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TYPES OF MAINTENANCE

OF INDUSTRIAL PHARMACY

By: Jessica FernandesReg. No. 150617004

Department of PharmaceuticsGuided By: Dr. Usha Nayak

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Maintenance Classification

Corrective or Breakdown Maintenance

Scheduled Maintenance

Preventive Maintenance

Predictive Maintenance

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Types of Maintenance

Corrective

Predictive

Preventive

Scheduled

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1. Corrective Or Breakdown Maintenance

• “Repairs that are made after the equipment is out of order and it cannot perform it’s normal function any longer”

• Eg: Electric Motor will not start

• Used in small factories which get temporary remand in excess of normal operating capacity

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Conditions

Production Department

Maintenance Department

Necessary Repairs

No further maintenance

until next breakdown

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Causes For Equipment Breakdown

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Failure to replace

worn out

parts

Lack of Lubrication

Neglected Cooling System

External Factors

Indifference towards minor faults

Indifference towards major faults

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Advantages of Breakdown Maintenance

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Lower Initial Costs

Requires Fewer StaffNo Planning

Needed

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Disadvantages of Breakdown Maintenance

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Reduction of Output

Faster Plant Deterioration

Increased Chances of Accidents

More Spoilt Material

Direct Loss of Profit

Breakdown at Inopportunate

Times

Plant Items Regulated by

Statutory Provisions are not subject to

breakdown maintenance

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Types of Maintenance

Corrective

Predictive

Preventive

Scheduled

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2. Scheduled Maintenance

• Aim: Avoiding Breakdown• Scheduled maintenance

incorporates: • Lubrication

• Inspection

White washing

of building

s

Overhauling of

machines

Cleaning Of Water & Other Tanks

Repair

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Types of Maintenance

Corrective

Predictive

Preventive

Scheduled

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3. Preventive Maintenance Principle: Prevention is better than cure

• Aims at minimising the problems of breakdown maintenance

• Locates Weak Spots

• Provides Regular inspection

• Initiates minor repairs thereby reducing the risk of unanticipated breakdown

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Objectives

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Minimizing the possibility of unanticipated production interruption.

Make plant equipment and machinery always available and ready for use.

Maintain optimum productive efficiency of the equipment.

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Maintain operational accuracy.

Reduce work content of maintenance jobs.

Achieve maximum production at minimum repair cost.

Ensure safety of life of the workmen.

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Elements/Procedure of PM :

• Who should do PM?• Where to start PM?• What to inspect in PM?• What to inspect for ?• How often to inspect ?• When to inspect- schedules ?• Preventive maintenance records• Control and evaluation of PM

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Who should do PM?

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Production

department.

Maintenance

department.

A separate division

of inspector

s and superviso

rs.

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Where to start PM?• PM should not be done for the entire

plant at once

• It is better to tackle one department or machinery at a time

• The entire PM programme hangs on inspections and their related duties of adjustments and repairs

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What to inspect in PM?• All industries have certain key items

which are more essential for continuing the production than others

• key items are : Material handling equipment Safety equipment Process equipment Special purpose – unique equipment and machines Water , air and fuel lines

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What to inspect for ?• After listing the equipment requiring

PM , the next step is to decide – what physical parts of each piece of equipment need attention

• After making the list of machines and their parts needing PM , a CHECK – LIST to ensure that no inspection point has been missed is made

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How often to inspect ?• Based on :

Past experienceCost and savings

• Over inspection Expensive

• Under inspection More breakdown

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When to inspect- schedules ?

• Scheduling involves determining calendar inspection dates that will fulfil the frequency requirements in the most efficient way

• In setting up schedule one must ensure to keep production going at lowest overall cost

• Schedules should be set in consultation with production department and as per the production needs , as far as possible

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Preventive maintenance records

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Record should show -• Type of equipment and description

• Whether it is a key item?

• Name of the manufacturer

• Cost and date of purchase of the equipment.

• Location of the equipment in the factory

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• Equipment identification number• Estimated cost of inspection and the

cost and data of planned repairs• Breakdowns , their dates and

reasons• Cost of breakdowns and other

associated implications

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Control and evaluation of PM :

• To maintain control of the PM programme , the following measures should be taken :

I. Periodic review of PM programme with the operating department

II. Review of monthly reports of PM inspections

III. Analytical approach to the evaluation of PM

• Analytical approach makes use of following relations :

a) ×100 = 10% Max

b) ×100= Percentage of performance

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Good updated records.

Adequate clerical help.

Proper filing

equipment.

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Advantages• Reduced breakdowns and connected

down-time• Lesser odd-time repairs and reduced

overtime to the maintenance work-force• Greater safety for workers• Fewer large-scale and repetitive repairs• Low maintenance and repair costs• Less stand-by or reserve equipment, and

spare parts

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Types of Maintenance

Corrective

Predictive

Preventive

Scheduled

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Predictive Maintenance

• New technique

• Extends service life of equipment without failure

• Makes use of human or other sensitive instruments like:

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Pressure

Amplitude meters

Temperature

Audio Gauges

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References • Khanna OP, Industrial Engineering and

Management, 1st Edition 1992, Page no: 13.5-13.12

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