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ZUKRINA AFRINA BINTI ZULKIFLI AND NURSYAMIMI HUSNA BINTI MOHD ARIFF.

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ZUKRINA AFRINA BINTI ZULKIFLI AND NURSYAMIMI HUSNA BINTI MOHD ARIFF.

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1. PREVENTIVE MAINTENANCE

a) Principle of topic :

- Preventive maintenance is a schedule of planned maintenance actions aimed at the prevention of breakdown and failures. The primary goal of preventive maintenance is to prevent the failure of equipment before it actually occurs. It is design to preserve and enhance equipment reliability by replacing worn components before they actually fail.

- Any going service or inspection performed on an asset to keep it up and running, while also ensuring it stays in compliance with OSHA or EHS regulations.

2. ADVANTAGES AND DISADVANTAGES

b) Advantages :

- Less equipment downtime.

- Fewer interruptions to critical operations.

- Longer asset life.

- Improved efficiency ( asset in good repair tend to operate better ).

- Increased workplace safety and improved compliance with OSHA.

c) Disadvantages :

- It can be expensive.

- It isn’t tailored to your plant’s needs.

- It involves extensive planned downtime.

- You need to schedule frequent shutdowns to give your maintenance team access to equipment, so that they can perform routine cleaning and repairs.

3. HOW IT WORKS & EXAMPLE.
- The act of performing regularly scheduled maintenance activities to help prevent unexpected failures in the future is known as preventive maintenance. Simply put, it is about repairing things before they break.

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TOPIC : MAINTENANCE PREVENTION

1. Principle of topic
1. Plan, rather than react. Focus resources on preventing downtime, not on reacting to downtime you should have prevented. When there’s a failure, determine the cause and figure out how to prevent that cause going forward. For example, motors in the finishing area fail frequently. The cause is a solvent that gets into the windings through the motor vents—so capture and exhaust the solvent, or use totally enclosed motors.
2. Adjust as needed. Getting all that feedback and advice is pointless if you
don’t use it when it may make a difference.
3.Be equipped to do the job. Thinking you can do the best job without the best test equipment, tools, and training is wishful thinking. Thinking you can do any job safely while skimping on safety training, PPE, and an (almost) obsessive safety culture is dangerous thinking.

2. - Advantage
1. Less equipment downtime
2. Longer asset life
3. Improve efficiency (asset in good condition perform better)
- Disadvantage
1. Upfront costs - keeping equipment well - maintaned requires investment
2. More labor-intensive, so you'll need more staff on hand
3. Potential for over-maintenance

3.  How it works
- Performing regular business and equipment inspection,cleaning,and lubricating essential equipment, and tidying your business's grounds

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MAINTENANCE PREVENTION

1. Principle of topic
- Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downtime from unexpected equipment failure. A successful maintenance strategy requires planning and scheduling maintenance of equipment before a problem occurs.

2. Advantages

Less risk factor- Because the equipment and your building are being regularly checked, they are at less risk to breaking down without notice. Therefore creating a safer working environment for employees.

Follows a schedule- By following a schedule, you are able to keep to a budget while maintaining your building. Also you will be able to keep track of all your equipment and pin point times when you will need to replace your equipment.

Longer equipment/building life- When equipment is being checked and maintained, it will be kept in its best shape, therefore extending its lifetime. With routine check-ups on building parts such as pipes, boilers, and roofing you’ll extend the life of your building as well.

Money saving-Over time, you will see that less money is being spend because you will not have to replace equipment as much, as well as dealing with last minute break downs. While there still may be some unplanned maintenance needed, the likely hood will go down when the building and equipment are regularly checked. Property wise, you’ll be able to catch roof leaks before they escalate and quickly repair them before mould and debris occur.

Less energy wasting- In general when equipment is not kept in the best conditions possible, it will drain more energy, hiking up your utilities bill. With properly maintained equipment, it will be saving you energy and money. While regularly kept lighting and cooling/heating systems will also help reduce the energy bill.

Less disruptions- With regular checks, you won’t be surprised when something goes wrong. It will be a quick fix because you will know what needs to be done. There will not be problems when it comes to closing down your property and disrupting your workers, if a large problem were to occur.

Disadvantages

More money upfront- When initially starting a preventative maintenance plan, it will cost you more to regularly maintain equipment and the building, than it would be if you waited for things to simply break down.

Over maintenance- Because there is a regular plan, sometimes items may not need to be checked as often as planned. If this is the case, you can change your maintenance plan to checking the specific equipment or areas less often, while still maintaining a schedule.

