Table of contents
- What is meant by maintenance?
- DIN standards in the field of maintenance
- What is the difference between servicing and maintenance?
- What is an inspection and why is it important?
- Why is regular maintenance important?
- How to minimise the need for repair work
- Sustainability and environmental aspects of repair work
- What is a repair and when is it necessary?
- Conclusion
Efficient and reliable asset management is crucial for companies to ensure their productivity, competitiveness and long-term profitability. In this context, the terms maintenance, inspection, servicing, repair and overhaul are central, but differ in their focus and the associated measures. In this guide, we shine a spotlight on the key differences to provide a comprehensive understanding of the respective approaches to maintaining and optimising assets.
What is maintenance?
Maintenance is the process of planning, monitoring and implementing measures to maintain or restore the functionality, reliability and lifespan of equipment, buildings or other facilities. The main objective of maintenance is to ensure proper operation and to guarantee the availability of the objects in question. Maintenance activities can take place in a variety of areas, including industry, building services engineering, vehicle maintenance and many other sectors where the smooth operation of plant and equipment is of crucial importance. DIN standards create a uniform set of rules for this purpose. They ensure the uniformity of procedures, techniques and terminologies, thus ensuring a high quality and reliability of the maintenance work carried out.
Here are some relevant DIN standards in the area of maintenance:
DIN 31011 ‘Risk management - Risk assessment techniques’: Contains guidelines for the application of risk assessment techniques that may also be relevant in maintenance
DIN EN 13306 ‘Maintenance –
Maintenance terminology’: defines terms related to
maintenance and servicing.
DIN EN 13306 ‘Maintenance –
maintenance process‘: Provides
guidelines for the maintenance process, including planning, implementation
and monitoring.
DIN 276-1 “Costs in
construction - Part 1: Building construction”: Contains requirements and recommendations
for the recording and presentation of maintenance costs in the construction industry.
What does maintenance involve?
Maintenance includes all measures that aim to ensure or restore the functionality, reliability and availability of systems, machines, buildings or other facilities. The purpose of maintenance is to ensure proper operation, extend the service life of the systems and minimise unplanned downtime.
What is a maintenance plan?
A maintenance plan is a structured document that defines the planned maintenance activities for a specific period. The plan is used to organise maintenance work, use resources efficiently and ensure that equipment is operational. A typical maintenance plan includes the following elements:
- Maintenance cycles: Definition of time intervals for preventive maintenance measures.
- Maintenance tasks: Clear description of the work to be carried out, including inspections, maintenance and repairs.
- Responsibilities: Definition of responsibilities for each maintenance activity.
- Resource requirements: indication of the resources required, such as personnel, spare parts, tools or external services.
- emergency measures: planning for corrective maintenance in the event of unforeseen failures.
Costs and benefits of maintenance: why it pays to invest in maintenance
Maintenance can incur significant costs, but the long-term benefits outweigh these. Regular maintenance and preventive measures can avoid expensive failures, extend the service life of the equipment and minimise unplanned downtime. This leads to higher overall equipment availability, reduced operating costs and improved safety standards. Investing in modern predictive maintenance technologies enables more accurate resource planning and helps to increase a company's efficiency and competitiveness. Maintenance investments are therefore a strategic measure to ensure long-term equipment reliability and optimise total cost of ownership.
Where is maintenance particularly important?
Maintenance is particularly important in industries such as manufacturing, energy supply, aerospace, transport and logistics, healthcare, and facility management. In these areas, effective maintenance is crucial to ensure the reliability of machines, equipment and infrastructure. It minimises downtime, ensures smooth operations and contributes to the safety, efficiency and quality of the respective services or products. To emphasise the importance of maintenance even more specifically, we would also like to share two case examples with you:
Case example 1: In a medium-sized electrical engineering company specialising in the manufacture of control and switchgear systems, maintenance is crucial. Thanks to regular inspections and maintenance work, an impending short circuit in a critical control system was detected and rectified at an early stage. This not only prevented production losses, but also potential safety risks. Maintenance ensures quality, extends the service life of the systems and strengthens customer loyalty by providing the company with reliable and safe electrical systems.
Case example 2: Maintenance is equally essential for a renowned company that manufactures highly complex production systems for the automotive industry. The company carries out regular inspections and preventive maintenance measures. The following example illustrates the importance of this: the timely replacement of wearing parts in a critical precision machine avoided an impending failure. This safeguards production capacity, minimises downtime and ensures the quality of the manufactured equipment. Maintenance also plays a central role in the safety of employees, as many machines are highly complex and potentially dangerous.
