Questions and Answers
What is the main goal of planned maintenance?
Optimize equipment functioning
In which type of environment is corrective or breakdown maintenance quite justified?
Small factories with non-critical downtimes and low repair costs
What does planned maintenance aim to minimize?
Downtime and maintenance costs
Which type of maintenance involves putting predictive and preventative strategies into action?
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What is the major goal of creating a proactive system in maintenance procedures?
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What is the key aspect of planned maintenance strategies to improve industrial machinery's dependability?
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What is a disadvantage of reactive maintenance identified in the text?
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How does reactive maintenance affect labor costs according to the text?
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Which factor may lead to breakdowns in reactive maintenance as mentioned in the text?
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What is a potential consequence of reactive maintenance on equipment repair expenses?
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How does reactive maintenance impact staff resource utilization based on the text?
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What is one potential root cause of breakdowns in reactive maintenance according to the text?
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What is the primary goal of preventive maintenance?
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Which of the following is considered a technique for preventive maintenance?
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What is the essence of preventive maintenance in terms of repair strategy?
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How does planned maintenance differ from preventive maintenance?
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Which factor justifies the higher labor costs associated with preventive maintenance?
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What role does lubrication play in preventive maintenance?
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What is one of the benefits of outsourcing preventive maintenance services?
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Which activity is NOT an example of Preventive Maintenance for conveyor belt systems?
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Why is proper belt tension important in conveyor belt maintenance?
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How does Preventive Maintenance contribute to cost savings?
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Which statement best describes the role of outsourcing in maintenance practices?
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What is a key benefit of Preventive Maintenance for equipment?
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What information is typically included in the 'Pre-Service Evaluation' section of a maintenance service report?
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Which section of a maintenance service report provides details about the actions taken to address and rectify identified issues?
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Why should no two units from the same manufacturer have the same serial number?
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What purpose do 'Notes/Remarks' serve in a maintenance service report?
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Which section of a maintenance service report is responsible for providing the results of the post-service inspection?
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Study Notes
Avoiding Reactive Maintenance
- Assessing possible outcomes and influence on operational efficiency is crucial to avoiding reactive maintenance.
Corrective or Breakdown Maintenance
- Corrective or breakdown maintenance occurs when repairs are made after equipment failure.
- Justified in small factories where downtime is non-critical and repair costs are less than other types of maintenance.
- Financial justification for scheduling is not felt.
Planned Maintenance
- Objective is to minimize downtime and lower total maintenance costs while optimizing equipment performance.
- A methodical approach involving all workers to improve output quality, increase uptime, and lower maintenance costs.
- Involves putting predictive and preventative planned maintenance strategies into action to improve dependability and efficiency.
- Aims to create a proactive system to address potential problems before they become serious.
Disadvantages of Reactive Maintenance
- Increased downtime costs due to unexpected equipment failures.
- Higher labor costs, especially with overtime.
- Elevated repair or replacement expenses due to delayed responses to problems.
- Potential secondary damage to other machinery or processes.
- Inefficient staff resource utilization.
Root Causes of Reactive Maintenance
- Neglected basic conditions due to ignored routine inspections and basic maintenance.
- Inadequate skills of maintenance crew members.
Preventive Maintenance
- Definition: actions carried out according to a time- or machine-run schedule to identify, stop, or mitigate a system's degradation.
- Essence: early component identification, replacement, and repair to prevent failures.
- Significantly decreases the possibility of large repairs and improves productivity and reliability.
Techniques for Preventive Maintenance
- Periodic reviews of equipment performance and condition.
- Routine lubrication to reduce friction and wear.
- Calibrations to maintain accuracy and optimal functionality.
- Inspections to identify potential issues.
Costs of Preventative Maintenance
- Higher labor costs for scheduled equipment inspections.
- Justified by prevention of major repairs and reduction in energy consumption from machines operating at peak efficiency.
- Outsourcing provides a cost-effective solution with specialized expertise.
Example of Preventive Maintenance in Action
- Conveyor belt maintenance in a manufacturing setting.
- Regular inspections, belt tension checks, cleaning and lubrication, and replacement of worn components.
Benefits of Preventive Maintenance
- Cost savings from preventing major repairs.
- Operational continuity by minimizing downtime.
- Extended lifecycle of equipment, reducing the need for frequent replacements.
Maintenance Service Report
- Description of the problem that prompted the maintenance service request.
- Pre-service evaluation of the equipment's condition before maintenance work.
- Corrective action taken to address and rectify the issues.
- Post-service evaluation to verify the maintenance actions were successful.
- Notes and remarks regarding the service and any special instructions for the client.
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