More workers- Preventative maintenance require more workers because regular checks are a must. When compared to reactive maintenance, you simply need to call someone in for a onetime fix. Instead this method requires workers to always be on site and perform daily works.

3. How it works and example

Through machine learning, operational data analytics and predictive asset health monitoring, engineers can optimize maintenance and reduce reliability risks to plant or business operations. Software designed to support preventive maintenance (which is sometimes called preventative maintenance) helps produce stable operations, ensure compliance with warranties and resolve issues impacting production — before they happen.

Example:

Industrial situations depend heavily on regularly scheduled maintenance to remain fully productive and free from costly, time-wasting mechanical breakdowns.

The term “preventive maintenance” covers a wide range of proscribed activities and general tasks. Each production component within a system will require some level of regular servicing, and that equipment typically will need to at least be cleaned and lubricated. In other situations, more extensive servicing may be required — involving the heavy reconditioning, repair or even replacement of certain parts.

At a higher level, preventive maintenance also involves providing upkeep for the physical plant that houses the various production systems. General tasks associated with this type of preventive maintenance include ensuring the HVAC system is in good working condition, all electrical systems are functioning and compliant with code standards, and all necessary lighting is operating correctly.

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Topic : Productive maintenance

1 . Principle of topic productive maintenance is the process of using machines,equipment,employees,and supporting processes to maintain and improve the intergrity of production and quality of systems.

2 . advantages
-no breakdowns
-less unplanned maintenance
-reduce equipment downtime
-no accidents
disadvantages
-managment is not willing to initiate a continuous improvement process with a long ROI,in which all employees contribute their knowledge and skills to sustainably increase value creation
-management is not willing to invest a lot of time in training and education of their employees
3 . How it work
-Maintenance,reliabilt and operations workers are always striving for 'perfect production'.This is very difficult since unexpected problems arise even in the best-planned facilities;however,total productive maintenance will get a facility as close at it can to 'perfecrt production'
4  .  Example
-PM frames maintenance as a business advantages-no downtime and no equipment failure,meaning only productive and profit. PM is also built on the 5S methodology,which helps organize and standardize facility procedures,leading to many benefits for both production and workplace quality.

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1. Principle of topic
Preventive maintenance is the act of performing regularly scheduled maintenance activities to help prevent unexpected failures in the future. Put simply, it's about fixing things before they break.

2. Advantages
- Less equipment downtime
- Longer asset life
- Fewer interruptions to critical operations

Disadvantages
- Upfront costs - keeping equipment well-maintained requires investment
- More labor-intensive, so you'll need more staff on hand
- Potential for over-maintenance

3. How it work
- Through machine learning, operational data analytics and predictive asset health monitoring, engineers can optimize maintenance and reduce reliability risks to plant or business operations. Software designed to support preventive maintenance (which is sometimes called preventative maintenance) helps produce stable operations, ensure compliance with warranties and resolve issues impacting production — before they happen.

Example
- Industrial situations depend heavily on regularly scheduled maintenance to remain fully productive and free from costly, time-wasting mechanical breakdowns.

- The term “preventive maintenance” covers a wide range of proscribed activities and general tasks. Each production component within a system will require some level of regular servicing, and that equipment typically will need to at least be cleaned and lubricated. In other situations, more extensive servicing may be required — involving the heavy reconditioning, repair or even replacement of certain parts.

- At a higher level, preventive maintenance also involves providing upkeep for the physical plant that houses the various production systems. General tasks associated with this type of preventive maintenance include ensuring the HVAC system is in good working condition, all electrical systems are functioning and compliant with code standards, and all necessary lighting is operating correctly.

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TOPIC:CORRECTIVE MAINTENANCE

-Corrective maintenance is the category of maintenance tasks that are performed to rectify and repair faulty systems and equipment. The purpose of corrective maintenance is to restore systems that have broken down. Corrective maintenance can be synonymous with breakdown or reactive maintenance.

ADVANTAGES OF CORRECTIVE MAINTENANCE:
-Lower cost
-Simple process
-Inspection opportunity

DISADVANTAGES OF CORRECTIVE MAINTENANCE:
-Unpredictability
-Interruption to production
-Shortened asset lifespan

HOW IT WORKS:
-Although corrective maintenance tasks are focused on restoring a piece of equipment to optimal functionality, it’s important not to let the opportunity go by to perform an additional quick inspection during the corrective maintenance task itself. Some assets in a facility will be monitored on a condition-basis and not necessarily maintained on a particular time-based schedule. If a corrective maintenance order is issued as a result of a failure mode trigger, it’s important to take the opportunity to inspect potential root causes for the failure in the first place. When a maintenance team takes advantage of the opportunity and identifies other issues to be addressed, it’s less likely that the failure will occur again or as frequently, boosting overall reliability.

