First of all, there are 5 different maintenance levels. Level I maintenance includes simple maintenance activities that are essential to the operations, and are carried out on easily and safely accessible elements thanks to machine-integrated support equipment. This type of operations may be carried out by the production operator and scheduled on the CMMS Mobility Work with to the Calendar feature.
Examples of preventive level I maintenance
Examples of corrective level I maintenance
Condition monitoring rounds
Light bulb replacement
Common locksmith operations, scrapers
Manual handling of mechanical elements
Setting and replacement of wear or outdated parts, on simple and accessible components
State value and life unit collection
Control console lamps testing
Filter clogging control
Level II maintenance is dedicated to interventions which require simple procedures. A qualified worker with detailed procedures may carry out this type of operations. An employee is said to be qualified after having taken a training which allows him to work safely on a good that may carry potential risks; then he is considered to be skilled for this task, in view of his knowledge and capabilities.
Examples of preventive level II maintenance
Examples of corrective level II maintenance
Parameter control on equipment in operation with measuring tools integrated to the equipment
Braids, stuffing box, etc. replacement
Troubleshooting flowcharts interpretation
Run-off surface descaling (cooling towers)
Weekly or monthly lubrication
Hard-to-reach filters replacement
Level III maintenance includes operations which require complex procedures. A qualified technician with detailed procedures may carry out this type of maintenance operations. Such procedures may be easily integrated to interventions on the CMMS Mobility Work, and are available at anytime on any mobile device or tablet.
Examples of preventive level III maintenance
Examples of corrective level III maintenance
Control and settings that require measuring tools external to the machine
Preventive maintenance visits on complex equipment
Repairing a refrigerant leak (cooling unit)
Ignition and combustion control (boilers)
Intrusive preventive maintenance intervention
Repairing means of production using measuring tools and individual diagnosis
Condition technical parameters collection, with individual measuring tools (fluid or material collection, etc.)
Level IV maintenance is dedicated to operations whose procedures imply particular techniques or technologies. A qualified technician or team with any general or special maintenance instructions may carry out this type of maintenance operations. Consult and share these operations on the maintenance social network Mobility Work.
Examples of preventive level IV maintenance
Examples of corrective level IV maintenance
Partial or general revisions that do not require to entirely dismantle the machine
Compressor valves replacement
Cable head replacement (alternative low voltage)
Infrared thermography (electrical, mechanical or thermal installation, etc.)
Pump revision in a specialized repair shop after a preventive discard
Technical parameters collection that require collective measuring tools (oscilloscope, vibration data collector) with data analysis
Repairing means of production using measuring tools or collective and/or highly complex diagnoses (portable programming, numerical control regulation system, regulators, etc.)
Pump revision in a repair shop consecutively to a preventive discard
Level V maintenance consists of operations whose procedures imply a particular know-how, and require special techniques, technologies or processes. By definition, this type of maintenance operations (renovation, reconstruction, etc.) may be carried out by the manufacturer or by a specialized company with support equipment defined by the manufacturer that is close to the manufacturing of the concerned equipment.
- General revisions with complete machine dismantling
- Dimensional and geometrical recovery
- Manufacturer major repairs and equipment reconditioning
- Wear or outdated goods replacement
Maintenance levels should not be mistaken with maintenance echelons which refer to the place where the interventions are being carried out. The three main steps are:
- On-site: interventions are carried out directly on the equipment on site.
- In a repair shop: the equipment to be repaired is transported to somewhere appropriate to the intervention
- At the manufacturer or specialized company: equipment is transported in order to carry out operations that require specific means.
In spite of maintenance levels and maintenance echelons being two clearly distinct concepts, there is often a correlation between level and echelon. For instance, for levels I to III, operations are usually carried out on-site, for level IV, in a repair shop, and for level V, off-site at a specialist (manufacturer or specialized company). Although this is generally true (in the military field for example), such statement should not be generalized. In the industrial field, some level V tasks may be carried out on-site.
A different structure
Sometimes, the five-level structure may be divided in four or three according to other norms or practices. A simplified three-level classification enables to distinguish:
- Basic maintenance operations (settings, consumable replacements, lubrication, etc.): they particularly consist of tasks carried on Line-Replaceable Units (LRU) whose failures or degradations are easy to detect, and whose replacement operations are easy and do not require any dismantling. These interventions gather level I to III from the five-level classification.
- Average maintenance operation (components repairs, intrusive controls, internal parts examination, visits, etc.): they apply particularly to Shop Replaceable Assembly (SRA) which cannot be easily replaced on-site. It corresponds to level IV on the five-level classification;
- Major maintenance operations correspond to level V and are usually carried out by the manufacturer or by specialized companies.