Maintenance Engineering (MEPP 408)

Introduction to Maintenance

Bijendra Shrestha, D. Eng.

Assistant Professor
Course Instructor
Department of Mechanical Engineering
25 March 2025 1
Course Details
Course Name : Maintenance Engineering
Code : MEPP
Course Number : 408
Credit :3
Group : Energy Technology and Hydropower
Automobile and Design & Manufacturing
Class : Tuesday (9:00-11:00)
Thrusday (2:00-4:00) 2
Evaluation
Internal : 15 Marks [Average of 2]
Report : 6 Marks [Strategy Report + Video Presentation]
Presentation : 4 Marks [Based on Module 4, 5, 6 and field visit]
Assignment : 0 Marks [Negative Marking -0.5 in each assignment]
Attendance : 0 marks [Negative Marking]
Total : 25 Marks
Requirements:
Attendance ≥ 80% , Else NQ
Note: Deadline will be finalized based on mutual understanding [Win-Win Condition]
 Maintenance
•Maintaining machines and tools is important for any business.
•In many places, maintenance seems to be more reactive:
if it breaks, fix it
•A better approach would be proactive maintenance:
maintain it so it doesn’t break in the first place
4
Maintenance objectives

5
History of Maintenance
•The History of Maintenance engineering is a reflection of the
evolution of industrial practices, driven by technological
advancements and the need for efficient operation of
machinery and equipment.

•This discipline has transformed significantly from its

rudimentary beginnings to the sophisticated methodologies
employed today. 6
Early Development
• Maintenance practices can be traced back to the introduction of machinery, where the
primary focus was on keeping equipment operational only after failures
occurred.
• Early maintenance was largely reactive, with operators addressing issues as they
arose.
• This approach was evident during industrial revolution, when the introduction of
steam engines necessitated more systematic maintenance due to safety
concerns, such as boiler explosions.
• The establishment of organization like the German TUV in the 19th Century aimed to
prevent such disasters through regular inspection and maintenance checks.
7
Source: [Link]
 Maintenance History

1. In the period of pre-World War II, people thought of

maintenance as an added cost to the plant which did not
increase the value of finished product.

Therefore, the maintenance at that era was restricted to fixing the

unit when it breaks because it was the cheapest alternative.
8
 Maintenance History
2. During and after World War II, at the time when the advances of
engineering and scientific technology developed, people
developed other types of maintenance, which were much cheaper
such as preventive maintenance.

In addition, people in this era classified maintenance as a function of

the production system.
Preventive maintenance means performing routine tasks to keep things running smoothly and avoiding breakdowns before
9
they happen.
 Maintenance History
3. Nowadays, increased awareness of issues such as
environment, safety, quality of product and
services makes maintenance one of the most
important functions that contribute to the success
of the industry.

World-class companies are in

continuous need of a very well organised
maintenance programme to compete world-wide.
10
 • Corrective • Corrective • Corrective
Maintenance • Preventive • Preventive
• Predictive

• Terotechnology – Study and practice of managing the entire lifecycle of physical assets, including Design, Installation,
Operation, Maintenance, and eventual disposal.
• Integrates various disciplines – Engineering, Economics, and Management to optimize the performance, reliability, and
cost-effectiveness of assets.
• The goal is to minimize the total cost of ownership over the life of the asset while ensuring it meets the required
performance standards. 11
Maintenance
British Standard Glossary of terms (3811:1993) defined maintenance as:

The combination of all technical and administrative actions, including

supervision actions, intended to retain an item in, or restore it to, a state in
which it can perform a required function.

Maintenance is a set of organised activities that are carried out in order to

keep an item in its best operational condition with minimum cost acquired.
Maintenance action include combination of all Technical and corresponding
Administrative, Managerial, and Supervision actions. 12
 •In a manufacturing plant, regular maintenance of machinery
Example involves both technical and non-technical actions.
Technical actions: Administrative actions:
• Lubricating machine parts • Scheduling the maintenance tasks
• Replacing work-out components, or • Maintaining an inventory of spare parts
• Performing diagnosis on equipment • Ensure all maintenance activities are
to prevent breakdowns. well documented.

