Industrial Maintenance

Industrial Maintenance
The purpose of industrial maintenance is to maintain the production tool in good condition (equipment
and installation). For this, it must: repair the production tool, predict and avoid malfunctions, increase the
availability of resources.
Industrial maintenance includes troubleshooting, repair, modification, improvement ...
1 – Maintenance staff
Maintenance personnel are trained personnel. It must
combine technological, organizational and relational skills.
The maintenance staff is confronted with:
- the complexity of the equipment (multi-technology,
automation, ...)
- a difficult work climate (work in the emergency)
- multiple occupational risks.
Their performances are difficult to evaluate. Business leaders
often give little importance to this non-productive service,
except in times of crisis.
2 - Equipment malfunction
The number and type of malfunctions occurring on any equipment evolve over time. The life of an
industrial equipment can be modeled by a trend line. This curve comprises three phases:
- Phase 1: break-in period
Frequent breakdowns decrease
with the elimination of youthful
defects.
- Phase 2: Maturity or stable
period
In this long period, breakdowns
are rare and often repetitive.
- Phase 3: Period of aging or usury
The number of failures increases
gradually. They are due to the
wear of parts. This is the end of
life of the equipment.
INDUSTRIAL MAINTENANCE 1
3 – Maintenance methods
The industrial maintenance can be understood in two opposite but complementary ways:
- Operate to the point of failure and then repair, it is called the corrective maintenance.
- Step-in to avoid malfunctions, it is called the preventive maintenance.
3.1 – Corrective Maintenance

Corrective maintenance consists of stepping-in when the equipment is
malfunctioning.
Maintenance personnel must be available and methods applied
quickly, otherwise delays in production may occur.
It is possible to repair the equipment temporarily or permanently.
Corrective maintenance methods are directed to the elements causing
low cost stop or slow loss of production.
Maintenance of a motor
3.2 – Preventive maintenance
Preventive maintenance consists of performing work on the equipment before malfunctions occur. The
work is performed during shutdown periods of the systems. Given that 20% of breakdowns represent 80%
of costs, this method is for items that cause significant production losses, costly downtime or unacceptable
consequences.
This method allows for better

equipment and a more regular
workload (better work planning and
staff).
Depending on the level of
technicality of the elements and the
context, several preventive
maintenance policies can be
implemented. We find in particular:
- Systematic maintenance,
- Conditional maintenance,
- Predictive maintenance.
3.3 – Systematic maintenance

Systematic maintenance performs interventions at fixed dates according to a predefined schedule or
periodically depending on the use of the equipment.
Example of a deadline for a type of intervention
Example:
Intervention Periodicity
Cleaning the cabinet filters 500 h
Tightening terminal block connections Yearly
Change of the motor bearings 7000 h
Systematic maintenance is for items that do

not come back too expensive but have a high
cost of failures.
Example:
Replacement of motor bearing, filter (oil, air,
cooling) sensor ...
3.4 - predictive or condition-based maintenance

Predictive or conditional maintenance interventions carried out
according to the level of wear of the elements. This requires
carrying out control campaigns on the equipment. When a result
indicates a degradation, a maintenance operation is programmed
during a system shutdown.
Example:
Example: Triggering thermal protection indicates motor overload.

Electric parameters must be monitored or changed when the
engine is stopped.
To assess the state of degradation of the components, the
maintenance service must:
- have personnel trained in nondestructive control.
- be equipped with adequate measuring equipment.
Energy analyzer: detects consumption drift.

Infrared Thermography: Detects abnormal temperatures and faulty connections.
Ultrasonic vibration tester: detects bearing wear, misalignment…
Tachometer: Detects drifts in servo loops.
4 - Troubleshooting method
Troubleshooting requires the respect of a method comprising four decisive steps:
a) the detection
b) the Localization
c) the diagnosis
d) the repair
5 - Technical documentation
The technical documentation of a system includes all the documents necessary to carry out a maintenance
operation.
5.1 Technical file

The technical file, written by the manufacturer, is supplied with
the system. It contains, according to standard NF X60-200, all
related documentation:
 Design:
- specifications
- description of the equipment, structural drawings,
nomenclature, spare parts catalog,
- Gemma, Grafcet, electrical drawings, listing of encoded
parts,
- a copy of the EC declaration of conformity, ...
 Operation:
- installation and commissioning instructions,
- user manual,
- a risk assessment.
 Maintainability:
- The systematic and regular controls with the schedule,
- Items exchangeable by the user or by the repairer,
- exploded views,
- The reference values,
- The adjustment elements,
- Interventions that can be performed by maintenance
levels,
- The notions of maintenance.
5.2 – Historical file:
The historical record can trace the life of the equipment since its commissioning in the company. The
recording of data is used for the establishment of different dashboards.
There are different services:
- Intervention reports
- The preventive visit reports
- The history of interventions
- The monitoring visit reports
- Modifications
- Movement of parts in stock
- The quantification of costs of maintenance
- …
6 - computer-assisted maintenance management

History management can be computerized. Computer-assisted maintenance management software is
designed to assist maintenance services. These computer tools organized around a database used to track
and organize any activity of a maintenance service.
Thanks to the history, the computer tool can do a calculation:
MTFB : mean time between failures

MTTR : mean time to recovery
An availability rate of 95% corresponds to a break of 440 hours per year, more than 18 days.

Industrial Maintenance

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Industrial Maintenance

3.1 – Corrective Maintenance

This method allows for better

3.3 – Systematic maintenance

Example of a deadline for a type of intervention

Systematic maintenance is for items that do

3.4 - predictive or condition-based maintenance

Example: Triggering thermal protection indicates motor overload.

Energy analyzer: detects consumption drift.

Ultrasonic vibration tester: detects bearing wear, misalignment…

Tachometer: Detects drifts in servo loops.

5.1 Technical file

6 - computer-assisted maintenance management

MTFB : mean time between failures

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