Maintenance Type Question & Answer

General Concept Questions

1. Can you explain the differences between breakdown, preventive, predictive, and corrective
maintenance?
2. In your view, which maintenance strategy is most cost-effective for critical equipment, and
why?
3. How would you decide which maintenance approach to use for a specific piece of
equipment?

Breakdown (Reactive) Maintenance

4. What are the risks of using breakdown maintenance for critical equipment?
5. Can you describe a situation where you had to manage an unexpected breakdown? How
did you handle it?
6. How do you minimize downtime and losses when breakdowns occur?

Preventive Maintenance
7. How do you develop and schedule a preventive maintenance plan?
8. What KPIs do you track to measure the effectiveness of preventive maintenance?
9. Give an example where preventive maintenance significantly improved equipment
reliability.

Predictive Maintenance
10. How do you implement predictive maintenance in a plant?
11. What types of condition-monitoring techniques have you used (vibration, thermography,
oil analysis)?
12. Describe a time when predictive maintenance helped you avoid a major failure.

Corrective Maintenance
13. How is corrective maintenance different from breakdown maintenance?
14. Can you describe an example where a problem found during inspection led to corrective
maintenance before failure?
15. How do you ensure corrective actions are documented and prevent recurrence?

Mixed / Decision-Making Questions

16. If you’re given a fleet of pumps of varying criticality, how would you assign maintenance
strategies (breakdown, preventive, predictive, or corrective) to each?
17. How would you justify the initial cost of predictive maintenance to management?
18. How do you integrate PDCA (Plan-Do-Check-Act) or continuous improvement cycles into
maintenance activities?
19. Define Reliability along with RCM.

Question-01: Can you explain the differences between breakdown, preventive, predictive, and
corrective maintenance?

Sample Answer:

Breakdown Maintenance
• Meaning: Also called reactive or run-to-failure maintenance. You take no action until
equipment actually fails.
• When Performed: After the machine breaks down.
• Goal: Restore functionality as quickly as possible.
• Advantages:
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o No planning cost upfront.

o Useful for non-critical, low-cost equipment.
• Disadvantages:
o Unplanned downtime.
o May cause collateral damage to other parts.
o Usually more expensive in the long run.
• Example: A light bulb is replaced only after it burns out.

Preventive Maintenance (PM)

• Meaning: Scheduled, routine maintenance done at predetermined intervals (time-based or
usage-based) regardless of condition.
• When Performed: Before failure, based on schedule or OEM recommendations.
• Goal: Reduce probability of failure, extend asset life.
• Advantages:
o Minimizes unexpected downtime.
o Increases reliability and lifespan.
• Disadvantages:
o Can lead to unnecessary work if the equipment is still in good condition.
o Requires planning and resources.
• Example: Changing engine oil every 5,000 km even if oil still looks good.

Predictive Maintenance (PdM)

• Meaning: Condition-based maintenance using data, sensors, and analysis (vibration,
temperature, oil analysis, etc.) to predict when a failure might occur.
• When Performed: Only when data indicates impending failure or degradation.
• Goal: Do maintenance at the right time — not too early, not too late.
• Advantages:
o Reduces unnecessary maintenance.
o Minimizes downtime.
o Can optimize spare parts and labor.
• Disadvantages:
o Higher initial cost (sensors, software, expertise).
o Requires skilled personnel and data infrastructure.
• Example: Replacing a bearing when vibration analysis shows it’s about to fail, not on a fixed
schedule.

Corrective Maintenance (CM)

• Meaning: Action taken to correct a defect or abnormal condition detected during inspections
or monitoring (before total failure).
• When Performed: After detecting a problem but before complete breakdown.
• Goal: Eliminate faults early to prevent breakdowns or performance issues.
• Advantages:
o Cheaper than waiting for full breakdown.
o Improves reliability.
• Disadvantages:
o Requires inspections/monitoring to detect issues.
• Example: Tightening a loose bolt found during an inspection; replacing a worn part flagged
during preventive check.

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Comparison Table
Feature Breakdown Preventive Predictive Corrective (Detected
(Reactive) (Scheduled) (Condition-Based) Fault)
Trigger After failure Fixed time / usage Condition monitoring After defect found in
schedule /data inspection
Planning None Planned Planned (based on Planned (post-
data) inspection)
Cost Low upfront, high Moderate High upfront, lower Moderate
later later
Downtime Unplanned Planned Planned / minimized Planned / minimized
Best for Non-critical, low- Equipment with High-value/critical Any equipment with
cost gear known wear equipment detected fault

“These are the four main maintenance strategies, and each has a different approach to equipment
care:
1. Breakdown Maintenance: Also called reactive maintenance. Action is taken only after
equipment fails. It’s simple but can lead to unplanned downtime and higher costs for critical
equipment.