Overall, these examples underscore the critical role of maintenance for the productivity and financial performance of the company.
What are the objectives of maintenance
Maintenance has several key objectives to ensure optimal performance, reliability and lifespan of equipment:
- Ensure availability : The aim of maintenance is to ensure the continuous availability of systems in order to minimise production interruptions and to guarantee smooth operations.
- Extend service life : Preventive measures are designed to minimise wear and premature wear in order to extend the service life of the systems and avoid expensive replacement investments.
- Cost optimisation: Maintenance aims to optimise operating costs by developing efficient maintenance plans, using resources effectively and minimising unplanned downtime.
- Ensure safety : A key issue is safety in the workplace. Maintenance identifies and eliminates potential safety hazards to prevent accidents and injuries.
- Increase efficiency : Maintenance aims to increase the efficiency of facilities by maintaining optimal operating conditions and minimising unnecessary energy loss.
- Quality assurance: Maintenance of machinery and equipment ensures consistent product quality, especially in production environments where high quality standards are required.
- Environmental protection: Maintenance helps to promote environmentally friendly practices by ensuring that equipment operates efficiently and minimises environmental impact.
How maintenance contributes to the longevity of your machines
Maintenance ensures the longevity of machines by performing regular checks, servicing and repairs. Preventive measures detect wear and possible defects at an early stage, prevent serious problems and extend the service life of the machines. Well-planned maintenance minimises unplanned downtime, increases productivity and lowers total operating costs, thereby maintaining the optimal functionality of the machines.
What is the difference between maintenance and servicing?
Maintenance is a broader term that encompasses all measures to ensure the functionality, reliability and lifespan of systems. Servicing, on the other hand, focuses specifically on preventive measures to detect and prevent wear and potential defects.
inspection: what is inspection and why is it important?
Inspection refers to the systematic examination, checking, or evaluation of objects, products, or assets to determine whether they meet established standards, specifications, or requirements. Inspections are carried out to identify defects, faults, or irregularities that require corrective action. Inspection is of fundamental importance in various areas, including production, quality assurance, safety, and maintenance. It enables the monitoring of processes and products to ensure that they meet requirements. Inspections are used to detect quality defects at an early stage, minimise waste and ensure compliance with safety standards. In maintenance, inspections are often used for preventive maintenance to monitor the condition of equipment and identify potential problems in good time. Overall, inspection helps to ensure quality, safety and efficiency in various contexts.
What actions does an inspection involve?
An inspection involves various actions that aim to check the condition of facilities, machines, buildings or other equipment and identify potential problems at an early stage. Depending on the type of objects to be inspected, the specific actions may vary, but typical activities during an inspection may include:
- Visual inspection: inspectors perform a visual inspection to identify visible signs of wear, damage or other irregularities.
- Measurements: measurements may be taken to ensure that certain parameters are within prescribed limits.
- Functional tests: the functionality of machines or systems is checked to ensure that they are working properly.
- Analysis of operational data: Inspectors may analyse operational data to identify trends or anomalies that could indicate potential issues.
- Document review: This is to check that all the required documents, such as maintenance records or certificates, are present and up to date.
- Compliance checks: Compliance with legislation and standards is checked to ensure that the equipment meets the required standards.
- Training and qualifications: inspectors can also check the training and qualifications of personnel to ensure that they are able to operate the equipment safely.
What is the difference between inspection and reconditioning?
Inspection is the evaluation and identification of defects, while servicing is the correction of existing problems to restore functionality. Inspection monitors and detects, servicing repairs.
What is the difference between inspection and maintenance?
Inspection is the examination of equipment to identify defects. Maintenance involves active care to ensure proper functioning and efficiency.
Maintenance: Why regular maintenance is important
Regular maintenance is important to ensure the optimal performance and lifespan of equipment, machinery and devices. During operation, these systems are subject to wear and tear, which can be identified and remedied through regular inspections and maintenance work. Preventive measures identify potential defects early, minimising unplanned downtime and avoiding expensive repairs. Regular maintenance also promotes efficient operation, improves workplace safety and helps ensure that equipment meets required standards and specifications. Overall, regular maintenance is a proactive approach to ensuring operational reliability, controlling costs and protecting equipment investments.
Definition of maintenance according to DIN 31051: DIN 31051 defines maintenance as ‘the combination of all technical and administrative measures, as well as management measures, during the life cycle of an object in order to maintain or restore its condition so that it can fulfil the required function’. The definition includes both technical aspects, such as maintenance and repair, and administrative and management-related aspects to ensure that the facilities can fulfil their required function throughout their entire life cycle. This comprehensive approach emphasises the importance of a holistic view of maintenance that takes into account both technical and organisational aspects.
