Instrumentation Maintenance Fundamentals: Reactive Maintenance Disadvantages Quiz and Flashcards

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Questions and Answers

What is the main goal of planned maintenance?

Optimize equipment functioning (correct)

Increase repair costs

Minimize worker participation

Maximize downtime

In which type of environment is corrective or breakdown maintenance quite justified?

Small factories with non-critical downtimes and low repair costs (correct)

Factories with high financial justifications for scheduling

Large factories with critical downtime

Factories with high repair costs

What does planned maintenance aim to minimize?

Worker participation

Downtime and maintenance costs (correct)

Equipment functioning

Repair efficiency

Which type of maintenance involves putting predictive and preventative strategies into action?

Planned maintenance Signup and view all the answers

What is the major goal of creating a proactive system in maintenance procedures?

To take care of possible problems before they become serious Signup and view all the answers

What is the key aspect of planned maintenance strategies to improve industrial machinery's dependability?

Implementing predictive and preventative actions Signup and view all the answers

What is a disadvantage of reactive maintenance identified in the text?

Increased Downtime Costs Signup and view all the answers

How does reactive maintenance affect labor costs according to the text?

Leads to Tight Labor Budgets Signup and view all the answers

Which factor may lead to breakdowns in reactive maintenance as mentioned in the text?

Neglected Basic Conditions Signup and view all the answers

What is a potential consequence of reactive maintenance on equipment repair expenses?

Higher Repair or Replacement Expenses Signup and view all the answers

How does reactive maintenance impact staff resource utilization based on the text?

Frequently Utilizes Staff in a Less-than-Ideal Manner Signup and view all the answers

What is one potential root cause of breakdowns in reactive maintenance according to the text?

Maintenance Crew Member Experience Signup and view all the answers

What is the primary goal of preventive maintenance?

Reduce equipment degradation Signup and view all the answers

Which of the following is considered a technique for preventive maintenance?

Periodic reviews of equipment performance Signup and view all the answers

What is the essence of preventive maintenance in terms of repair strategy?

Replacing components before they show signs of wear Signup and view all the answers

How does planned maintenance differ from preventive maintenance?

Preventive maintenance takes proactive measures to fix minor problems Signup and view all the answers

Which factor justifies the higher labor costs associated with preventive maintenance?

Reducing energy consumption Signup and view all the answers

What role does lubrication play in preventive maintenance?

Reduce friction and wear Signup and view all the answers

What is one of the benefits of outsourcing preventive maintenance services?

Avoiding major repairs Signup and view all the answers

Which activity is NOT an example of Preventive Maintenance for conveyor belt systems?

Emergency Repairs Signup and view all the answers

Why is proper belt tension important in conveyor belt maintenance?

To prevent slippage or excessive wear Signup and view all the answers

How does Preventive Maintenance contribute to cost savings?

By preventing major repairs Signup and view all the answers

Which statement best describes the role of outsourcing in maintenance practices?

It optimizes costs and provides specialized expertise Signup and view all the answers

What is a key benefit of Preventive Maintenance for equipment?

Operational Continuity Signup and view all the answers

What information is typically included in the 'Pre-Service Evaluation' section of a maintenance service report?

Findings from the initial assessment before maintenance work Signup and view all the answers

Which section of a maintenance service report provides details about the actions taken to address and rectify identified issues?

Corrective Action Signup and view all the answers

Why should no two units from the same manufacturer have the same serial number?

To ensure traceability and unique identification Signup and view all the answers

What purpose do 'Notes/Remarks' serve in a maintenance service report?

Offer recommendations or remarks regarding the service Signup and view all the answers

Which section of a maintenance service report is responsible for providing the results of the post-service inspection?

Post-Service Evaluation Signup and view all the answers

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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