Types of Maintenance
1). Breakdown Maintenance- proceeds after equipment breaks down.
There are two kinds of breakdown maintenance:
- Planned maintenance: Carried out when it is more economical to deal with a problem after the machine has failed than to prevent the failure.
- Unplanned repair- involves failures that would have been better to prevent . It puts the production schedule at risk and often carried out in panic.
2). Preventive Maintenance:-Health Management for Machines- 3 Activities
1. Daily cleaning, checking, lubricating, tightening to prevent deterioration.
It can be weekly, monthly, quarterly or yearly -similar to car maintenance.
2. Periodic inspection or equipment diagnoses to measure deterioration.
Goal here: Be proactive -prevent costly, extensive repair & future damage.
3. Restoration to correct specification / requirement & recover deterioration
Similar to your car tire rotation, oil/filter change, dental hygiene cleaning.
3). Predictive Maintenance: - It is actually a sub-set of Preventive Maintenance
It utilizes historical information/ data from PM logs, computerized maintenance management system (CMMS) data base- plan future/predictive maintenance.
It utilizes automated sensors to detect changes in physical equipment characteristics, which are known precursors to equipment breakdown and are otherwise difficult to detect. Vibration, Infra red, Temperature, ultrasonic analysis to help predict (being pro-active)- future maintenance requirements.
4). Corrective Maintenance: - Improve activities that………….
· Keep equipment from breaking down.
· Facilitate inspection, repair and use; Ensure safety considerations.
· Improve machines (could be technical, performance, quality, repeatability, safety, or whatever corrective improvement that will make it even better.
Based on these breakdowns records and improvement ideas, maintenance specialists / equipment designers study recurring problems to improve or modify machines to ensure less likely to break down, easy to maintain /safe
5). Maintenance Prevention:
- Equipment design or redesign to make equipment-”maintenance free”, like easily repairable and use, safe, inexpensive-like maintenance-free battery.
- Feedback of specialists / operators obtained during corrective maintenance process may lead to design maintenance prevention items-life-time bearing
6). Total Productive Maintenance (TPM)-100% cross-functional Involvement
- Involves all types, disciplines- collective team & total collaborative effort Operators, engineers (design, process), maintenance personnel, suppliers, Quality, safety & supervisory personnel –A Macro team focused strategy.
- TPM ensures common goal and team work and purpose (the Indy race car) philosophy to “win the race” collectively for successful implementation.
- The combined efforts of breakdown mix, preventative mix, predictive mix, correction mix & maintenance mix establish TPM mix-Focus organization toward the best team-oriented economic solutions for equipment operation.