What is maintenance?
Maintenance is the regular, proactive care of equipment to maintain its proper functioning and efficiency and to detect potential defects at an early stage.
What is the difference between maintenance and repair?
Maintenance includes preventive measures that aim to maintain the normal condition and to detect and repair potential defects at an early stage. This includes regular inspections, cleaning and preventive repairs. Repair, on the other hand, focuses on the targeted rectification of defects or damage that has already occurred, in order to restore normal functionality. Why maintenance and repair are important: Both aspects are important because maintenance prevents failures and extends service life, while repairs are necessary to get machines back into operation after a defect. A good balance between preventive maintenance measures and effective repairs is crucial for optimal equipment performance and service life.
What is the difference between maintenance and servicing?
Maintenance is a proactive and regular care to keep equipment in good working order, while servicing is a broader term that encompasses both preventive and corrective measures. Preventive maintenance aims to address potential defects before they occur, similar to maintenance. Servicing is thus broader in scope and also includes repair, while maintenance is mainly preventive in nature.
What is the difference between servicing, repair and maintenance?
- Servicing refers to the general care of equipment, including preventive measures and inspections.
- Repair refers to the targeted elimination of defects to restore normal operation.
- Maintenance includes regular measures to ensure the proper functioning and efficiency of equipment.
What maintenance tasks need to be performed?
Practical tips for machine maintenance: How to recognise small problems before they lead to large and costly breakdowns and repairs.
- Regular inspections: Conduct regular visual inspections to look for potential signs of wear, leaks or other irregularities.
- Listen for unusual sounds: Be alert to strange noises during operation, as these may indicate developing problems such as wear or loose parts.
- Monitor operating parameters: Keep an eye on important operating parameters such as temperatures, pressures and vibrations. Deviations from normal values may indicate problems.
- Document maintenance work: Record maintenance activities and repairs in a log. This enables systematic analysis and early detection of recurring problems.
- Check lubrication : Make sure that lubricants are regularly checked and replenished or replaced as needed. Lubrication points are critical to smooth operation.
- Conduct functional tests : Conduct regular functional tests to ensure that all components are working properly. This includes electrical controls, sensors and other monitoring devices.
- Training for operating personnel: Provide training for operating personnel so they can recognise the early signs of problems. A trained eye can detect small deviations in operating performance.
- Routine cleaning: Keep machinery clean to avoid the build-up of dirt and dust. Dirt can cause overheating and premature wear.
- Safety checks: Incorporate safety checks into maintenance tests to ensure that safety devices and emergency stop switches are working properly.
- Implement early warning systems : Use modern technologies such as sensors and early warning systems to automatically indicate deviations from normal values before major problems occur.
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Maintenance: When maintenance is required
Maintenance is necessary to ensure the continuous functionality and reliability of systems. Effective maintenance management includes the rapid identification of problems, the planning and execution of repairs, and the implementation of measures to avoid recurring problems.
Definition: Maintenance according to DIN 31051
DIN 31051 defines the term ‘repair’ as measures taken to restore systems or parts of systems to a proper condition after a defect has been detected, after a malfunction has occurred or after the permissible service life has been reached. Repair includes both the restoration of function and the renewal or replacement of components to make the systems operational.
The role of maintenance in the life cycle of machinery and equipment
Effective maintenance during the life cycle not only ensures the continuous functionality of machinery and equipment, but also helps to minimise total cost of ownership. A well-planned maintenance strategy takes into account the specific requirements of each phase of the life cycle and optimises resources to achieve reliable performance and maximum service life.
Maintenance therefore plays a crucial role in the entire life cycle of machinery and equipment. Its contribution extends across various phases:
- Construction and commissioning: At the beginning of the life cycle, maintenance involves ensuring correct installation and commissioning. Defects that occur during this phase may require repairs to ensure full functionality.
- Operating phase: During regular operation, maintenance helps to cope with normal signs of wear. Repairs are necessary to rectify defects that may arise from use, environmental conditions or material fatigue.
- Preventive maintenance: In preventive maintenance, servicing has a preventive role in that it detects small problems at an early stage and rectifies them before they lead to larger failures or expensive damage.
- Modification and upgrade: During the course of the lifecycle, modifications or upgrades may be required to meet changing requirements or to incorporate new technologies. Repair therefore also takes account of adaptations or extensions.
- Decommissioning or disposal: At the end of the lifecycle, maintenance is associated with decommissioning and disposal. The aim is to prepare the systems for environmentally friendly decommissioning or temporary shutdown. The goal can therefore also be to maintain the systems in a condition that allows for easy recommissioning.
