Maintenance Management
MP3704
Types of Maintenance
Machinery Engineering Cycle
Types of Maintenance
• According to Time of Maintenance
Maintenance
Corrective Preventive Proactive Improvement
Maintenance Maintenance Maintenance Maintenance
(CM) (PM) (PaM) (IM)
1- Corrective Maintenance (CM)
1) Corrective/Reactive/Breakdown Maintenance:
Involves repairing equipment after it has already failed. This type
of maintenance occurs reactively and is typically repaired to
restore equipment to a working state after it breaks down (bring it
back to original state/operating condition).
Only done after the failure occurs.
No advance planning or scheduling.
Disadvantages of Corrective Maintenance:
o Can cause unexpected downtime and production losses.
o Higher repair costs due to emergency fixes.
o Shortens equipment lifespan due to excessive wear and tear.
Types of Corrective/Breakdown Maintenance
According to Planning or Scheduling
Planned
Breakdown
Breakdown Maintenance
Maintenance Unplanned
Breakdown
Maintenance
Minor
Types of Corrective Maintenance (CM) Stoppage
According to time of repair failure/fault
Minor
Breakdown
Breakdown
Medium
Breakdown
Major
Breakdown
Types of Corrective Maintenance (CM)
According to Maintenance Activities Fail-
Salvage repair
CM
Rebuild
Types
Servic- Over-
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1. Fail-Repair:
Identifying the failure, diagnosing the cause, repairing or
replacing the faulty component and restoring the system to its
operational state.
Examples:
o Replacing a Burnt-Out Power Supply
o Refilling hydraulic oil to repair a hydraulic pump.
2. Re-build:
Fully disassembling, inspecting, repairing, or replacing worn
components, and reassembling a machine or system to restore it
to like-new condition.
3. Overhaul:
Comprehensive and detailed repair process that involves
disassembling, inspecting, repairing, and reassembling a machine
or system to restore its functionality.
4. Salvage:
Recovering and reusing functional parts from failed or
decommissioned equipment. Instead of discarding the entire
machine, usable components are extracted, inspected, and either
reused, refurbished, or repurposed in other equipment.
Examples:
o Bearings, if they are still in good condition.
o Wiring and connectors can be reused in other motors.
5. Servicing:
Performing minor repairs, adjustments, or part replacements to
restore a faulty or underperforming machine to proper working
condition.
Examples:
o Servicing a Faulty Conveyor Belt due to a misalignment issue.
2- Preventive Maintenance (PM)
1. Inspection:
Regularly checking equipment for signs of wear, damage, or
potential failure.
Examples:
o Inspecting belts and bearings in a conveyor system for wear or
misalignment.
2. Calibration:
Adjusting and verifying the accuracy of equipment, instruments,
or sensors to ensure they provide correct and consistent
measurements.
Examples:
o Calibrating a Pressure Gauge
3. Alignment:
Ensuring that the components of a machine or system (such as
shafts, gears, or belts) are properly aligned with each other.
Examples:
o Shaft Alignment – Ensuring the shafts of rotating equipment
(e.g., motors, pumps) are aligned to avoid uneven wear or
vibrations.
4. Servicing:
Regular maintenance tasks performed on equipment to ensure it
continues to operate efficiently and reliably such as: lubricating,
and cleaning
Examples:
o Lubricating moving parts to minimize wear.
5. Testing:
Evaluating equipment, systems, or components to ensure they
are operating correctly, meet performance standards, and are
free from defects or potential issues.
Examples:
o Testing a Fire Alarm System by testing sensors and detectors to
ensure they detect smoke or heat accurately.
6. Adjustment:
Modifying equipment settings to ensure it operates at optimal
performance as calibrating controls, changing operational
parameters, or making small changes to components like tension,
speed, or pressure to maintain smooth and efficient functioning.
Examples:
o Adjusting the Tension on a Conveyor Belt
7. Installation:
Setting up, placing, or integrating new equipment, components,
or systems into an existing setup to ensure that everything
operates correctly and efficiently.
Benefits of Preventive Maintenance Program:
• Availability of information
• Prevention of sudden failure
• Optimizing equipment performance
• Managing the manpower
• Minimizing the inventory stock
• Reducing number of breakdowns
• Increasing efficiency and performance
• Decreasing Maintenance costs.
Steps of Setting up a PM Program
1. Identify and classify the equipment to be maintained.
2. Identify the PM needs (Maintenance procedures)
3. Identify spare part list that are required for each equipment.
4. Identify the Required tools
5. Prepare the PM assignments. (Maintenance Requirement Cards
MRCs)
6. Schedule the PM assignments on annual basis.
Eng. Nermeen Adly
