Breakdown and Preventive

Maintenance

Made By:-VIKRAM SINGH YADAV

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

Useful Life or Adult Stage

et a R er uli a F

Time