Examples of maintenance
These examples show the wide range of maintenance activities that are carried out to keep equipment in optimal operating condition and extend its useful life:
- Lubrication and oil changes: Vehicles have many moving parts such as engines, gearboxes and axles. Regular lubrication of these parts and changing the engine oil are crucial maintenance measures.
- Inspections: Aircraft are subject to regular inspections to ensure that all mechanical, electrical and safety-related systems are working properly . These inspections include visual checks, inspections of aircraft components, and checks of engines and electronic systems.
- Cleaning: Regular cleaning of heating, ventilation and air conditioning systems is crucial to ensure proper functioning . Removing dust, dirt and debris improves equipment efficiency, reduces energy consumption and extends the life of the equipment.
- Calibrating measuring equipment: Scales, thermometers or gauges must be regularly calibrated to ensure that their measurements are accurate and reliable.
- Corrosion protection: Ships are highly exposed to seawater corrosion. To prevent damage, special coatings and anti-corrosive agents are applied.
- Electrical inspections: Regular inspections are carried out in industrial facilities or power stations to ensure safety and performance.
- Replacement of worn parts: Brake pads and discs are subject to wear due to regular use and must be replaced periodically to maintain optimal performance and safety of the vehicle.
- Software updates: Updating software in control systems
How to minimise the need for maintenance with regular inspection and servicing
Regular inspection of machinery and equipment reduces the need for repair work. Systematic visual inspections can identify potential problems at an early stage. This includes the identification of signs of wear, unusual noises or signs of malfunction. Early detection makes it possible to identify small problems before they develop into serious defects. This proactive approach helps to avoid costly repairs by creating room for preventive measures before major damage occurs.
Preventive maintenance is another crucial factor in minimising the need for repairs. By regularly performing proactive measures according to a predefined schedule or operating cycle, potential causes of failure can be addressed before they become critical. This includes activities such as lubrication, cleaning, inspection of components and replacement of worn parts. Preventive maintenance aims to maintain the proper condition of the equipment and slow down the natural wear and tear. Investing in preventive measures extends the service life of machines while reducing the need for extensive repair work.
In this context, the replacement of defective components is also essential. During regular inspections, machinery and equipment are examined for wear, damage or malfunctions. If defective components are identified, replacement is a preventive measure to maintain proper operation and prevent more serious problems.
How often should inspections be carried out?
The frequency with which inspections should be carried out depends on various factors, including the type of equipment, how it is used, the environment and legal requirements. It is therefore important that the inspection intervals are determined in accordance with the specific requirements and conditions of the equipment. A structured maintenance management system that is tailored to the specific context can help to determine the optimal times for inspections.
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What influence does refurbishment have on sustainability and environmental protection?
Refurbishment is important in the context of sustainability and environmental protection in that it contributes to a resource-efficient practice and reduces waste. Here are some aspects of how refurbishment contributes to a sustainable approach:
- Extension of lifespan: Refurbishment helps to extend the lifespan of machinery and equipment. By restoring and repairing defective components, the premature replacement of functional parts is avoided. This leads to a more effective use of resources and reduces the need for new production.
- Waste reduction: Repairing defective parts and components instead of replacing them replacement minimises waste. This sustainable approach reduces the need for new raw materials and helps to reduce the environmental impact of the production of spare parts.
- Energy savings: Repair work often requires less energy compared to manufacturing new products. The energy savings result both from avoiding the production of new parts and the reduction of the need to transport materials.
- Environmentally friendly material selection: Environmentally friendly materials can be used during the repair process to minimise the environmental impact. The selection of recycled or environmentally friendly materials supports sustainable practice.
- Promoting circular economy: Repair is a key part of the circular economy. By repairing and reusing products, the linear path of ‘make, consume, dispose’ is broken, leading to more sustainable use of resources.
- Increase resource efficiency: Repair contributes to increasing resource efficiency by optimising the use of raw materials and energy. This is crucial for sustainable development and the responsible use of limited resources.
What is the difference between maintenance and servicing?
The distinction between maintenance and servicing is generally based on the type of measures carried out and the condition of the systems:
Maintenance: Maintenance involves preventive measures to maintain the normal operation of equipment. This includes regular inspections, servicing and minor repairs to detect and rectify potential defects at an early stage. The aim is to avoid breakdowns and extend the service life of the equipment.
Repair: Repair occurs when assets experience a defect, malfunction or have reached their design life. Repair actions are reactive in nature and involve the targeted resolution of problems, often through the replacement or renewal of components. The main objective is to restore the assets to their intended state.
