MAINTENANCE

 The process of preserving a condition or situation or the state of being

preserved.

 Maintaining, repairing, and replacing if necessary devices, equipment,

machinery, building infrastructure, and supporting utilities in industrial,
business, governmental, and residential installations

REASONS FOR MAINTENANCE

Maintenance serves to protect the owners’ real estate investment in a

number of ways

1. Physical Integrity
To keep the assets in good working order so as to minimize disruptions
and downtimes.

2. Risk Management
To keep the assets in a state of good repair for the owners’ health and
safety.

3. Aesthetic Preservation
To keep the assets from deteriorating in appearance and becoming
unsightly.

4. Responsible Stewardship
To ensure that the assets achieve their full potential service life.

5. Duty of Care
To satisfy a legislated duty that is owed to owners, occupants and
guest on the property.

6. Duty to Mitigate
To prevent unnecessary damage to assets that may result in their
premature failure.
TYPES OF MAINTENANCE

Break Down Maintenance

It means that people waits until equipment fails and repair it. Such a thing
could be used when the equipment failure does not significantly affect the
operation or production or generate any significant loss other than repair
cost.

Preventive Maintenance

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ),

design to retain the healthy condition of equipment and prevent failure
through the prevention of deterioration, periodic inspection or equipment
condition diagnosis, to measure deterioration. It is further divided into
periodic maintenance and predictive maintenance. Just like human life is
extended by preventive medicine, the equipment service life can be
prolonged by doing preventive maintenance.

Periodic Maintenance
Time based maintenance consists of periodically inspecting, servicing and
cleaning equipment and replacing parts to prevent sudden failure and
process problems

Predictive Maintenance

This is a method in which the service life of important part is predicted based
on inspection or diagnosis, in order to use the parts to the limit of their
service life. Compared to periodic maintenance, predictive maintenance is
condition based maintenance. It manages trend values, by measuring and
analyzing data about deterioration.

Condition Monitoring

Condition monitoring is the process of determining the condition of

machinery while in operation.

 The key to a successful condition monitoring programme includes:

1. Knowing what to listen for
2. How to interpret it
3. When to put this knowledge to use

 Successfully using this programme enables the repair of problem

components prior to failure.

 Condition monitoring not only helps plant personnel reduce the

possibility of catastrophic failure, but also allows them to order parts in
advance, schedule manpower, and plan other repairs during the
downtime.

Corrective Maintenance
It improves equipment and its components so that preventive maintenance
can be carried out reliably. Equipment with design weakness must be
redesigned to improve reliability or improving maintainability
Advantages and Disadvantages

Break Down Maintenance

Advantages Disadvantages
Lower startup cost Unpredictability

Limited personnel requirement Equipment not maximized

Reduced maintenance costs Indirect costs

Potentially increased margins

Preventive Maintenance

Advantages Disadvantages
Over all very cost effective Catastrophic failure still a risk
Flexibility can allow for adjustment of Labour Intensive
schedule to accommodate other work

Increased equipment life Performance of maintenance based on

schedule not required

Saved energy cost resulting from Risk of damage when conducting

equipment running from pick unneeded maintenance
efficiency
Reduced equipment or process Saving not readily visible without a base
failure line

Over all saving between 12% to 18%

Predictive Maintenance
 Advantages
Increased component operational
life/availability
Allows for pre-emptive corrective
action
Decreased part and labour cost
Improved safety and environment
Energy savings
Over all saving between 8% to 12%
over preventive maintenance
Condition Monitoring
Advantages
Extend bearing service life
Maximise machine productivity
Minimise unscheduled downtime
Safely extend overhaul intervals
Improve repair time
Increased machine life
Disadvantages
Increased investment of diagnostic
equipment
Increased staff training for analyzing
data
Saving not readily visible without a
baseline/history
Disadvantages
Monitoring equipment costs
Operational costs (running the
program)
Skilled personnel needed
Strong management commitment
needed.
A significant run-in time to collect
machine histories and trends is
usually needed.
 Improve product quality
Reduce product cost
Enhance product safety

Corrective Maintenance

Advantages Disadvantages
Lower short-term costs Increased long-term costs due to
unplanned equipment downtime.

Requires less staff since less work is Possible secondary equipment or process
being done damage.

