MBEYA UNIVERSITY OF SCIENCE

AND TECHNOLOGY

DEPARTMENT OF MECHANICAL AND INDUSTRIAL

ENGINEERING (MIE)

INDUSTRIAL SAFETY AND MAINTENANCE

MODULE CODE:ME 6314

 PREVENTIVE AND CORRECTIVE
MAINTENANCE
 CORRECTIVE MAINTAINANCE:-
 Real approach,
 Dealing with breakdowns or problems when they occur…
 PREVENTIVE MAINTENANCE:-
 Proactive approach;
 Reducing breakdowns through a program of lubrication,
adjustment, cleaning, inspection, and replacement of worn
parts.
 PREVENTIVE AND CORRECTIVE
MAINTENANCE
 The best approach is to
seek a balance between
preventive maintenance and
breakdown maintenance.
The same concept applies
to maintaining production
systems.
 The age and condition of
facilities and equipment,
the degree of technology
involved,
 The type of production
process,
 The decision of how much
preventive maintenance is
desirable.
 CORRECTIVE MAINTENANCE (CM)
• CM refers to maintenance actions performed to restore a failed
or malfunctioning system/asset to its operational state. It is
reactive in nature, as it occurs after a failure has been detected.
• The elements of CM are:
i. Failure/fault identification. A failure has to be identified and
located.
ii. Troubleshooting/diagnosis. The cause of the failure has to
before corrective actions are taken.
iii. Repair planning & execution. Resources to be used are
mobilized.
iv. Testing. The equipment is tested to validate the repair work
v. Report (documentation).
 CORRECTIVE MAINTENANCE:
• Corrective maintenance is a practical approach for non-critical,
low-cost, or redundant systems where failures are manageable.
Its typically applied to small scale operations.

When Is Corrective Maintenance the Best Choice?

• Corrective maintenance is most effective when:

✔ The asset’s failure does not disrupt operations severely.
✔ The cost of preventive maintenance outweighs repair costs.
✔ The equipment is inexpensive or easily replaceable e.g. Light
bulbs, fuses etc.
✔ Failures are unpredictable and do not pose safety risks.
 PREVENTIVE MAINTENANCE:
Preventive maintenance involves all actions that are meant at
keeping/preserving the optimum working condition of an
equipment.

Compared to corrective maintenance, it is best for critical

operations (e.g. aviation & health care), high valued assets, high
safety risk operations and where equipment deterioration is
predictable.

Its elements include; cleanliness, inspections, lubrication,

calibrations, replacement of parts and tightening/adjustments.
 PREVENTIVE MAINTENANCE:
 Preventive maintenance extends back to the design and
selection stage of equipment and facilities.

 Poor design can cause equipment to wear out at an early age or

experience a much higher than expected breakdown rate.

 Durability and ease of maintenance can have long term

implications for preventive maintenance programs.

 Training employees in proper operating procedures and in how

to keep equipment in good operating order – and providing the
incentive to do so – are also important.
 PREVENTIVE MAINTENANCE:

• Preventive maintenance is periodic i.e. repeated after given

intervals
• Preventive maintenance is generally scheduled using some of
the following contributions:-
i. The result of planned inspections that reveal a need for
maintenance.
ii. According to the calendar (passage of Time).
iii. After a predetermined no. of operating hours.
• OEM (original equipment manufacturer) provides the initial
information on when to do (intervals) and which parts are to
be replaced.
• The main objectives of Preventive maintenance are to
minimize downtime by preventing failures and cost saving.
 PREVENTIVE MAINTENANCE:
Advantages of Preventive Maintenance:
• Reduces unwanted downtime
• Extends equipment lifespan
• Lowers repair costs (avoids major breakdowns)
• Improves safety by preventing catastrophic failures
• Enhances operational efficiency and performance.
Despite the obvious advantages of PM, most industries still use
both CM and PM for a balanced approach. CM for less critical
assets and PM for critical assets
 CM vs. PM comparison
Aspect Corrective Maintenance (CM) Preventive Maintenance (PM)

Reactive: Fixes failures after they Proactive: Prevents failures

Definition
occur. before they happen.

Lower short-term costs, but higher Higher upfront costs but reduces
Cost
long-term risks. major repair expenses.

Scheduled, minimizing
Downtime Unplanned, often disruptive.
operational impact.

Labor Intensity Irregular, emergency-based. Planned, systematic.

