DR.

MAHADEO GHADGE

What is Maintenance

The activity carried out to prevent the

occurrence of failure and activity
carried out after failure to rectify the
defect is called maintenance.

Why Maintenance Required

Plant and machines in any
organisation is expected to run
continuously without any interruption
during the production period.
Interruptions are frequently felt on
account of machine break downs due
to failures of machine parts /
components.
There is always some loss of
production on account of machine
failure.

CAUSES OF FAILURE OF MACHINES

Down Time
The duration by which any machine goes
out of production due to break down is
called down time.
The down time is the total time taken on
account of maintenance to rectify the fault.
The total time taken on account of
maintenance involves the time actually
spent by the respective maintenance team
to correct the fault and waiting time for
want of spares required for rectify the
defect.
Down time = Repair time + waiting time

Waiting Time
The waiting time is the most
unproductive elements of total down
time . The reason for waiting time
could be : Want of spares
Want of crew members
Lack of communication.
Lack of proper supervision

Mean Time Between Failure

( MTBF)
This is the average time a machine
can operate without the occurrence of
any failure.
MTBF indicates the operational
reliability of the machine. Higher the
value of MTBF, higher will be the
operational reliability of the machine
because of lesser number of failures.

Mean Time Between Failure

( MTBF)
To improve the operational reliability ,
the number of failures should be
reduced. Failures can be reduced if
the machines are maintained properly
with adequate care and attention.
Failures can reduce by better
maintenance.

OBJECTIVES
OF MAINTENANCE
OBJECTIVES
OF PP
Continuous increase in the production through
improved overhauling of machines in a plant
at scheduled intervals.
Eliminating any risk of accidents in the plant
that might be cause of a machine breakdown.
Proper maintenance of machines & their parts
to prevent & decrease the wear & tear of
machines & their parts.
Through examination of the machines against
their productivity & accuracy level.
Minimizing plant shut down time.

Maintenance

Corrective
Unplanned
Break Down

Preventive

Planned
Correct/Rectify
Faults

Indirect

Conditioning
Monitoring

Failure Reports

Direct
Cleaning
Lubricating
Replacement
Overhauling

PREVENTIVE MAINTENANCE
Machines are checked much in advance of any kind of
failures.
Checklists are developed for each equipment or machine
so that machine parts are checked for any incipient
problems.
Once the problem is identified in advance, the required
corrective action is taken before the machine stops
functioning.
Different behavior of various machine parts encounter
different problems at different frequencies.
Some parts should be checked in each shift; others may
be checked once a day, a month, in three months, in six
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CORRECTIVE MAINTENANCE
During preventive maintenance checks, certain
problems are noticed about the condition of the
machine. The machine may be operating in a condition
that may cause damage to the machine if continued to
operate. Therefore the machine is to be stopped with
out delay to correct the situation.
The corrective action taken after the checks under
preventive maintenance is termed as corrective
maintenance.
Similarly, condition-monitoring checks may reveal that
the machine has lots of vibrations.
The steps for correcting the situation are termed as
corrective maintenance.

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BREAKDOWN MAINTENANCE
The sudden stoppage of a machine due to
some failure or problem is termed as
breakdown of the machine.
In some organizations, machines are attended
only when the machine has stopped
functioning.
The maintenance carried out in this manner is
called breakdown maintenance.
In breakdown maintenance, repair and
corrective action is taken up when the problem
has actually cropped up.
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Inspection maintenance
Lubrication Maintenance
Cleaning maintenance
Record Maintenance
Spare part maintenance
Service maintenance
Emergency maintenance
Maintenance training

The worn out or deteriorated machine part

The machine part with corrosion (rust)
Loosely held nut or bold in machine
Improper alignment
Defect in machine due to overheating
As soon as defects are identified , the
corrective action should be taken
Inspection can be internal and external

Proper & regular lubrication help in reducing

rate of wearing and tearing of machine. To
ensure good lubrication following activities
are often required
Identifying right part
Cleaning of oil tank
Replacing
Lubricating
Scheduling the frequency of lubrication

Cleaning is done to remove unwanted things

or dust witch affect badly performance of
machine or tools.
Cleaning of transformer or resistor
Electrical fuses
Filters.
Motor Fan blades
Oil tank

Manufacturers instruction manual

Drawing of parts
Spare part manual
Circuit diagram
Machine detail
Machine record