2. Preventive Maintenance: Scheduled maintenance performed at fixed intervals, based on

time or usage. The goal is to reduce the probability of failure and extend asset life. It’s
planned but may sometimes be unnecessary if the equipment is still in good condition.

3. Predictive Maintenance: Condition-based maintenance that uses monitoring tools and data
(like vibration, temperature, or oil analysis) to predict failures before they occur. This allows
maintenance to be done at the optimal time, minimizing downtime and reducing
unnecessary work.

4. Corrective Maintenance: Action taken after detecting a defect or abnormal condition during
inspections or monitoring, but before a complete breakdown. It corrects issues early to
prevent failure, often based on inspection results or condition monitoring.

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In short, breakdown is reactive, preventive is scheduled, predictive is condition-driven, and corrective

is fault-driven before failure. In practice, a combination of these strategies ensures reliability and
operational efficiency.”

Question-02: In your view, which maintenance strategy is most cost-effective for critical
equipment, and why?

Sample Answer:
“For critical equipment, predictive maintenance is usually the most cost-effective strategy. While
preventive maintenance can prevent failures, it may involve unnecessary work and part
replacements. Breakdown maintenance is too risky because unplanned failures can cause production
losses, safety hazards, and high repair costs.

Predictive maintenance uses condition monitoring tools—like vibration analysis, thermography, and
oil analysis—to identify potential failures before they happen. This allows maintenance to be
performed just in time, reducing downtime, minimizing spare-part costs, and extending equipment
life.

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In short, predictive maintenance balances reliability, cost, and operational efficiency, making it ideal
for critical assets.”

Question-03: How would you decide which maintenance approach to use for a specific piece of
equipment?

Sample Answer:

“When deciding which maintenance approach to apply for a specific piece of equipment, I consider
three main factors:
1. Criticality of the equipment – I start with a criticality assessment. If the equipment is
essential to safety, production continuity, or regulatory compliance, it may justify a more
proactive or predictive maintenance approach.
2. Failure patterns and history – I review past maintenance records, manufacturer
recommendations, and known failure modes. Equipment with predictable wear or
degradation is better suited to preventive or condition-based maintenance, while equipment
with random failure patterns may require run-to-failure or more frequent inspections.
3. Cost-benefit analysis – I compare the cost and downtime implications of different
approaches. Predictive maintenance may have a higher initial cost but can save on
unplanned downtime for high-value assets. Conversely, low-cost, non-critical equipment may
be best managed with reactive maintenance.

In practice, I often use a mix of strategies—like Reliability-Centered Maintenance (RCM)—to match

the maintenance plan to the actual risk profile and performance requirements of each asset.”

Question-04: What are the risks of using breakdown maintenance for critical equipment?

Sample Answer:

“Using breakdown (run-to-failure) maintenance on critical equipment carries significant risks.

• Unplanned downtime: Sudden failure can halt production or services, leading to large
financial losses.
• Safety hazards: Critical equipment failures can endanger personnel and the environment.
• Higher repair costs: Emergency repairs or replacements are usually more expensive than
planned maintenance.
• Secondary damage: A failed critical component can damage other connected systems.
• Regulatory or reputational impact: In some industries, unexpected outages can violate
compliance standards or harm customer trust.

For these reasons, breakdown maintenance is usually reserved for non-critical, low-cost assets where
failures have minimal consequences.”

Question-05: Can you describe a situation where you had to manage an unexpected breakdown?
How did you handle it?

Sample Answer:

“In my previous role as a maintenance engineer at a power plant, one of the feedwater pumps failed
unexpectedly during peak operation. I immediately initiated the emergency response protocol—
isolating the pump to ensure safety, notifying operations, and deploying a standby unit to keep the
system running. While the backup-maintained production, I led a quick root-cause analysis with the
team to identify the fault and organized the required spares and technicians for repair. After
restoring the pump, we updated our preventive maintenance schedule and added condition-
monitoring checks to prevent similar breakdowns in the future.”
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Question-06: How do you minimize downtime and losses when breakdowns occur?

