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Breakdown and Preventive Maintenance
Made By:-VIKRAM SINGH YADAV
Necessity of Maintenance Management
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 lostProduction has to be rescheduledMore waste material due to sudden stoppage of processFailure to recover overheadsMost over-time workResorting to more subcontracting workTemporary work shortagesDuties and Responsibilities of Maintenance Department
Inspection & Supervision
Engineering & Improvements
Maintenance of the Plant
Repairs & Replacement
Overhaul of Plant
Construction Jobs
Disposal
Clerical Works
Different Types of Maintenance
Planned MaintenanceBreakdown MaintenanceScheduled MaintenancePreventive MaintenancePredictive MaintenancePlanned 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.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 likeAudio GaugesVibration AnalysersAmplitude metersPressure, temperature and resistance strain gaugesPreventive Maintenance
Preventive Maintenance Program consists following activities
Design and installation of equipmentContinuous 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 equipmentImportant factors
Analyzing recordsAvailability of skilled peopleLocation of maintenance facilityPlanning and schedulingApplication of work standardsEffective Inventory Control Total No. of EquipmentsService Life of PartsJob ConditionsSources of SupplyDelivery PeriodEfficiency of the purchasing departmentAdvantages of Good Preventive Maintenance Program
The production down time will be lessThe 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 investmentIt reduces product rejects, wastages and ensures better quality controlIt 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
Failure Rate
Time
Infant Mortality or Early Failure stage
Wear Out Stage
Useful Life or Adult Stage