TP_10 Troubleshooting and

maintenance techniques
Lecture 1: Introduction to Maintenance
Fayoum Integrated Technical Educational Cluster
(ITEC)

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 Hagag Maher Abdelhameed
Assistant Professor of Industrial Engineering
Mechanical/Industrial Engineering Department
Mail : Hagagmaher@Fayoum.edu.eg.
Mob. 01229801023 & 01008249063
Facebook: Hagag Maher

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TP_10 Troubleshooting and maintenance techniques

Total Score : 100 Points

Final Exam (Theoretical) 20 %

Midterm exam 10 %
Attendance 5%
Daily Evaluation and Attendance to
Practical Activities 15 %
Assignments for Practical 10 %
Final Practical Exam 40 %

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 Course Syllabus
Introduction to maintenance
Basics and concept troubleshooting and maintenance techniques
Maintenance Classifications
Failure detection and troubleshooting techniques
Maintenance scheduling for mechanical components.
Preventive maintenance and its applications.
Predictive maintenance and its applications.
Common standards for human and machine safety.
Maintenance Costs.

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 Material Link
Scan to find Course Materials
https://drive.google.com/drive/u/0/folders/1OrSJw5gGUu4gQoMaby1XaJpIX1jOxQ
gS?fbclid=IwAR3tZT3VPwJ9tdvsADbvzTL1pA7e7X-
d3b0OB_ed2YcXneAdDSMFVp5feWU

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 Opening Questions

Corrective
Troubles-
hooting

What is? Maintenance Predictive

Main.
Planning Run to Failure

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 Maintenance

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 Introduction to Maintenance
Maintenance is the work undertaken in order to keep or
restore a facility to an acceptable standard level.

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 Introduction to Maintenance
HSE Effect
Criticality Analysis
Major Minor Centrifugal Pump Criticality
(A)
(System level)
Process Effect
Drain system C
Major Water system B
Minor
(B)
Oil system A
Stand By
Availability Steam system A
Without With Fire-fighting system A
(C) (D)

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 Introduction to Maintenance
Maintenance is the work undertaken in order to keep or
restore a facility to an acceptable standard level.

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 Introduction to Maintenance
Maintenance may be classified into four categories:
• Corrective or Breakdown maintenance
• Preventive or Scheduled maintenance
• Predictive (Condition-based) maintenance
• Proactive maintenance

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 Why Planned Maintenance Done?

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 Introduction to Maintenance

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 Introduction to Maintenance
CORRECTIVE MAINTERANCE
MAINTENANCE (CM)

• Corrective maintenance
covers all Maintenance UNPLANNED PLANNED
which is carried out in
order to correct (repair) a
fault in equipment. ❖Break Down
❖Planned Maintenance
❖Emergency Repairs
• Most cost effective to let ❖Urgent ❖Prepared Properly
❖Possible to Control
equipment run unattended ❖Not possible to Control
❖You control the
❖You are controlled by the
until it fails. Used on equipment Equipment
lowest priority equipment.

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 Introduction to Maintenance
PREVENTIVE
PREVENTIVE MAINTENANCE
MAINTERANCE (PM)
Preventive maintenance
covers all Programmed INDIRECT DIRECT
maintenance which is
carried out in order to Condition Directed Fixed time
prevent the occurrence of Maintenance (CD) Maintenance(FTM)
failures before they
develop to a breakdown
or Interruption in Detection of failures Cleaning, Lubrication
production. Before break down Fixed time replacement

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 Introduction to Maintenance
PREVENTIVE MAINTERANCE (PM)
• Perform maintenance tasks on a piece of equipment at regular
intervals, whether the equipment needs it or not.
• Preventive maintenance covers all Programmed maintenance which is
carried out in order to prevent the Occurrence of failures before they
Develop to a breakdown or Interruption in production.
• Preventive maintenance - Time-based PM
- Pure time (calendar) based: Weekly, monthly, annually, etc.
- (running) time based: 1000 km, 1000 RH, 3000 RH, etc.

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 Introduction to Maintenance
Preventive Maintenance
-Reduce number of break downs & urgent repairs
-More planning and control of corrective maintenance

Result
-Increased availability performance & efficiency
-Decreased cost of maintenance

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 Introduction to Maintenance
Predictive Maintenance
Perform maintenance based upon real-time data collected on a piece of
equipment. This data shows the ‘health’ of the equipment

Proactive Maintenance
Determine root causes of failure and implement ‘fixes’ (e.g., redesigning
the piece of equipment so that it does not break down as frequently)

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 Introduction to Maintenance
Maintenance Maintenance
Policies
Policies:
The policy is a
Condition-
certain rule- Failure-Based Time-Based Based Risk-Based
based for long Reactive
(ReM):
Preventive
(PM): Predictive Proactive
(PaM):
(PdM):
term according
to the working
Oil analysis
conditions - Calendar: - Vibration - RCFA
- RTF Weekly - analysis
Monthly - FMEA \
- CM - Temperature FMECA
- Running: analysis
1000 R.H. - HAZOP
- Pressure
1000 K.M. analysis - RCM
- Wear analysis

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 Troubleshooting
Troubleshooting is a form of problem solving, often applied
to repair failed products or processes on a machine or a
system.
• It is a logical, systematic search for the source of a problem in
order to solve it, and make the product or process operational
again.
• Troubleshooting is needed to identify the symptoms.
Determining the most likely cause is a process of elimination—
eliminating potential causes of a problem.
• Finally, troubleshooting requires confirmation that the solution
restores the product or process to its working state.
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 Troubleshooting
• Usually troubleshooting is applied to something that has
suddenly stopped working, since its previously working state
forms the expectations about its continued behavior.

• A basic principle in troubleshooting is to start from the simplest

and most probable possible problems first.

• A troubleshooter could check each component in a system one

by one, substituting known good components for each
potentially suspect one.

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 LEARNING TO TROUBLESHOOT
EXPERIENCE
• To develop a wide range of skills, a technician needs initiative,
training, and assistance. To be successful in your training, you must
become an active participant. You must seek out training
opportunities and take responsibility for developing your skills. You
cannot passively rely on your company, your supervisor, or chance to
do the job for you. Experience is the most common way technicians
develop troubleshooting skills. It comes naturally with the job, and is
sometimes called “OJT” (on-the-job training). It means getting out
there and getting your hands dirty.

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 Training Opportunities ‫فرص التدريب‬

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 Other Information
• Textbook
R. Keith Mobley,
“MAINTENANCE
ENGINEERING
HANDBOOK”, McGraw-Hill.
• Reference book
1. William L. Mostia, Jr., P.
E., “TROUBLESHOOTING A
TECHNICIAN'S GUIDE, ISA
technician series.

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 Summary:
❑Maintenance definition

Discussion ❑Troubleshooting definition

&Questions! ❑Maintenance types

❑Maintenance policies

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 T H A N K S F O R L I S T E N I NG
Hagagmaher@fayoum.edu.eg Hagag Maher

01008249063
Hagag Maher
01229801023

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