Supervisory actions:
Managerial actions: • Overseeing the technical teams
• Setting up maintenance protocols • Ensure safety compliance
• Training staff • Verifying that the maintenance procedures are
• Allocating budgets for tools and resources. carried out correctly and efficiently
Together, these actions ensure that the maintenance process runs smoothly and that
machinery remains operational and efficient. 13
 Engineering and Maintenance
• Engineering – Responsible for the specification, acquisition, and deployment of new
plant efforts
• Maintenance – all aspect after the plant has been commissioned.
Example: A beverage company is expanding its production capacity and needs to install a new bottling line.
Engineering team responsible for:
Specification :
- production speed, size of the bottles, and material used.
- Engineers has to research and define the specifications for the machines that will meet production needs.
Acquisition:
- Sourcing and purchasing the appropriate bottling machines from suppliers based on the specification.
- Includes negotiating contracts, ensure compliance with safety standards, and verifying energy efficiency ratings.
Deployment:
- Overseeing the installation and setup of the bottling line at the factory.
- Ensure the equipment is properly placed, connected, and integrated into the existing system before handing over for
operation. 14
Maintenance: Once the new bottling line has been installed and commissioned, the
maintenance team take over.
Their responsibilities include:
• Routine maintenance : Performing regular checks, lubrication, and cleaning of the
bottling line to ensure smooth operation and prevent breakdown.
• Repairs: Fixing any issues that arise, such as replacing worn-out conveyor belts, repairing
sensors, etc.
• Preventive Maintenance: Scheduling inspections and replacing parts before they fail to
minimize downtime and extend the life of the equipment.

In General, the engineering team handles the technical planning and setup,
while the maintenance team ensures the equipment continues to function
efficiently after it’s operation. 15
Maintenance Engineering (MEPP 408)
Introduction to Maintenance

Bijendra Shrestha, D. Eng.

Assistant Professor
Course Instructor
Department of Mechanical Engineering
27 March 2025 16
Maintenance Engineering
• Maintenance Engineering is the discipline and profession of
applying engineering concepts to the optimization of
equipment, procedures, and departmental budgets to achieve
better maintainability, reliability, and availability of equipment

• Maintenance engineers use engineering theories and practices

to plan and implement routine maintenance of equipment and
machinery

• Done in conjunction with optimizing operating procedures and

budgets to attain and sustain the highest levels of reliability and
profit. 17
Maintenance Engineers
Maintenance engineers must have knowledge
of, not limited to:
• Operation and maintenance of machinery specific to a
company's particular business
• In-depth knowledge of equipment operation, logistics,
probability, and statistics
• Planning and implementing maintenance programs
• Different types of equipment and machinery
• Interpersonal skills and management skills to manage various
levels of personnel
18
Maintenance Engineer’s Job
The job of Maintenance Engineers are, not limited to:
• Planning, implementing maintenance programs
• Monitoring of equipment
• Detecting faults and impending equipment or production failures before occurrence
• Observing & overseeing maintenance performed by technicians, outside vendors and
contractors
• Ensuring smooth and safe daily plant operations
• Recommending improved systems and decide replacement of outdated systems
• Maximizing efficiency of daily operations, discovering and solving any operational
problems in the plant
Note:
• Good maintenance engineer is vital for success of manufacturing operations.
• Company’s success depends on the quality of maintenance engineering department 19
Maintenance Decisions
Current condition of Machine – How to Know???
1. Visual inspection
Regular visual inspections are straightforward way to access the physical condition
of a machine.
Looks for:
• Wear and tear on belts, chains, or gear
• Leaks, rust, or corrosion
• Loose bolts or fittings
• Changes in machine behavior, such as unusual noises or excessive heat

1. Vibration analysis – to detect misalignments, imbalance, or bearing wear

2. Used thermal cameras to identify hot spots in electrical systems, motors, or
mechanical parts.
-Hot spots often indicate friction, electrical faults, or excessive load,
which can lead to breakdown. 20
 2. Historical data and performance trends
• Analyzing historical maintenance records and operational data can
help identify patterns.
• Downtime Records: Tracking how often a machine has been down for
repairs can help predict when it may need maintenance.
• Energy Consumption: A sudden spike in energy use might indicate a
problem with efficiency, signaling that maintenance is needed.