Non-critical, low-cost, or redundant Critical, high-value, or safety-

Best For
equipment. sensitive assets.

Basic repair tools, troubleshooting CMMS, sensors, checklists,

Tools Used
guides. condition monitoring tools.

Fixing a broken conveyor belt after Replacing the belt every 6

Example
it snaps. months before it wears out.
 PREDICTIVE MAINTENANCE (PdM)
• PdM is a philosophy or attitude that, simply stated, uses the actual
operating condition of plant equipment and systems to optimize
total plant operation.
• PdM is an advanced, data-driven maintenance approach that uses
real-time monitoring and analytics to predict equipment failures
before they occur. Unlike preventive maintenance (which follows a
schedule) or corrective maintenance (which reacts to failures), PdM
anticipates issues based on actual asset conditions.
• A comprehensive predictive maintenance management program
uses the most cost-effective tools (e.g., vibration monitoring,
thermography, tribology) to obtain the actual operating condition of
critical plant systems and based on this actual data schedules all
maintenance activities on an as-needed basis.
 PREDICTIVE MAINTENANCE:
Technique What It Monitors Best For
Vibration Bearings, motors,
Rotating machinery
Analysis pumps
Heat patterns in
Thermography Electrical panels, motors
electrical/mech.

Lubricant Engines, gearboxes,

Tribology
contamination hydraulics

Leaks, steam traps,

Ultrasound High-frequency
electrical faults, thickness
Testing sounds
measurements
Current Motor/electrical
HVAC, industrial motors
Analysis load
PREDICTIVE MAINTENANCE:

Vibration analysis
PREDICTIVE MAINTENANCE:

Ultrasonic testing
PREDICTIVE MAINTENANCE:

Thermography
 PREDICTIVE MAINTENANCE:
Advantages of Predictive Maintenance
• Maximizes availability (fixes issues before failure).
• Reduces unnecessary maintenance (only acts when needed).
• Extends asset lifespan by avoiding over-maintenance.
• Lowers costs (prevents catastrophic breakdowns).
• Improves safety by preventing hazardous failures.

Limitations
• High initial cost (sensors, software, training).
• Requires skilled personnel (data analysts, engineers).
• Not ideal for simple/low-value equipment (CM/PM may be cheaper).
 TRIBOLOGY

This is the study of wear, friction and lubrication. Several tribology techniques
can be used for predictive maintenance: lubricating oil analysis, spectrographic
analysis, ferrography, and wear particle analysis. Component wear and lubrication
problems are responsible for at least 70 % of mechanical failures.
• Oil analysis - an analysis technique that determines the condition of lubricating
oils used in mechanical and electrical equipment. It is used to determine
viscosity, fuel soot, dilution, oxidation, nitration, solid contents, Total acid
number (TAN), Total base number (TBN) etc.
• Spectrographic analysis – determines the elements present in the lubricant.
• Ferrography – similar to spectrographic analysis but uses magnetic field to
separate contaminants but it's limited to ferrous and magnetic materials.
• Wear particle analysis - provides direct information about the wearing
condition of the machine. Particles in the lubricant of a machine can provide
significant information about the condition of the machine. This information is
derived from the study of particle shape, composition, size, and quantity
 WEAR MECHANISM
This is various microscopic physical processes, by which the particles are removed
as wear debris as a result of sliding motion between two surfaces. These mechanisms
are categorized as:
• Adhesive wear: The molecular attractions existing between two relatively moving
surfaces create adhesion between the touching asperities. If the adhesive strength
is greater than the internal cohesive strength of the material, there is a tendency to
create a wear particle after several cycles of contact.
• •Abrasive wear: When a hard material is sliding against a soft material.
• •Surface‐fatigue wear: when a surface layer starts to break due to stress induced
fatigue.
• Corrosive (chemical): occurs when a sliding surface chemically reacts with the
partner surface or the environment or both.
• Thermal wear: this general occurs in polymers where heat alters the properties of
a material and causes it to deteriorate.

