Maintenance development stages

Maintenance development stages

1. Break-down maintenance: is remedial or corrective maintenance that occurs when equipment fails and must be repaired on an emergency or priority basis. It means that people

waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than

repair cost.

• Obviously this is not an ideal way of keeping equipment or machinery operating because of the

down time of the equipment or machinery when break down occurs.

• This results in loss of production due to idling of equipment and machinery and consequently idling of labour also. Ultimately customers orders cannot be delivered as promised

2 Preventive maintenance (1951):

It is a daily maintenance (cleaning, inspection, oiling and retightening),

design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.

3. Periodic maintenance (Time based maintenance - TBM):

Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

4. Predictive maintenance:

This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages

trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.

In this concept, OPERATORS operates the machines for production and the MAINTENANCE group is responsible with work of maintaining those machines, however, maintenance became a problem as more maintenance personnel are required.

3. Autonomous Maintenance:

When the maintenance part is not always controlled by outside forces like maintenance group and the operator can able to handle it everyday, called autonomous maintenance.

4.Productive Maintenance:

Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement

gave birth to

(4) Productive maintenance. According to Nakajima, ‘Total productive Maintenance is productive maintenance carried out by all employees through small group activities. In TPM, the machine operator is responsible for the maintenance of the machine as well as its operation.