• Diagnosis of Machines by Maintenance Engineers is Like Doctors for human body.

• These are the signals which convey what kind of condition the machine presently in.
To understand the conditions [Condition Monitoring]
21
 Maintenance Decisions
• Why do we need maintenance? Can I just use and throw the machines?
Criticality of equipment?
• How long is machine going to run?
[Remaining Useful Life of Machine]
• What are the costs of doing maintenance?
• What are the costs of not doing maintenance?
• What are the benefits of maintenance?
• How can maintenance increase profitability of company?
22
 Maintenance – Look, Listen, Analyze, and Act (LLAA)
• LLAA approach is a fundamental methodology in maintenance practices, particularly in condition-
based and preventive maintenance.
• Emphasizes proactive monitoring and timely intervention to enhance equipment reliability and
safety
1. Look : Regular visual inspections of equipment and facilities
are essential.
•Observing Equipment Condition: Check wear, leaks,
corrosion, or any physical damage.

•Monitoring Operation performance: Watch how machinery

operates under normal conditions to identify any irregularities. 23
2. Listen : Auditory inspections can reveal issues that may not be
visible.
•Listening for Unusual Sounds: Identify abnormal noises such as
grinding, squealing, or rattling that may indicate mechanical problems.

•Monitoring Vibration Levels: Using sound analysis tools to detect

changes in vibration patterns that could signal impending failures.
24
3. Analyze : Data analysis is vital for understanding the
condition and performance of assets / equipment.
•Data Collection: Gathering information from inspections,
maintenance logs, and performance metrics.

•Maintenance techniques: Using CMMS or other tools to

analyze data trends and predict potential failures before they
occur, thereby minimizing downtime and repair costs.
25
 4. Act : Taking appropriate actions based on observations and
analyses is critical.
•Implement maintenance system
•Adjusting maintenance strategies: Modifying maintenance
plans based on the insights gained from analysis to optimize
performance and extend equipment lifespan.

By integrating these four components – Look, Listen, Analyze, and Act – Organizations can
create robust maintenance strategy that enhances operational efficiency and reduces the
risk of unexpected failures.
26
Type of Maintenance

27
Unplanned Maintenance
Unplanned maintenance refers to repairs or maintenance that occur
unexpectedly usually due to sudden failure or breakdown of equipment.
Example:
• A machine in a production line suddenly stops working
because of motor has failed.
• Fix car when it suddenly breaks down in the middle of
the road.

• Not scheduled - the equipment has stopped working, causing downtime or delays.
• Disturb production, cost more time and money to fix. 28
 Planned Maintenance
Planned maintenance refers to scheduled maintenance activities that are
done regularly to keep equipment in good working order and prevent
unexpected breakdowns.
Example:
1. A company schedules monthly inspection of its conveyor belts to check for
wear and tear and to replace any work parts before they cause a
breakdown.
2. regular check-up of car,
3. scheduling a dentist appointment every 6 month.
You plan it ahead to keep everything running smoothly and to avoid problems.
29
 Reactive and Proactive Maintenance
Reactive Maintenance (Unplanned Maintenance)
• Maintenance culture dependent on failures & breakdowns
• Work is executed without advance preparation
• This should only be the most urgent repairs & maintenance i.e.
emergency/breakdown maintenance
• Emergency/breakdown maintenance should be < 2% of total
maintenance workload.

