Preventive Maintenance (Time based): Maintenance repairs are performed on a regular schedule to minimize component degradation and extend the life of equipment. Preventive maintenance is performed after a set amount of elapsed calendar time or machine run time, regardless of whether the repair is needed. While more cost-effective than reactive maintenance, preventive maintenance still requires substantial human resources and replacement parts inventories. Preventive maintenance which was chosen as an improvement step over Breakdown Maintenance is of immense importance in industries. The output & quality of next step process is quite dependent on previous process. Hence it is very important that all processes are managed efficiently. Preventive maintenance plays important role here in upkeep of all process equipments.
Predictive Maintenance (Condition based):
Predictive maintenance can be defined as measurements that detect the onset of degradation mechanism, thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability. Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule. Preventive maintenance is time-based. Activities such as changing lubricant are based on time, like calendar time or equipment run time. For example, most people change the oil in their vehicles every 5,000 to 8,000Kms travelled. This is effectively basing the oil change needs on equipment run time. No concern is given to the actual condition and performance capability of the oil. It is changed because it is time. This methodology would be analogous to a preventive maintenance task. If, on the other hand, the operator of the car discounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubrication properties, he/she may be able to extend the oil change until the vehicle had travelled 15,000Kms. This is the fundamental difference between predictive maintenance and preventive maintenance, whereby predictive maintenance is used to define needed maintenance task based on quantified material/equipment condition.
There are many advantages of predictive maintenance. A well-orchestrated predictive maintenance program will all but eliminate catastrophic equipment failures. In fact, independent surveys indicate the following industrial average savings resultant from initiation of a functional predictive maintenance program.
• Return on investment: 10 times
• Reduction in maintenance costs: 25% to 30%
• Elimination of breakdowns: 70% to 75%
• Reduction in downtime: 35% to 45%
• Increase in production: 20% to 25%.
• Increased component operational life/availability
• Allows for preemptive corrective actions
• Decrease in equipment or process downtime
• Better product quality
• Improved worker and environmental safety
• Improved worker morale
• Energy savings
• Estimated 8% to 12% cost savings over preventive maintenance program.
Considering their unquestionable utility, new Automotive standard IAFT 16949 : 2016 Section 184.108.40.206, Total Productive Maintenance, shall include documented maintenance objectives, for example: OEE, MTBF, MTTR, and Preventive Maintenance compliance metrics. (Includes the need of plan & actions) which strengthen the requirement for equipment maintenance and overall proactive management of the Total Productive Maintenance (TPM). Also it implies at least the inclusions like Planned Maintenance activities & use of Predictive Maintenance methods to continually improve effectiveness & efficiency of the production equipment.
• To understand the concepts & methods of Preventive & Predictive Maintenance
• To understand how to Implement Preventive & Predictive Maintenance
• To understand how to gradually replace TBM activities by CBM activities
• To appreciate use of modern technologies in equipment maintenance
Basics & Documents of Maintenance
• Types of Maintenance
• Why Breakdown occurs & countermeasures to prevent. General Objectives to Improve P, Q, C, D, S, M; Concepts of MTTR, MTBF, MTTF & MTBQF
Analysis of Failures & Root Cause Analysis
• Physical roots, Human roots, Latent roots, Multiple roots & their interactions
• Failure Mechanisms & Determination, Material Stresses, etc.
• Bearing Failure Modes & detailed Rolling Element Bearing Failure Analysis Procedure
• Documents: Master List of Equipment, Equipment History Cards, Spare Parts Ledger, Preventive Maintenance Charts & Schedules
• Calculation of Maintenance Manpower, Load Leveling, Preparing & Monitoring of TBM Schedules
Condition Based – Predictive Maintenance
• Substitute Characters, Static & Dynamic Equipments, P-F Curve, Components of Predictive Maintenance
• Vibration analysis is used primarily with rotating equipment to find problems such as misalignment, out-of balance conditions, and bearing defects. Prior to using vibration analysis, maintenance technicians have to wait until a bearing fails to realize there was a problem
• Ultrasound functions primarily for leak detection, particularly for steam and air leaks. These leaks can be expensive and many companies let them go unnoticed
Oil and Wear-Particle Analysis
• Some people equate oil analysis and wear-particle analysis. These are two very different technologies. Oil analysis determines the condition of a lubricant. Wear-particle analysis determines the condition of equipment based on the concentration of wear particles in the lubricant
• Thermography serves primarily to find electrical components that are hotter than normal. Such a condition usually indicates wear or looseness. Thus, thermography allows technicians to perform maintenance on only the electrical components that need attention without requiring that all components get the same level of attention
• Some simple but important tips for Electrical Maintenance
Methodology: Online workshop sessions & Videos with many examples of industrial life. All methods of Preventive & Predictive Maintenance will be discussed with their comparative strengths & weaknesses. There are three tests & discussions between modules to reinforce learning, exercises, experience sharing & case studies followed by Quiz Test at the end to reinforce understanding. Education meets application.
Who Should Attend: Managers, Engineers, Supervisors, Process Specialists, Senior Technicians involved in Maintenance, Process Control and Improvement activities.
Medium: English/ Hindi/ Marathi
Fees and Registration:
Fees: Rs. 3,000/- + GST 18% per person.
Incentive: Rs. 2,800/- + GST 18% per person for a group of Three or more Members from the same or different Organizations.
Fees include participation, course material (Soft copies) and certificate.
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