EXAMPLE:
1. Production line. A technician is performing preventive maintenance on a line of production equipment and notices significant wear on a critical part or component.

2. HVAC systems. A technician responds to an emergency heating system repair in the middle of winter and notices partially clogged or dirty filters.

3.Public works. While performing routine roadway repairs, a technician may notice some signage damage from a recent storm.

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1. Principle of topic
Breakdown maintenance is maintenance performed on equipment that has broken down and is unusable. It is based on a breakdown maintenance trigger. It may be either planned or unplanned.
This is the opposite of preventive maintenance, in which interventions are made before an asset runs to failure. A breakdown is an equipment outage that requires immediate attention from the maintenance team.

While breakdown maintenance sounds like a last resort or the result of poor planning, some facilities will consciously allow certain assets to run to failure because they are easy or cheap to replace, and don’t pose a safety hazard in the event of a breakdown. In reality, most organizations will use a combination of breakdown maintenance and preventive maintenance to ensure they don’t spend money unnecessarily maintaining nonessential assets while ensuring high-value assets are protected under a preventive maintenance plan.

2. Advantages of breakdown maintenance
*Cost Saving due to Breakdown Maintenance
The first and foremost advantage of breakdown maintenance is that it leads to cost-saving for the company because when the company goes for maintenance activity than it has to pay to the people doing maintenance and if the asset is in working condition then that maintenance activity is merely a formality as there is no use of doing maintenance if the machine is running properly.

*Time Saving
It leads to saving of time because when the company does regular maintenance than it leads to stoppage of machines for which maintenance activity is being done and if the production of the company is dependent on that machine then it will lead to waste of time

*Minimal planning is required.

*The process is very simple so it is easy to understand.

*Fewer staff are required as less work is done day-to-dayfor both workers as well as company which in turn will lead to decrease in the efficiency of the workers.

3.Disadvantages of breakdown maintenance
#Breakdown Maintenance leads to Stoppage of Work
The biggest disadvantage of breakdown maintenance is that it leads to sudden stoppage of the work because since under this method of maintenance there is no planned maintenance the machine can breakdown any time and if it breakdowns during high demand period then it can create a big problem for the company as it takes time to repair the machine which has broken down. In simple words, if we do not take health insurance and we get seriously ill then it will be a big financial burden as there is no health insurance in case of companies planned maintenance is like health insurance which ensures that the company does not suffer financial loss due to sudden breakdown of the machine.

#Lack of Safety
Another problem with breakdown maintenance is that it not only leads to sudden breakdown of machines but also poses risks to the safety of the workers doing work on such machines and companies who do not pay attention to the safety of their workers will not get the respect and patronage of their workers which in the long run can be a big problem as no company can run efficiently and effectively without its workers.

#Dent to Image of Company
While breakdown maintenance saves company money and time but when the machine breakdowns suddenly and the company is not able to complete its order due to sudden breakdown then it will dent the image or goodwill of the company as in the business world companies prefer those people or companies who complete the orders on time and due to company following breakdown maintenance policy the chances of company’s image taking a hit are more due to sudden breakdown of machines.

#Faster plant deterioration.

#Hurried maintenance jobs that lead to poor execution.

#Longer repair times compared to other maintenance types.

#ncreased chances of accidents or injuries.

#Breakdown generally occurs inappropriate times leading to poor and hurried maintenance

4.How it works
-Breakdown maintenance, sometimes called run-to-failure maintenance, occurs when an asset completely breaks down and needs repair to resume operation. In many cases, breakdown maintenance is the default maintenance strategy, particularly for organizations that rely on reactive maintenance.
-Production is stopped because there is an issue with a piece of critical equipment – the induction motor that operates the conveyor belt. The maintenance coordinator gets a call from the production team and issues an emergency work order. Soon, a maintenance tech is at the scene.

-Every second of downtime, with the belt not moving, translates into lost profit for the company. Speed is of the essence.

-However, the support of the CMMS should not be overlooked. Having access to mobile maintenance software like Limble offers multiple lanes through which you can speed up maintenance work.

The access to maintenance logs, checklists, performance data, troubleshooting steps, user manuals, and other relevant info will not always be enough to shorten the repair times. But more often than not, it will.

5.Example
-Planned breakdown maintenance is run-to-failure maintenance, where an organization has decided that letting a piece of equipment break down before servicing is the most cost-effective and least disruptive option.