Proactive Maintenance (Planned Maintenance)

• Maintenance culture focused on continuously improving
• Work is planned & prepared in advance
• Maintenance executed on time
• Faults & Defects are eliminated before they occur
• Even corrective maintenance can be planned to execute it effectively
30
Note: CMMS stores data on equipment, schedules preventive/predictive maintenance, tracks work orders,
and manage inventory and maintenance resources, all of which improved efficiency and reduce equipment
downtime. 31
32
 Breakdown maintenance
•Emergency Repair
•Repair is undertaken only after the failure of the
equipment.
•The equipment is allowed to run undisturbed till it fails.
•Lubrication and minor adjustment are done during the
period.
Breakdown maintenance occurs when an asset stops functioning, often unexpectedly, leading to
downtime.
Examples include: Machine malfunctions, power outages, or component failure in industrial settings.
It may be good in small factory and or industry, where
• Number of equipment are few
• Equipments are very simple and repair doesn’t need for any specialist or special
tools.
• Where sudden stoppage / failure of equipment will not cause severe financial
loss in terms of deliver commitment or further damage to other equipment
/components.
• Where sudden failure will not cause sever safety of environmental hazards.

Note: Breakdown maintenance system cannot work in a big industry having large
number of equipment.
Breakdown Maintenance
•Breakdown maintenance is defined as the process of addressing
equipment that has ceased functioning.
• Refers to fixing and repairing machinery or equipment after it has completely
stopped functioning or broken down.

•The primary goal is to minimize maintenance costs for non-

essential assets while focusing resources on high-value
equipment that requires preventive care.
35
Breakdown Maintenance workflow
Types of Breakdown Maintenance
1. Unplanned Breakdown Maintenance (Emergency Maintenance)
2. Planned Breakdown Maintenance (Run-To-Failure : RTF)

37
 Unplanned Breakdown Maintenance
(Emergency Maintenance)
•This occurs without warning when critical equipment's fails
unexpectedly.
•It often leads to significant downtime and can incur high costs
due to expedited repairs and potential operational disruptions.
•Organizations typically strive to minimize unplanned
breakdowns through better planning and resource allocation.
38
 Planned Breakdown Maintenance
(Run-to-Failure)
•This strategy involves allowing certain equipment to
operate until it fails, which is anticipated.
•It is most effective for non-critical assets that are
inexpensive to replace or do not pose safety risks during
failure.
•For instance, light bulbs in a facility might be replaced
only after they burn out. 39
Objectives of Breakdown Maintenance
The objectives of implementing breakdown maintenance include:
1. Cost reduction
By avoiding unnecessary preventive maintenance on less critical assets, organizations can
save money.
2. Efficient Downtime management
Consolidating repairs can help minimize overall downtime, making operations more
efficient.
3. Resource Allocation
Focusing maintenance efforts on high-value assets ensures that critical equipment
receives the attention it needs while reducing staffing requirements for less important
machinery.
40
Advantages:
• Lower immediate Costs
Reduces expenditure on preventive measures for non-essential equipment.
• Simplified Resource Management
Requires fewer staff and resources for ongoing maintenance tasks

Disadvantages:
• Potential for Higher Long-term costs
Unplanned failures can lead to expensive emergency repairs and lost productivity.
• Safety Risks
Equipment failures can pose safety hazards, especially in critical operations where reliability
is paramount.
41
 Effective management of breakdown maintenance often involves using
Computerized Maintenance Management Systems (CMMS) to track failures,
schedule repairs, and analyze data for future improvements.

CMMS enhance maintenance operations, mainly by:

• Automating workflows
• Tracking asset performance
• Optimizing resource allocation

42
Maintenance Engineering (MEPP 408)
Introduction to Maintenance

Bijendra Shrestha, D. Eng.

Assistant Professor
Course Instructor
Department of Mechanical Engineering
1 April 2025 43
 Corrective Maintenance
In this type, actions such as repair, replacement, or restore will be carried out
after the occurrence of a failure in order to eliminate the source of this failure or
reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms, corrective maintenance is defined as:

the maintenance carried out after recognition and intended to put an item into a state in
which it can perform a required function.
 Corrective Maintenance (CM)
• The main objectives of corrective maintenance are the maximisation
of the effectiveness of all critical plant systems, the elimination
of breakdowns, the elimination of unnecessary repair, and the
reduction of the deviations from optimum operating conditions.
• Aimed at restoring an asset to a condition in which it can perform its
intended function.
• Subdivisions:
1. Immediate Corrective Maintenance (Begins immediately after
failure)
2. Deferred Corrective Maintenance (delayed as per maintenance
rules)
The way to perform corrective maintenance activities is by conducting
four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.

