Importance of maintenance department :

1. Corrective and Breakdown Maintenance

Corrective maintenance and breakdown maintenance are interrelated terms, but with slight distinctions:

Corrective Maintenance:

• Focus: This approach targets fixing problems that have already surfaced. Equipment malfunctions, performance issues, or complete breakdowns trigger corrective maintenance actions.
• Proactive vs. Reactive: Corrective maintenance leans slightly more towards the proactive side. While it addresses existing problems, it might involve troubleshooting to identify the root cause and prevent similar issues in the future.
• Planning: Corrective maintenance can be planned or unplanned. Planned corrective maintenance might address a recurring issue identified during previous breakdowns. Unplanned corrective maintenance occurs when a machine unexpectedly malfunctions.

Breakdown Maintenance:

• Focus: Breakdown maintenance is purely reactive. It refers to repairs performed only after equipment completely fails and becomes unusable.
• Planning: Breakdown maintenance is by definition unplanned. It disrupts operations and can lead to significant downtime.

Here’s an analogy to illustrate the difference: Think of your car. Corrective maintenance would be like noticing a strange sound and taking your car to the mechanic to diagnose and fix the issue before it breaks down entirely. Breakdown maintenance would be waiting until your car sputters to a halt on the side of the road before calling for a tow truck.

When is Corrective/Breakdown Maintenance Used?

• Less Critical Equipment: Corrective or breakdown maintenance might be suitable for non-critical equipment where downtime isn’t overly disruptive to production.
• Cost-Effectiveness Calculations: In some cases, if the cost of preventive maintenance outweighs the potential cost of breakdowns for a particular piece of equipment, corrective/breakdown maintenance might be a calculated decision.

2. Scheduled Maintenance

The Key Elements of Scheduled Maintenance:

• Planning: This is the foundation. It involves creating a comprehensive maintenance plan that outlines the specific tasks required for each piece of equipment, the frequency of those tasks (daily, weekly, monthly, etc.), and who is responsible for completing them. Manufacturer recommendations, industry best practices, and the plant’s own historical data all play a role in crafting this plan.

• Scheduling: Once the plan is defined, specific times are allocated for each maintenance task. This ensures tasks are completed consistently and avoids equipment neglect. Scheduling considers factors like production downtime and resource availability to minimize disruption to operations.

• Execution: When the scheduled time arrives, qualified technicians perform the planned maintenance tasks. This might involve inspections, lubrication, adjustments, minor repairs, or part replacements. The goal is to identify and address potential problems before they snowball into major issues.

Preventive maintenance (PM) is a proactive strategy for ensuring the smooth operation and longevity of equipment. Instead of waiting for machinery to break down (reactive maintenance), PM focuses on preventing problems before they occur. Imagine it as taking your car for regular oil changes and tune-ups – essential to keep it running smoothly and avoid expensive breakdowns on the road.

Here’s a breakdown of preventive maintenance in a plant:

• Core Principles: PM revolves around regular inspections, servicing, and upkeep of equipment based on a predetermined schedule. Manufacturer recommendations, industry best practices, and the plant’s own historical data on equipment performance all guide the creation and execution of a PM program.

• Tasks and Activities: The specific tasks involved in PM vary depending on the equipment, but common activities include:

  • Inspections: Checking for signs of wear and tear, leaks, or loose components.
  • Lubrication: Replacing or replenishing lubricants to minimize friction and wear.
  • Adjustments: Fine-tuning equipment to ensure optimal performance.
  • Cleaning: Removing dirt, debris, and contaminants that can hinder performance.
  • Minor Repairs: Addressing small issues before they escalate into major problems.
  • Part Replacements: Replacing worn-out parts based on a predetermined schedule or when performance indicators suggest they’re nearing failure.

• Benefits of PM: A well-implemented preventive maintenance program offers a multitude of advantages:

  • Reduced Downtime: By proactively addressing potential problems, PM minimizes unexpected equipment failures that halt production. This translates to increased uptime and higher output.
  • Extended Equipment Lifespan: Regular maintenance catches minor issues early on, preventing them from morphing into bigger problems that shorten a machine’s lifespan. PM helps equipment run smoothly for longer.
  • Enhanced Safety: Regular inspections inherent in PM identify potential safety hazards before accidents occur. This proactive approach safeguards the well-being of employees.
  • Cost Savings: While there’s an upfront cost associated with PM, it’s significantly cheaper than dealing with unexpected equipment failures and costly repairs. Catching problems early on prevents minor issues from escalating into major ones.
  • Improved Efficiency: Well-maintained equipment operates at peak performance. This translates to efficient use of energy and raw materials, minimizing waste and maximizing output. PM keeps things running smoothly and efficiently.

When is Preventive Maintenance Used?

Preventive maintenance is the preferred approach for most, if not all, plant equipment. Here’s why:

• Universality: PM applies to a wide range of equipment, from critical machinery that directly impacts production to auxiliary systems like lighting and ventilation.
• Cost-Effectiveness: The cost savings associated with preventing breakdowns and extending equipment lifespan outweigh the upfront investment in PM in the long run.
• Safety: A proactive approach to maintenance minimizes the risk of accidents caused by equipment malfunctions.
• Predictability: PM schedules bring predictability to plant operations, allowing for better planning of production and resource allocation.

While corrective/breakdown maintenance might seem tempting for less critical equipment, it often leads to higher overall costs due to potential downtime and the risk of cascading failures. Preventive maintenance is the cornerstone of a reliable, safe, and cost-effective plant operation.

Before establishing the predictive maintenance program within a factory, an organization must take several steps, which include:

• Analyzing the need and failure history of the equipment
• Reviewing all available records on downtime, defected equipment, losses (yield and energy), potential regulatory fines and workplace safety
• Establishing definitions and concepts as well as building a case for predictive maintenance
• Educating major stakeholders about the technique and getting buy-in 
• Completing an equipment inventory and evaluative the current equipment conditions
• Selecting equipment for the program of initial implementation
• Developing system details based on individual systems and components
• Evaluating any existing preventive or predictive maintenance data
• Deciding which systems to include and what to inspect for
• Defining the program’s criticality and establishing predictive maintenance frequency and schedule type
• Evaluating the anticipated resources and assigning maintenance worker’s roles and responsibilities.