Wear erosion may be uniform like the wearing‐away of piston rings in an internal
combustion engine or non‐uniform the pitting in gear teeth and cam surfaces.
 TOTAL PRODUCTIVE MAINTENANCE (TPM)

• TPM is a proactive, team-based approach to maintenance that

aims to maximize equipment effectiveness, eliminate
breakdowns, and improve productivity by involving all
employees from operators to management in maintaining
equipment.
• It has been adopted from Japanese JIT system, where employees
are given greater responsibility for quality, productivity and the
general functioning of the system. This approach is directed at
the production function and assume that maintenance will
provide the basic tasks required to maintain critical production
assets. All of the quantifiable benefits of TPM are in terms of
capacity, product quality, and total production cost.
• It is a program of zero breakdowns and zero defects aimed at
improving or eliminating losses.
TOTAL PRODUCTIVE MAINTENANCE (TPM)
• These losses are equipment breakdowns, setup and adjustment
slowdowns, idling and short-term stoppages, reduced capacity,
quality-related losses and startup/restart losses.
• The benchmark of all TPM programs is the Overall Equipment
Effectiveness (OEE). Measuring OEE must go beyond
just the availability or machine uptime. It must
factor in all issues related to equipment
performance. The formula for equipment
effectiveness must look at the availability, the rate
of performance, and the quality rate. This allows all
departments to be involved in determining
equipment effectiveness.
OEE = Availability x Performance Rate x Quality Rate
 TOTAL PRODUCTIVE MAINTENANCE (TPM)
OEE = A x P x Q
where:
A (Availability) = planned time - downtime
planned time

P (Performance rate) = (standard time/unit)(units produced)

Operating time

Operating Time = (planned time - downtime)

Q (quality rate) = (total production) - (number of defects)

total production

World class OEE ≥ 85%

TOTAL PRODUCTIVE MAINTENANCE (TPM)
 TOTAL PRODUCTIVE MAINTENANCE (TPM)
PILLARS OF TPM
s/n PILLAR GOAL BENEFITS

1 Autonomous Empower operators to perform Early fault detection,

Maintenance basic maintenance (cleaning, reduced downtime,
lubrication, inspections). increased ownership.
2 Planned Schedule maintenance based on Minimizes unplanned
Maintenance data (preventive & predictive). failures, extends
equipment life.
3 Focused Continuously improve equipment Solves chronic problems
Improvement performance via small-group e.g., bottlenecks, defects
projects
4 Early Design and install new equipment Reduces future
Equipment for easy maintenance breakdowns and lifecycle
management (maintainability) costs
5 Quality Eliminate defects by maintaining Improves product quality
Management ideal machine conditions. and reduces rework.
 TOTAL PRODUCTIVE MAINTENANCE (TPM)

PILLARS OF TPM
s/n PILLAR GOAL BENEFITS

6 Training & Upskill employees in maintenance, Better troubleshooting,

Education problem-solving, and TPM fewer human errors.
principles.
7 Safety, Health Ensure zero accidents and eco- Safer workplace,
& Environment friendly operations. compliance with
regulations.
8 TPM in Extend TPM principles to support Reduces indirect losses
Administration departments (purchasing, (e.g., delays, paperwork
logistics). errors).
 TOTAL PRODUCTIVE MAINTENANCE (TPM)

TPM was founded on the principles of 5S.

5S stands for:
• Sort (seiri) – identify and separate things according to their type
(organize).
• Set (seiton) (Set in order) – Place similar things together (a place
for everything and everything in its place)
• Shine (seiso) – Ensure tools, equipment and workspace are clean.
• Standard (sekeitsu) - standardize all work processes, making them
consistent
• Sustain (shitsuke) - constantly reinforcing the first four steps.
 TOTAL PRODUCTIVE MAINTENANCE (TPM)

Steps in implementing TPM

1. Get management commitment.
2. Train employees on TPM principles.
3. Start with 5S & Autonomous Maintenance.
4. Measure OEE and identify losses.
5. Form small improvement teams (Kaizen).
6. Expand to all 8 pillars gradually.
7. Standardize & sustain best practices.
Benefits of TPM are reduced downtime, losses, defects, costs and
increase in safety, quality of goods and OEE
 MAINTENANCE PLANNING
• Determine the job content.
• Develop work plan. This entails the sequence of the activities in the
job and establishing the best methods and procedures to accomplish
the job.
• Establish crew size for the job (labour size)
• Plan and order parts and material.
• Check if special tools and equipment are needed and obtain them.
• Assign workers with appropriate skills.
• Review safety procedures.
• Set priorities for all maintenance work.
• Assign cost accounts.
• Complete the work order.
• Review the backlog and develop plans for controlling it.