owning the machine
Reactive vs Proactive