In the fault elimination step, several actions could be taken such as

adjusting, aligning, calibrating, reworking, removing, replacing or
renovation.
47
 Example : Biomass Pellet Fueled Combustion Device
• Fault detection – Operator notices that the CC is not reaching the desired temperature, leading
to inefficient cooking or heating.
• Fault Isolation – to determine the cause, the technician checks various components. For eg. Fuel
feed system to see if pellets are being fed properly, The air supply system to check air flow is
sufficient for combustion, the ignition system to ensure proper ignition of pellets.
After Inspection, the technician finds the air supply system is blocked due to ash accumulation
in the air inlet.
• Fault Elimination - Technician corrective actions such as cleaning the air inlet and removing ash,
inspecting and ensuring the blower is working properly, adjusting air intake settings for optimal
combustion.
• Verification of fault elimination - After cleaning and adjusting, the technician restarts the
combustion device and monitors the temperature. If system reaches the required heat levels,
confirming that the issue has been resolved. 48
Example
A manufacturing plant experiences an unexpected shutdown due to a critical machine failure.
1. Fault detection: Maintenance personnel identify that the machine has stopped working,
triggering an immediate response to assess the situation.
2. Fault Isolation: Upon inspection, the team determines that the failure is confined to a
specific component within the machine, such as malfunctioning motor.
3. Fault Elimination: The defective motor is carefully removed and replaced with a
functioning one. Technician ensure that the new motor is properly installed and aligned.
4. Verification of Fault Elimination: After the replacement, the machine undergoes a series
of tests to confirm that it operates correctly and meets all performance specifications
before being returned to services.
Note: By following these steps, the manufacturing plant minimize downtime and ensures
that the machine is restored to optimal working conditions. 49
 Corrective maintenance has several prerequisites in
order to be carried out effectively:

1. Accurate identification of incipient problems.

2. Effective planning which depends on:
the skills of the planners,
the availability of well developed maintenance database about
standard time to repair,
a complete repair procedures, and
the required labour skills, specific tools, parts and equipment.
3. Verification of repair.
Breakdown Maintenance Corrective Maintenance:
Timing: Performed after equipment or Timing: Can be performed either a failure (Like
machinery has already failed or broken breakdown maintenance) or proactively when
down. issue or irregularities are detected before
Purpose: The goal is to restore functionality complete failure.
as quickly as possible after an unplanned Purpose: To address issue that can be lead to
failure. failure, reduce performance, or pose safety risks,
Nature: Reactive; action is taken only after ensuring the equipment functions correctly.
the failure occurs. Nature: Can be both reactive (fixing existing
Example: Fixing a machine that suddenly problems) or proactive (fixing potentiall issues).
stops working during production. Example: Repairing a component that is showing
signs of wear or malfunction, but before it causes
a total breakdown.
51
Opportunistic maintenance
• refers to performing maintenance tasks during unplanned or planned downtime
when the equipment or system is already non-operational or undergoing
repairs.
• The idea is to take advantage of the situation to conduct additional
maintenance activities on other components, even if they are not yet due for
servicing, to prevent future breakdowns and optimize the overall maintenance
schedule.
For example, if a machine is stopped for a minor repair, a technician might also decide to
inspect and replace nearby parts that are close to the end of their life cycle, even if they
haven’t failed yet. This reduces the need for future shutdowns and helps avoid unexpected
failures. 52
 Preventive Maintenance
Neither equipment nor facilities should be allowed to go
the breaking point.
• Planned maintenance of plant and equipment that this designed to improved
equipment life and avoid any unplanned maintenance activity.
• Includes:
• Painting, lubrication, cleaning, adjusting, and minor component replacement to extend
the life of equipment and facilities.
• Purpose is to minimize breakdowns and excessive depreciation.
53
Preventive Maintenance
It is a set of activities that are performed on
plant, equipment, machinery, and systems
before the occurrence of a failure in order to
protect them and to prevent or eliminate any
degradation in their operating conditions.
Key for successful preventive maintenance is scheduling and execution54
British Standard 3811:1993 Glossary of terms defined preventive
maintenance as:

the maintenance carried out at predetermined intervals or

according to prescribed criteria and intended to reduce the
probability of failure or the degradation of the functioning and the
effects limited.

