Today we are going to learn the basics

of maintenance & the method for the

accountability of losses & the method
to over come those losses by
appropriate maintenance activity.

By,
Raghuttam Jorapurkar
 What is Maintenance?

Maintenance is defined as engineering actions

which are necessary for retaining or restoring an
equipment, machine or system to the specified
condition to achieve its maximum useful life.
 Types of Maintenance

There are major three types of maintenance

1. Preventive Maintenance

2. Breakdown Maintenance

3. Corrective Maintenance
 1. Preventive Maintenance
It includes two types of Maintenance

1.1 Periodic Maintenance

(TBM : Time Based Maintenance)

1.2 Predictive Maintenance

(CBM : Condition Based Maintenance)

 1.1 Periodic Maintenance (TBM)

In this type of maintenance, spares / consumable

replacement activity of the equipment or machine
is carried out as per predefined time period.

Disadvantage : Spare cost become high

Note : TBM is only spare part replacement activity

 1.1 Periodic Maintenance (TBM)

A Periodic time based maintenance plan is

to be prepared for our company.
 1.2 Predictive Maintenance (CBM)
It is the determination of the condition of in-service
equipment in order to predict when maintenance
should be performed

This maintenance can be easily carried out by

electronic equipment like bearing echo meter,
multimeter, IR temperature meter etc.

Advantage : Cost effective & utilization of spares

can be achieved up to 99%
 1.2 Predictive Maintenance (CBM)
A Periodic condition based
maintenance plan is to be prepared
for our company.
 1.2 Predictive Maintenance (CBM)
While performing this type of maintenance, check sheet
should be updated for further analysis. Machine /
equipment history card is to be updated regularly for
analysis & timely action.
 2. Breakdown Maintenance
The maintenance activity conducted to
bring back the machine / equipment in
working order which has worn out or failed.

This maintenance is carried out on all items

where the time of failure or wearing out are
not yet captured in history of the machine or
equipment.
 3. Corrective Maintenance

To improve reliability & maintainability,

corrective maintenance is must

It can be achieved by implementation of

kaizens on :

a. MTBF improvement
b. MTTR reduction
 Breakdown

If downtime is more than 10 minutes due to

equipment problem, it is “breakdown”
 Minor Stoppage

If downtime is less than or equal to 10 minutes

due to equipment problem, it is “minor stoppage”
 Mean Time To Repair (MTTR)

• It is a basic measure of the maintainability of

repairable items.

• It represents the average time required to repair the

equipment

Total Breakdown Time

M. T. T. R. =
Total Breakdown Incidences
 Mean Time To Repair (MTTR)

• It can be measured in minutes, hours or days

• It should be very low & ideally it should be zero

• While calculations of MTTR, there is no

consideration of minor stoppages
 Mean Time To Repair (MTTR)

Question : Calculate MTTR for the month of May 2014

in which there were 2 breakdowns of 65 & 75 min
 Mean Time To Repair (MTTR)
According to formula of

Total Breakdown Time

MTTR =
Total Breakdown Incidences

65 min + 75 min
MTTR =
2
 Mean Time To Repair (MTTR)

140 min
MTTR =
2

= 70 min

= 70/60 hours

= 1.16 hours
 Mean Time Between Failure (MTBF)

It is nothing but the average time between

failures of the system/equipment

Total Working Time – Total Breakdown Time

MTBF =
Total Breakdown Incidences
 Mean Time Between Failure (MTBF)

• It can be measured in minutes, hours or days

• It should be very high & ideally it should be infinite

• There is no consideration of minor stoppages

 Mean Time Between Failure (MTBF)

Question : Calculate MTBF for the month of May 2014

in which there were 2 breakdowns of 111 & 222
min
(Given : No. of working days were 24)
 Mean Time Between Failure (MTBF)

Working time = Working Days X 24 hours

Working time = 24 days X 24 hours

= 576 hours
 Mean Time Between Failure (MTBF)

Breakdown time= 111 min + 222 min

Breakdown time = 333 min

= 333/60 hours

= 5.55 hours
 Mean Time Between Failure (MTBF)
Now as per formula of MTBF
Total Working Time – Total Breakdown Time
MTBF =
Total Breakdown Incidences

576 – 5.55
MTBF =
2

MTBF = 285.22 hours

 Uptime

It is a measure of the time a machine has been

up without any downtime

It is measured in percentage

Available Time – Breakdown Time

Uptime = X 100
Available Time
 Uptime
Suppose, available time is 24 day & breakdown
time is 4 hours, then uptime will be
Available Time – Breakdown Time
Uptime = X 100
Available Time

(24 X24) – 4
Uptime = X 100
(24 X 24)

Uptime = 93.31 %
Any Queries ?