Maintenance, Maintenance types, breakdown maintenance, preventive maintenance

The maintenance division of the factory ensures the availability of machines and equipment to perform their function at optimum conditions. This article contains objective of plant maintenance, important of plant maintenance, maintenance types and discussion.

Maintenance :

  With the development of special-purpose machine and equipment, it cost a lot more money so their idle time and downtime becoming a lot more expensive day by day. Therefore, it is important that plant machinery and equipment should be properly maintained.


Objective of plant maintenance :

  • The maintenance division of the factory ensures the availability of machines and equipment to perform their function at optimum conditions.
  • The objective of plant maintenance division is to achieve minimum breakdown and to keep the plant in excellent condition at the lowest possible cost.
  • Kept the plant in such condition that, it should run without any interruption.

Importance of maintenance department :

  • Depending upon the size of the maintenance department and type of production, it has a wide variety of duties.
  • The maintenance department plays an important role in production because plant breakdown creates problems such as time loss, Rescheduling of production, temporary work shortages, need for overtime, inefficient productivity, etc.
  • If an equipment goes out of service in a flow production plant, the whole line soon comes in a halt. It results loss in productivity.
  • The maintenance engineer inspects the plant, determines necessary changes to be made, and reports to the plant manager.
  • Maintenance department involves alterations and improvement in existing equipment and building to minimize breakdown.


Maintenance types :

                                                 Maintenance can be classified into 4 categories -
  1. Corrective or breakdown maintenance,
  2. Scheduled maintenance,
  3. Preventive maintenance,
  4. Predictive maintenance.

1. Corrective or Breakdown maintenance :

                                                                                                          In Corrective or Breakdown maintenance repairs are made after the equipment is out of order and it can not perform its normal function. In that case the maintenance department comes into action and makes necessary repair after checking. They do not attend the equipment until another breakdown occurs.
Breakdown leads to poor maintenance, excessive delays in production, more spoilt material and profit loss.
This types of maintenance is justified for small plants, where they do not feel financial justification for scheduled techniques Corrective or Breakdown maintenance need few records and small staff.

2. Scheduled maintenance :

                                                                      Breakdown maintenance can’t be applied in the maintenance of cranes, lifts, hoists and pressure vassals. Scheduled maintenance must be applied in such a condition. Scheduled maintenance department inspect equipment early and makes necessary changes to avoid breakdown. Scheduled maintenance incorporates, inspection, lubrication, and repair certain equipment.


3. Preventive maintenance :

                                                                      In preventive maintenance locates weak spot like bearing, part under excessive vibration, pressure vessel etc which needs regular inspection and minimal repair thereby reducing the danger of breakdown.
Preventive maintenance involves periodic inspection of components and keeps them to correct  such condition while they are still in the minor stage. To make plant equipment always ready for use and achieve maximum production.

4. Predictive maintenance :

                                                                  It is newer maintenance technique uses human senses or sensing instrument such as Audio gauge to sense machine sound, Vibration analyzer for checking vibration, Amplitude meter, thermometer, pressure gauge, etc, to predict trouble before breakdown.
In predictive maintenance, equipment condition are measured periodically to take timely action such as equipment adjustment, repair, or overhaul.
Predictive maintenance increases the lifetime of the equipment.


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