Sample Answer:

“When a breakdown occurs, my priority is safety and rapid containment. I first isolate the fault to
prevent further damage or hazards, then activate any available standby equipment or alternative
processes to keep operations running. At the same time, I coordinate with the maintenance and
supply teams to quickly mobilize spares and technicians. After the repair, I perform a root-cause
analysis and update preventive measures so future downtime is minimized.”

Questions-07: How do you develop and schedule a preventive maintenance plan?

Sample Answer Structure:

Identify Critical Equipment

• Start with an asset register.
• Rank equipment by criticality (safety, production, cost impact).
Review Manufacturer Recommendations & History
• Collect OEM manuals and maintenance guidelines.
• Review past breakdown data, mean time between failures (MTBF), and maintenance logs.
Define Maintenance Tasks
• Specify what tasks are needed for each asset (inspection, lubrication, replacement,
calibration, etc.).
• Include safety checks and regulatory requirements.
Set Maintenance Intervals
• Use OEM intervals as a baseline.
• Adjust based on usage, environment, and failure history.
• Combine time-based (e.g., monthly) and usage-based (e.g., after 500 hours) triggers.
Build a PM Schedule
• Map tasks on a calendar or in a CMMS (Computerized Maintenance Management System).
• Level-load manpower, tools, and spare parts availability.
• Minimize production disruption by aligning with planned shutdowns.
Communicate & Train
• Issue work orders with clear instructions.
• Train maintenance staff on procedures and safety.
Monitor & Improve
• Track KPIs (downtime, MTBF, cost, compliance rate).
• Use PDCA cycle (Plan–Do–Check–Act) to refine intervals and tasks.
• Incorporate feedback from technicians and operations.

Short Interview Version:

“I begin by identifying and ranking critical equipment, then review OEM guidelines and failure history
to define the required maintenance tasks. I set appropriate intervals—time-based or usage-based—
and load them into a CMMS to build a balanced schedule that minimizes production disruptions. I
ensure work orders are clear, resources are available, and results are tracked. Using KPIs and the
PDCA cycle, I continuously refine the plan to improve reliability and cost-effectiveness.”

Questions-08: What KPIs do you track to measure the effectiveness of preventive maintenance?

Sample Answer:

“To measure the effectiveness of preventive maintenance, I track KPIs that show both reliability and
cost impact. The main ones are:
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• Planned vs. unplanned maintenance ratio – how much of our work is proactive instead of
reactive.
• Mean Time Between Failures (MTBF) – to see if preventive tasks are extending asset life.
• Mean Time to Repair (MTTR) – to ensure repairs are done quickly and efficiently.
• Schedule compliance (%) – how consistently preventive tasks are completed on time.
• Maintenance cost per unit of production / asset – to confirm preventive work is cost-
effective.
Together these KPIs show whether our preventive program is reducing downtime, improving
reliability, and saving money.”

Questions-09: Give an example where preventive maintenance significantly improved equipment

reliability.

Sample Answer:

“In my previous role at a combined cycle power plant, we were seeing frequent unplanned outages
of a critical boiler feed pump due to bearing wear. I introduced a preventive maintenance program
that included scheduled vibration analysis, oil sampling, and bearing inspections every month
instead of quarterly. Within six months, unplanned stoppages dropped to zero, MTBF doubled, and
overall pump availability improved from 85% to over 98%. This not only reduced repair costs but also
ensured uninterrupted power generation.”

Questions-10: How do you implement predictive maintenance in a plant?

Sample Answer:

“To implement predictive maintenance, I start by identifying the plant’s most critical assets and their
common failure modes. I then select appropriate monitoring technologies—such as vibration
analysis for rotating equipment, infrared thermography for electrical panels, or oil analysis for
gearboxes—and install sensors or plan regular data collection. The data is trended in a CMMS or
condition-monitoring platform, and when anomalies are detected, I schedule targeted maintenance
before a failure occurs. Finally, I review results and adjust thresholds to continuously improve
prediction accuracy and reduce unplanned downtime.”

Questions-11: What types of condition-monitoring techniques have you used (vibration,

thermography, oil analysis)?

