All activities involved in keeping a system’s
equipments working are the part of maintenances
management. Maintenance of machine involves the
efforts directed towards the upkeep and repairs of
that machine. Maintenance are the set of activities
performed to keep an equipment in the specified
condition or it is remedial action to restore the
equipment to its specified condition. Maintenance
can be improved by enlarging repair crews, by
increasing repair capabilities and providing more
inventory of replacement items.
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Maintaining system capability
Minimizing total costs
Ensuring maximum plant availability by preventing
unexpected breakdowns and by reducing shutdown
periods
Maintenance of equipment and its rated productivity
and original accuracy
Elimination of unsafe conditions that cause accidents
thereby ensuring safety of workmen
Minimization of wear and tear to increase the
longevity of the equipment
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Excessive friction between the parts
Failure to replace parts that are known to wear
Neglected cooling system
Neglected common minor faults
Overloading of machines, wrong fuel, obstruction of
air intakes, faults in another items of equipment
Design or manufacturing defects of the equipment
Installation deficiencies
Improper handling of the machines by the oprators
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Down time cost
Idle wages
Loss of material
Cost of repairs
Opportunity costs
Effect on another machines
Tool breakage
Overtime wages paid to the maintenance
Higher costs for urgency of spare parts
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For keeping Plants and equipments in good working
conditions
plants and equipments are the heart of the production
system, therefore proper maintenance of plant and
equipments is essential for keeping them in good
working condition. This ensures optimum utilization
of production facilities and resources. All production
equipments are designed to give a predetermined
quantity and quality of output. This objective can be
achieved by proper maintenance.
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For maximizing the production performance
Proper maintenance helps to maximize the
production performance by preventing breakdowns
and by minimizing the loss caused by breakdowns.
In a developing country like India, maintenance has
a significant importance. The capital is scarce and its
best possible use is essential. Moreover, the natural
conditions like climate and extreme humidity
requires special upkeep of equipment. Proper
maintenance results in better performance and longer
life of machinary.
Planned maintenance
a)Preventive maintenance
b)Corrective maintenance
 Unplanned maintenance
 Routine maintenance
a) Running maintenance
b) Shutdown maintenance
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Planned maintenance refers to the system of
maintenance wherein the maintenance work is
planned in advance, work is executed as per
schedule, actions taken are recorded on completion,
historical and statistical records so produced and
maintained are revived/ analyzed to identify the
gaps/ deficiencies in planning and feedback is
utilized to devise strategies for accomplishing better
performance.
It anticipated failure and adopts necessary actions to
check failure before they occurs. It includes activities
like inspections, lubrications, cleaning and upkeep,
minor adjustments and replacements found necessary
at the time of inspection.
Preventive maintenance is one of the key activities of
preventive maintenance which is usually performed
by making use of human sense- watch(eyes),
hear(ear), touch(hand ,leg, body), smell(nose), and
taste(tongue)- but the trend is now changing towards
use of condition monitoring instruments. Such a
maintenance practice is known as predictive
maintenance or condition based maintenance.
Preventive maintenance can significantly reduce the
rate of wear and tear of machinery but cant wholly
eliminate it. Equipment thus functionally degrades
over a period and its performance gradually drops
below is acceptable limits. Corrective maintenance is
the maintenance work undertaken to compensate for
wear and tear, planned either on yearly, six monthly,
or some other basis, to restore the equipment back to
an acceptable condition.
Since in spite of elaborate planned maintenance system,
chance equipment failure can still occur, the firm
will always have some unplanned maintenance work.
Unplanned maintenance thus is the maintenance
work performed which is not planned in advance.
a) Emergency maintenance
b) Breakdown maintenance