What is the definition of servicing or maintenance?
Servicing includes all measures that are aimed at maintaining or restoring the intended condition of systems. This includes inspections, maintenance, repairs and other suitable measures. Maintenance is therefore a specific type of servicing and includes all measures that are designed to maintain or restore the intended condition of systems through inspections, repairs and preventive measures.
Repair: What is meant by a repair and when is it necessary?
A repair refers to the targeted elimination of defects, damage or malfunctions in machines, systems or devices. The purpose of a repair is to restore the affected components or systems to a functional state in order to ensure normal operation. Repairs may involve various measures, such as replacing defective parts, readjusting components, welding, rectifying electrical faults or other maintenance work. Repairs are needed when machinery or equipment has developed deficiencies caused by normal wear and tear, operating conditions or other factors. The need for repair can be indicated by various signs, including: 1. Malfunctions 2. Visible damage 3. Performance degradation 4. Anomalies in inspections 5. Electrical or mechanical failures
Timely repairs help to extend the service life of equipment, minimise unplanned downtime and improve overall operational efficiency. An effective repair strategy integrates repairs in response to detected defects, thus ensuring the reliability and availability of machinery and equipment.
Definition and significance of repair
In the context of equipment, repair refers to the targeted elimination of faults, defects or damage in order to restore the functionality of the equipment. This measure aims to minimise possible downtime and to restore the normal operating condition as quickly as possible.
The definition according to DIN EN ISO 9000: 2000, clause 3.6.9 is: a specific treatment of a defective or damaged product to influence or change the product. According to DIN 31051, repair is also considered part of maintenance.
The DIN standard DIN EN ISO 8402: 1995-08, clause 4.18, also provides a description of the term: ‘Repair includes every measure to be carried out on a defective product with the aim of enabling this measure to fulfil the intended use of the product’.
When is a repair necessary?
A repair is necessary when a system, machine or device is defective or no longer functions properly. This can be caused by wear, mechanical damage, electronic failures or other problems. The need for repair usually arises in order to restore the functionality of the affected components and to minimise possible downtime. A thorough analysis of the defect and a professional repair are required to extend the service life of the equipment and ensure smooth operation.
What is the difference between repair and overhaul
The terms ‘repair’ and ‘refurbishment’ are often used interchangeably, but they can have different meanings depending on the context. In general, they refer to the rectification of defects, damage or malfunctions, but the difference often lies in the scope of the work and the strategic approach. Here are some differences:
Repair
– Purpose: Repair focuses on fixing a specific defect or damage to restore normal functionality.
– Scope: Repairs are often isolated and address a specific defect or malfunction. They may be done on an ad hoc basis to solve a specific problem.
- Timing: Repairs are usually done when a defect occurs or is identified during an inspection. They may be reactive to fix immediate problems.
Corrective maintenance
– Purpose: Corrective maintenance is a broader term that covers the restoration, care and preservation of equipment or systems over their entire life cycle.
– Scope : Maintenance includes not only the rectification of defects, but also preventive measures to extend the service life and keep the assets in optimal condition.
- Timing: Maintenance is both reactive and proactive. In addition to rectifying acute problems, preventive measures are taken to prevent future defects.
Repair as part of the maintenance strategy
Integrating repairs into the maintenance strategy enables a flexible response to changing conditions and helps to minimise costly failures. It also supports a proactive approach by identifying and correcting defects before they lead to more serious problems. Overall, the inclusion of repairs helps to maximise equipment availability, extend service life and optimise the overall efficiency of production processes.
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Conclusion: Differences and sequence of measures summarised again
Maintenance, servicing, inspection, repair and overhaul are related, but represent different aspects of the life cycle of machinery and equipment. Maintenance focuses on regular care, inspection and minor repairs to maintain normal operation. Maintenance is a broader term that encompasses preventive and corrective measures to ensure the reliability and lifespan of equipment. Repair aims to rectify specific defects or damage, while overhaul is a holistic strategy that includes both preventive and reactive measures to ensure that machines are in optimal condition throughout their entire lifecycle.
The sequence of these measures begins with preventive measures, followed by regular inspections and maintenance work to identify potential problems at an early stage. In the event of defects or malfunctions, repair is the next step to specifically rectify specific defects. If the challenges are more extensive or if the service life needs to be extended, reconditioning measures come to the fore. A well-coordinated and proactive combination of these measures is crucial to maximise plant availability, control costs and ensure the sustainable use of resources. Long-term investments to extend the service life of equipment are particularly important for companies that aim for sustainable and efficient operations. Such investments pay off over time by improving the reliability, performance and profitability of equipment.
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