Sample Answer:
“I have hands-on experience with multiple condition-monitoring techniques to ensure equipment
reliability and prevent unplanned downtime:
1. Vibration Analysis: I regularly monitor rotating equipment such as pumps, motors, and fans.
By measuring vibration amplitude and frequency, I can detect misalignment, imbalance,
bearing wear, and gear faults early.
2. Thermography (Infrared): I use infrared cameras to inspect electrical panels, transformers,
and mechanical equipment. This helps identify hotspots, loose connections, or insulation
failures before they cause major issues.
3. Oil Analysis: I perform regular oil sampling on turbines, compressors, and hydraulic systems.
Oil analysis helps detect contamination, wear particles, and lubricant degradation, allowing
timely maintenance actions.

By combining these techniques, I can proactively assess equipment health, schedule maintenance
efficiently, and reduce the risk of unexpected failures.”

Questions-12: Describe a time when predictive maintenance helped you avoid a major failure.

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Sample Answer:

Situation: “While working at a combined-cycle power plant, one of our critical centrifugal pumps
started showing slightly higher vibration levels than usual during routine monitoring.”
Task: “My responsibility was to investigate and prevent any unplanned downtime, as this pump was
critical for the cooling system.”
Action: “Using vibration analysis and trend monitoring, I identified early signs of bearing wear. We
scheduled a predictive maintenance shutdown and replaced the bearing before it failed. At the same
time, I coordinated oil analysis to ensure no further damage had occurred.”

Result: “By taking action based on predictive maintenance data, we avoided a catastrophic pump
failure, prevented an unscheduled outage, and saved both repair costs and production losses. The
team also updated our monitoring thresholds to catch similar issues earlier in the future.”

Questions-13: How is corrective maintenance different from breakdown maintenance?

Sample Answer:

1. Corrective Maintenance (CM):

• Definition: Performed to fix equipment after a defect or fault is detected but before total
failure occurs.
• Nature: Planned or semi-planned; often based on inspections, condition monitoring, or
minor reported issues.
• Example: Replacing a worn-out bearing detected during vibration analysis before the
machine stops working.
• Goal: Prevent unplanned downtime by addressing problems early.
2. Breakdown Maintenance (BM):
• Definition: Performed only after equipment has completely failed and is no longer
operational.
• Nature: Unplanned and reactive; can cause sudden production losses.
• Example: Replacing a motor after it burns out during operation.
• Goal: Restore equipment to working condition, but downtime and costs are usually higher.

Key Difference:
• Corrective maintenance is planned after a problem is detected but before failure, while
breakdown maintenance is unplanned and occurs after total failure.

Questions-14: Can you describe an example where a problem found during inspection led to
corrective maintenance before failure?

Example answer:
“During a scheduled vibration inspection of a boiler feedwater pump at our plant, the analyst noticed
an unusual increase in vibration amplitude at the non-drive end bearing. We immediately performed
a detailed condition check and found early signs of bearing wear and slight misalignment. Instead of
waiting for the pump to fail, we scheduled a short outage, replaced the bearing, and realigned the
pump. This corrective maintenance eliminated the defect before it escalated into a catastrophic
failure, prevented an unplanned shutdown, and saved significant downtime and repair cost.”

Questions-15: Can you describe an example where a problem found during inspection led to
corrective maintenance before failure?

Sample Answer:

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 Maintenance Type Question & Answer

“I make sure every corrective action is documented in our computerized maintenance management
system (CMMS). After the repair, I record the failure mode, root cause, parts replaced, labor hours,
and any lessons learned. We then hold a brief review or toolbox talk to communicate the findings to
the team. If the issue was due to a systemic cause—like a design flaw, improper operating practice,
or missing preventive maintenance—we update the relevant maintenance procedure, inspection
checklist, or operator training so it doesn’t happen again. In this way, each corrective action not only
fixes the immediate problem but also feeds into our reliability data and helps prevent recurrence.”

This covers:
• Documentation (CMMS, work orders, logs)
• Root cause analysis (why it failed)
• Feedback loop (update PMs, SOPs, training)
• Sharing lessons learned

Questions-16: If you’re given a fleet of pumps of varying criticality, how would you assign
maintenance strategies (breakdown, preventive, predictive, or corrective) to each?

Sample answer:
“First, I would conduct a criticality analysis of the pump fleet. For each pump, I’d consider how
essential it is to production or safety, what the consequences of its failure would be (cost, safety,
environmental), its failure history, and how easily it can be repaired or replaced.
• High-criticality pumps (e.g., boiler-feed or safety-related pumps) would get predictive
maintenance such as vibration analysis, oil analysis, or thermography, combined with well-
planned preventive maintenance tasks. This minimizes unexpected failures.
• Medium-criticality pumps (important but with redundancy or low failure impact) would
typically receive preventive maintenance at defined intervals, perhaps supplemented by
some condition monitoring if justified.
• Low-criticality pumps (non-essential, easy/cheap to replace) could be left on a
breakdown/run-to-failure basis, as the cost of predictive or preventive maintenance may
exceed the cost of an occasional repair.
• Corrective maintenance is applied when inspections reveal defects or performance
deterioration—regardless of criticality—to fix problems before they escalate.
This way, resources are focused where failure would hurt most, and maintenance costs stay aligned
with risk.”