-Examples of unplanned breakdown maintenance include corrective maintenance and reactive maintenance. Corrective maintenance is performed when a breakdown occurs between scheduled preventive maintenance occurrences. Reactive maintenance is performed if a breakdown occurs because a maintenance strategy has not yet been put in place.

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Name :,muhammad zhafri & muhammad  fadzli

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Name :,muhammad zhafri & muhammad  fadzli

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topic : preventive maintenance

1. Principle of topic
Preventive maintenance (or preventative maintenance) is maintenance that is regularly and routinely performed on physical assets to reduce the chances of equipment failure and unplanned machine downtime that can be very costly for maintenance teams and facility managers
-Daily maintenance cleaning, checking, lubricating and tightening
-Periodic inspections and equipment diagnoses. (To measure deterioration)
-Periodic restoration and overhaul. (To correct and recover from deterioration

2. Advantages & disadvantages

Advantages
-Less equipment downtime
-Longer asset life
-Improved efficiency (assets in good
condition perform better)

Disadvangates
-Upfront costs - keeping equipment well-maintained requires investment
-More labor-intensive, so you'll need more staff on hand
-Potential for over-maintenance

3. how it works & example
the regular and routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downtime from unexpected equipment failure. A successful maintenance strategy requires planning and scheduling maintenance of equipment before a problem occurs.

Examples :
Industrial situations depend heavily on regularly scheduled maintenance to remain fully productive and free from costly, time-wasting mechanical breakdowns.

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name:-muhammad ammar bin husin

topic:-corrective maintenance

1.principle of corrective maintenance
- process of restoring assets after unplanned downtime.
- It includes troubleshooting, disassembling, readjusting, repairing, replacing, and realigning equipment.

2.advantages of corrective maintenance

- less or no planning needed
- simple process

3.disadvantages of corrective maintenance
- higher investment in diagnostic equipment
- higher investment for training

4.how it work and example
- corrective maintenance that repairs or brings into working condition those that have stopped working or are damaged
example:-

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topic:preventive maintenance

1. Principle of topic
-Preventive maintenance is act of performing regularly scheduled maintenance activities to help prevent unexpected failures in the future.Put simply,its about fixing things before they break

2.Advantages
- Lower risk of breakdown
- Save money
- Promote health ans safety

Disadvantages
- It can be expensive
- Unexpected failures
- Possible over-maintenance

3.How it work and example
- preventive maintenance include ensuring production line equipment is working efficiently or heating, ventilation or air conditioning elements are inspected, cleaned and updated.

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Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downti

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NAMA : - muhammad al-hazim                  .              - muhammad ashraf                           TOPIC :  PREVENTIVE                                                                      .                 MANTENANCE                                            .                                                                      1-    HOW IT WORK & EXAMPLE                                

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NAMA : - muhammad al-hazim                  .              - muhammad ashraf                           TOPIC :  PREVENTIVE                                                                      .                 MANTENANCE                                            .                                                                      1-    HOW IT WORK & EXAMPLE                                

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2 - PRINCIPLE OF TOPIC

1. Legal Standards Required: It is important that you maintain and inspect your technical system regularly, because there may be legislation relating to your plant safety or industrial hygiene and safety.

2. Product Quality Assurance: The quality of the product depends on the condition of the facility it was manufactured.

3. Reduction in Reactive Maintenance Costs:Effective preventive maintenance can reduce any unnecessary costs that occur because of repairs and can ensure that a technical system doesn’t breakdown.

4. Environmental Standards Requirements:It is possible that effective preventive maintenance can prevent system breakdowns that can lead to environmental impacts.

5. Decrease in High Maintenance Costs:Depending on whether you’ve already reached the optimum intensity level of preventive maintenance or not, you can possibly decrease your maintenance costs.

3 - ADVANTAGE

Lengthen asset lifespan.

Lower risk of breakdowns.

Increase efficiency.

Decrease unplanned downtime.

Promote health and safety.

Boost customer satisfaction.

Save money.

- DISADVANTAGE

It involves extensive planned downtime. You need to schedule frequent shutdowns to give your maintenance team access to equipment, so that they can perform routine cleaning and repairs. ...

It can be expensive. ...

It isn't tailored to your plant's needs.

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TOPIC
1.     Preventive Maintenance

2.     Breakdown Maintenance

3.     Corrective Maintenance

4.     Maintenance Prevention

5.     Productive Maintenance

In group of 2 person, choose 1 topic above then discuss the item as below:

a. Principle of topic
b. Advantages & disadvantages
c. How it works & example (show in pictures)

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Name :
Topic :

1. Principle of Topic
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2. Advantages & Disadvantages
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3. How it works & example
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