55
 Preventive Maintenance
• It is good for those machines and facilities which failure would cause
serious production losses.

• Its aim is to maintain machines and facilities in such a condition that

breakdowns and emergency repairs are minimised.

• Its activities include painting, cleaning, replacements, adjustments,

major overhauls, inspections and lubrications to extend the life of
equipment and facilities.
56
 Preventive Maintenance Flowchart

57
 Necessity of Preventive Maintenance
1. Reduce production downtime, resulting in fewer machine breakdowns.
2. Better conservation of assets and increased life-expectancy of assets, thereby eliminating premature
replacement of machinery and equipment's.
3. Reduce overtime costs and more economical use of maintenance workers due to working on a
scheduled basis instead of a crash basis to repair breakdowns.
4. Timely routine repairs circumvent fewer large-scale repairs.
5. Reduced cost of repairs by reducing secondary failures. When parts fail in service, they usually
damage other parts.
6. Reduced product rejects, rework, and scrap due to better overall equipment conditions.
7. Identification of equipment with excessive maintenance costs, indicating the need for corrective
maintenance, operator training, or replacement of obsolete equipment.
8. Improved safety and quality conditions. 58
 Preventive Maintenance (PM) Risks
1. Damage to an adjacent equipment during PM task.
2. Damage to the equipment receiving the PM task.
3. Damage during the performance of an inspection, repair, adjustment, or
installation of a replacement part.
4. Installing material that is defective, incorrectly installing a replacement part,
or incorrectly reassembling material.
5. Reintroducing infant mortality by installing new parts and materials.
6. Damage due to an error in reinstalling equipment into its original location.
Note: These errors go unnoticed until they cause unplanned shutdown. 59
 Preventive Maintenance Frequency

Equipment
Health

x1 Y1 x2 Y2 x3 Y3 x4
Time

X1, X2, X3, X4 indicates the actual operation periods during which the equipment conditions
deteriorates and periods Y1, Y2, Y3,… are the period of capital repairs/overhauls during which a
deteriorated equipment is restored back to near its original conditions.

Note: X1, X2, X3, X4 and Y1, Y2, Y3 may or may not be equal.
Bathtub Curve

61
• The bathtub curve is a
critical concept in a preventive
maintenance, illustrating the
failure rates of assets over their
lifecycle.
• It consists of three distinct phases:
Infant mortality, normal life, and
Wear-out.
• Understanding this curve helps
maintenance teams to apply
appropriate strategies at different Failure rate Wear-out
Infant
stages to enhance reliability and Mortality
Useful life
extend asset life. Time 62
 Phases of the Bathtub Curve
1. Infant Mortality Period:
• This initial phase is characterized by a high
failure rate due to early defects or issues
that arise shortly after the asset is put into
service.
• Because of incorrect operation, incorrect
foundation, incorrect understanding of
the machines, some design defect, etc.
• Preventive maintenance strategies during
this phase focus on intensive testing and
quality checks to identify and rectify
potential problems before they lead to
significant failures.
• Once these are taken care of, the failures
reduce and come down.
• And then enter useful period. 63
2. Normal Life Period
• In this stage, the failure rate
stabilizes, and failures become
less frequent and more random.
• Preventive maintenance
becomes essential, involving
regular inspections and
schedule maintenance tasks to
ensure optimal performance
and prevent unexpected
breakdowns. 64
3. Wear-Out Period
• As assets age, they enter the wear-out
phase where the failure rate increases
significantly due to deterioration and
reaching to the end of their useful life.
• At this point, predictive maintenance
techniques are crucial.
• Maintenance teams analyze data to
anticipate failures and perform
maintenance just in time to avoid
breakdowns.
Note: Toward the end of the life of the machine, wear/tear increases and the failure engage with time and time would have
come, when it is not wise to do any maintenance and it would be necessary for to almost replace the machine. 65
• During the infant mortality phase, focus
on rigorous quality assurance.
• In the Normal Life phase, implement
routine preventive maintenance
measures.
• As assets approach the Wear-Out period,
shift towards predictive maintenance
to manage increasing failure rates
effectively.

