Lesson 5: Maintenance systems
In this lesson, we will explore different maintenance systems used to ensure the availability of machinery and equipment, including on-demand maintenance, planned preventive maintenance, maintenance based on technical condition testing, Total Productive Maintenance (TPM), and Reliability Centered Maintenance (RCM).
- The reliability and availability of machinery, equipment, and components are crucial in various industries.
- The choice of maintenance system depends on factors like repairability, the consequences of failure, and available technological options.
- Let’s delve into different maintenance systems that organizations employ to ensure smooth operations and minimize downtime.
On-Demand Maintenance and Repair
- In this system, repairs are carried out only after a failure has occurred.
- Failed components or parts are repaired or replaced when needed, along with regular care and lubrication operations.
- Advantages: Certain components can be used to their wear limits.
- Disadvantages: Unplanned intervention leads to longer downtime, and immediate replacement isn’t always possible.
Planned Preventive Maintenance (PPM)
- PPM focuses on preventing faults and eliminating unexpected failures.
- Common in industries, it involves scheduled inspections and repairs based on a predefined cycle schedule.
- Maintenance activities during PPM include regular inspections, adjustments, and significant repairs.
- The goal is to maintain machinery and equipment in optimal working condition and prevent unexpected failures.
Preventive Maintenance Based on Technical Condition Testing (Diagnostics)
- Traditional preventive maintenance relies on analyzing component wear and logic laws.
- However, complex factors can influence component service life, making wear analysis less accurate.
- Diagnostics involve continuous or periodic instrumental condition tests during operation to determine the timing of maintenance and repair.
- This approach considers uncertain factors like material quality, operating conditions, and handling of machinery.
Total Productive Maintenance (TPM)
- TPM, originating in Japanese industry, emphasizes preventive maintenance involving all employees.
- It began with adopting preventive maintenance from the USA and evolved into a holistic approach.
- TPM includes elements like improving equipment utilization, introducing autonomous maintenance by operators, planned maintenance, training programs, and designing reliable and maintainable machinery.
- It focuses on employee involvement and collaboration in maintaining equipment.
- The choice of a maintenance system depends on the specific needs of an organization, including the nature of machinery, repairability, and operational consequences.
- Maintenance systems aim to enhance machinery reliability, minimize downtime, and extend equipment life.
- Organizations may adopt a combination of maintenance systems to meet their unique requirements.