Prone to neglect of assets

10 BIGGEST CAUSES OF MACHINERY BREAKDOWNS

1. Not reading the operator's manual

2. Improper maintenance
 3. Poor electrical connections

4. Overrunning machine's capability

5. Not replacing worn parts when

needed

6. Tightener misalignment

7. Improper storage
 8. Improper weather-related use

9. Ignoring warning signals

10. Asking untrained personnel to

operate equipment

Activity 1:
Direction: Write TRUE if the statement is correct and FALSE if it is wrong.
1. All tools and equipment must be properly maintained so that workers
are not endangered.
 2. Preventive maintenance is the systematic care and protection of tools,
equipment and machines in order to keep them in a safe, usable
condition limit downtime and extend productivity.
3. The degree of detail to include regarding tools and equipment
maintenance will depend on the kinds of tools/equipment used.
4. Damaged or defective equipment/tools should be tagged and removed
from service.
5. Most manufacturers can provide maintenance schedules for their
equipment.
6. Properly stored tools and equipment will be easy to find when needed
and are less likely to be lost.
7. Use bins for storing small parts is a good practice on proper storage.
8. Productivity is increased because time is not lost looking for tools,
parts and equipment is one of the benefits of proper storage.

What is Inventory?

 Inventory is a detailed item list, report, or record of things in one's

possession, especially a periodic survey of all goods and materials in
stock.
 The process of making such a list, report, or record.
 The items listed in such a report or record.

Why maintain Inventory of Tools and Equipment

The most important advice you can be given at the beginning of your career
is to purchase top-grade tools. These are made from high- quality steel and
manufactured to precision. Special consideration is given to balance so that
the tools/ equipment will be properly maintained and prevent losses. Since
the technician must work with his tools daily, a regular inventory of
tools/equipment is very important.

Maintaining and Storing Tools and Equipment

An important aspect of many businesses is the maintenance and storage of

tools and equipment. The investment in tools and equipment is a significant
part of the overhead expenses in any operation. Proper selection and
maintenance of equipment are important factors in managing a business.
Selecting the proper tool for the jobs are using the tool properly will increase
efficiency and reduce maintenance problems. Purchase tools that are well-
made and suited to the indented use. Commercial usage may entail more
heavy-duty demands on equipment.

Different Types of Forms

Correctness of the entry of different forms used in electrical work is

necessary in order to acquire right, complete, and accurate number of
materials and tools needed for specific electrical job.

Here are samples of different forms used in electrical work.

1. Purchase requisition- is a document generated by a user department or

store room personnel to notify the purchasing department about items it
needs to order, their quantity, and the time frame. It may also contain the
authorization to proceed with the purchase. This also called purchase
request or requisition.

2. Inventory- are raw materials, working-process goods, and completely

finished goods that are considered to be the portion of a business assets that
are ready or will be ready for sale. Inventory represents one of the most
important assets that most businesses possess, because the turnover of
inventory represents one of the primary sources of revenue generation and
subsequent earnings for the company shareholders/owners.

3. Job Order or Work Order Form- is a written instruction to perform a

task according to specified requirements, time frame, and cost estimates.

4. Borrower’s Form- is a form used to request for tools and equipment

needed for a particular job. It indicates the department the borrower is
connected, with the date, the job that is to be done, the person who will
approve the request, when it waste turned, and if it was in good condition.
PROPER STORAGE OF TOOLS AND EQUIPMENT

The proper care and storage of tools and equipment are not only the concern
of the management but of the workers who use the equipment.

Importance of proper storage of tools and equipment

1. It is an important factor for safety and health as well as good business.
2. Improves appearance of general-shop and construction areas.
3. Reduces overall tool cost through maintenance.
4. This also ensures that tools are in good repair at hand.
5. Teaches workers principles of (tool) accountability.

Pointers to follow in storing tools and equipment:

1. Have a designated place for each kind of tools.
2. Label the storage cabinet or place correctly for immediate finding.
3. Store them near the point of use.
4. Wash and dry properly before storing.
5. Store knives properly when not in use with sharp edge down.
6. Put frequently used items in conveniently accessible locations.
7. Gather and secure electrical cords to prevent entanglement or snagging.
8. Cutting boards should be stored vertically to avoid moisture collection.
9. Metal equipment can be stacked on one another after drying such as
storage dishes and bowls.
10. Make sure the areas where you are storing the equipment are clean, dry
and not overcrowded.

Good practices in the proper storage of tools:

 Parts should be properly stored and labeled
 Tools should be properly placed on the board, and labeled. Consider
drawing the shapes of the tools on the board so that they always get
put back in the same position.
 Use bins for storing small parts
 Consider making an individual (or individuals) responsible for the good
maintenance of tools and parts

Benefits of proper storage of tools:

 Tools and parts are kept in good condition and are easy to find.
 Costs are reduced.
 Productivity is increased because time is not wasted looking for tools,
parts and equipment.
 Workshop staff develop a sense of responsibility and pride in their
work.

Activity 2:
Directions: Identify the following.
1-5 Importance of proper storage of tools and equipment

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6-15 Pointers to follow in storing tools and equipment

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16-17 Good practices in the proper storage of tools: (at least 2)

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18-20 Benefits of proper storage of tools: (at least 3)

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