66
Preventive maintenance schedules to be two types:
•Fixed Time Maintenance (FTM)
•Condition Based Maintenance (CBM)
Fixed Time Maintenance: - Simple routine or cycles of work loads are
established for different day, week, month, year, etc.
Hourly: Lubricant Level, Sharpness of tool
Daily: Cleaning of Machine, Tightening of nuts, minor
adjust of parts.
Weekly: Major displacement, Lubrication
Monthly: Corrosion
 Parameter (Machine Condition)

Normal trend

Month

Just by a trend, Maintenance Engineer can planned necessary activities to reduce repair downtime and other
to match the high demand related to cost.
 Predictive Maintenance (PDM)
• Predictive maintenance is a set of activities that detect changes in the
physical condition of equipment (signs of failure) in order to carry out the
appropriate maintenance work for maximising the service life of
equipment without increasing the risk of failure.

• It is classified into two kinds according to the methods of detecting the signs
of failure:
• Condition-based predictive maintenance
• Statistical-based predictive maintenance 69
 Predictive Maintenance (PDM)

• Condition-based predictive maintenance depends on continuous or

periodic condition monitoring equipment to detect the signs of
failure.

• Statistical-based predictive maintenance depends on statistical

data from the meticulous recording of the stoppages of the in-plant
items and components in order to develop models for predicting
failures.
 Techniques for Predictive Maintenance

Transducers for monitoring CBM

Vibration Accelerometer
Wear Debris Spectrophotometer
Oil Particle Count Meter
Temperature IR Detector
Electric Current Ammeter
Pressure Pressure Gage
Flow rate Orifice meter, venturimeter
NDT techniques 71
SCORE Model
KU Experiment-06 on SCORE Test Rig III with Nottingham configuration
Performance

1400.00 100

power Wth, mBar, Temp

90 Pmean (LHS scale mBar)
1200.00
80
1000.00 Th-Tc Right scale K
70
800.00 60 Thleft
50
600.00 40 frequency
400.00 30
Tcright
20
200.00
10 Tcleft
0.00 0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00

minutes

P2pk P1pk
Tc left
Th right

Th left Tc right
 Condition-Based Monitoring (CBM)
•Condition monitoring means the use of advanced technologies in
order to determine equipment condition, and potentially predict failure.
•CBM involves the actual condition of equipment to determine
whether maintenance is needed, rather than relying on a fixed
schedule.
•The goal of CBM is to perform maintenance only when there are
indicators that equipment performance is deteriorating or that
failure is imminent.
74
CBM
• Focuses on assessing the current state of equipment through various
monitoring techniques, including sensors and data analysis.
• The primary goal is to perform maintenance only when specific indicators
signal that action is required, thereby optimizing maintenance efficiency and
minimizing downtime and costs.
• CBM process typically involves three key components:
1. Data Collection: Sensors gather real-time data on various parameters such as
vibration, temperature, pressure, etc.
2. Data Analysis: A software system, often a computerized maintenance management
system (CMMS), analyzes this data to identify patterns or anomalies.
3. Decision making: Maintenance teams use the analyzed data to decide when to
perform maintenance activities based on the actual condition of the equipment.
75
76
Benefits include:
• Reduction/elimination of unplanned failures
• Reduced overall maintenance costs
• Improved equipment performance - Key Performance Indicators (KPIs)
• Increased asset life
• Reduction/elimination of collateral damages
• Prioritized actions and jobs made easier
• Increased efficiency of maintenance management
• Avoiding opening up of equipment at fixed intervals
• Increased uptime/reduced downtime
 Challenges in Condition-Based Maintenance
• Initial Costs: Implementing a CBM program may require significant
upfront investment in technology and training.
• Data Management: Handling large volumes of data from sensors can
be complex and requires robust analytical capabilities.
• Cultural Shift: Transitioning from traditional maintenance practices to a
CBM approach may requires changes in organizational culture and
mindset.
78
 Summary - CBM
• Arise when equipment need preservation.
• Monitors the actual condition of the asset to decide what
maintenance needs to be done.
• CBM dictates that maintenance should only be performed when
certain indicators show signs of decreasing performance or
upcoming failure.
• Checking a machine for these indicators may include visual inspection,
performance data, scheduled tests, etc.
 Routine Maintenance
• Means carrying out minor maintenance job at regular intervals.
• involves minor jobs such as cleaning, lubrication , inspection.
OR
minor adjustment of pressure , flow , tightness, tightening of loose
part.
• Also includes inspection of bearing, v-belts, coupling, jointing
foundation bolts, and protective covers, etc
• The small and critical defects - observed during such inspection are rectified
immediately and biggest jobs are planned for rectification during next availabl
shutdown.
Routine maintenance is essential for effective scheduled and preventive maintenance
Design – out maintenance
Assignment 1

DOM – redesign equipment to fix problems permanently so it doesn’t need as much maintenance.
Maintenance cost
• Maintenance cost are a critical aspect of manufacturing operations, impacting both
financial performance and operational efficiency.
• Maintenance costs can significantly influence overall production expenses and should be
carefully managed to optimize profitability.
• Maintenance cost refers to the expenses associated with the upkeep of equipment,
machinery, and facilities to ensure they remain operational.
• Maintenance costs can be categorized into several components:
• Labor costs: This includes salaries for maintenance staff and any external contractors hired for
repair.
• Parts and Materials: Expenses for consumables like lubricants, filters, and replacement parts.
• Downtime: Periods when equipment is non-operational due to maintenance, leading to lost
productivity.
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 Total Maintenance Cost Calculation
The total cost of maintenance (TC) can be calculated using the formula:
TC = FC + VC +AC + FCS
Where,
FC = Fixed cost (e.g. Labor for scheduled maintenance)
VC = Variable cost (e.g. Labor and materials for corrective actions)
AC = Administrative costs (e.g. Spare parts inventory)
FCS = Failure Costs (Cost incurred due to equipment failure)
Note: Understanding this total cost helps organizations evaluate their maintenance
strategies and make informed decisions about resource allocation. 84
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A manufacturing company has a critical machine with the following annual costs:
• Maintenance Cost: $20,000.
• Production Downtime Cost (per hour): $5,000.
• Downtime Hours Due to Poor Maintenance: 30 hours.
• Cost of New Equipment: $150,000.

Case 1: Minimal Maintenance Case 2: Enhanced Maintenance

•Total Downtime Cost: 30×5,000=150,000 •Doubling maintenance cost to $40,000 reduces downtime to 5 hours.
•Total Cost = Maintenance Cost + Downtime Cost •Total Downtime Cost: 5×5,000=25,000
= 20,000+150,000=170,000 •Total Cost = Maintenance Cost + Downtime Cost
= 40,000+25,000=65,000

Case 3: Equipment Replacement

•New machine eliminates most downtime (e.g., 1 hour annually).
•Total Cost = Equipment Cost + Minimal Maintenance = 150,000+20,000=170,000

By analyzing these costs, business can make informed decisions to maximize uptime and profitability.
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Maintenance commitment refers to dedication of resources – both financial and human – to
ensure that equipment is maintained properly. This includes:
• Preventive maintenance programs: Regularly scheduled inspections and maintenance tasks aimed at
preventing equipment failures.
• Predictive maintenance programs: Utilizing data analytics to forecast potential equipment failures
before they occur, thereby reducing unexpected downtime.
• Training and development – investing in training programs for staff to enhance their skills in
performing maintenance tasks efficiently. 87
End of module 1 & 2

Computerized Maintenance Management

System

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