This shows you:

• Do a criticality assessment first
• Match maintenance strategy to consequence and failure mode
• Use predictive for critical equipment, preventive for moderate, run-to-failure for low
• Use corrective when inspections reveal an issue

Questions-17: How would you justify the initial cost of predictive maintenance to management?

Sample answer:

“I would present predictive maintenance to management as a cost-saving and risk-reduction

investment rather than an added expense. First, I’d quantify the current impact of unplanned failures
— lost production hours, overtime labor, spare parts, and reputational or safety risks. Then I’d
compare that to the projected cost of implementing predictive technologies like vibration or oil
analysis. For example, if one unplanned pump failure costs $50,000 in lost production and repair, and
predictive monitoring can prevent two such failures a year at a monitoring cost of $15,000, the
payback period is only a few months. I’d also highlight ‘soft’ benefits: improved equipment life,
optimized spare-parts inventory, and increased safety. By presenting data, pilot results, and ROI
calculations, I can show management that predictive maintenance reduces total life-cycle cost and
improves reliability, availability, and profitability.”
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 Maintenance Type Question & Answer

This structure covers:

• Quantify current pain (unplanned downtime cost)
• Estimate PM cost (equipment, training, service)
• Show ROI/payback (compare costs)
• Mention soft benefits (longer asset life, safety, compliance)

Questions-18: How would you justify the initial cost of predictive maintenance to management?

Sample answer:

“I apply the PDCA cycle to maintenance activities so that each task becomes part of a continuous
improvement loop.
Plan: Use equipment history, criticality analysis, and manufacturer recommendations to plan
preventive or predictive maintenance schedules. Identify KPIs (MTBF, MTTR, cost, downtime) and set
targets.

Do: Execute the planned maintenance tasks — inspections, lubrication, condition monitoring, repairs
— following established procedures.

Check: After the work, review performance and results. Compare actual downtime, failures, and
costs against the plan. Audit work orders and data in the CMMS to identify gaps or trends.

Act: Based on what was learned, adjust the maintenance program: change intervals, update
procedures, improve training, or introduce new tools/technologies. Communicate lessons learned to
the team.

Repeating this cycle turns maintenance into a proactive, continuously improving process instead of a
reactive one.”

This hits:
• Plan = develop strategy & KPIs
• Do = execute tasks
• Check = measure results & audit
• Act = improve & standardize

Questions-19: Define Reliability along with RCM.

“Reliability is the ability of a system to perform its required function under stated conditions for a
specified period of time, which depends on three key attributes: availability (how often it is ready for
use), maintainability (how quickly it can be restored after a failure), and dependability (the overall
trustworthiness of the system).”

The Concepts

Term What it means Simple question it

answers
Reliability Probability the system performs its intended function “Will it keep working
correctly for a specified time under stated conditions. without failing?”
Availability Proportion of time the system is actually up and usable “Is it ready when I
(includes downtime due to failures + repairs). need it?”
Maintainability How quickly and easily the system can be restored to full “How fast can we fix it

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Term What it means Simple question it

answers
operation after a failure (MTTR). if it breaks?”
Dependability An umbrella term combining reliability, availability, “Overall, can I trust
maintainability, and also safety/integrity. it?”

Strictly speaking:

Dependability = Reliability + Availability + Maintainability + Safety

…but many texts use a simplified trio:

Reliability attributes = Availability + Maintainability + Dependability

It’s not a literal arithmetic sum. It means reliability as an attribute of a system depends on these
three aspects.

Reliability-Centered Maintenance (RCM) is a structured process used to determine the most

effective maintenance strategy for each piece of equipment, ensuring that it continues to perform its
intended function with acceptable reliability, safety, and cost.
Key points about RCM:
• It focuses on functions rather than just components.
• It identifies the failure modes that could prevent the equipment from fulfilling its function.
• It then selects the most appropriate maintenance tasks (preventive, predictive, run-to-
failure, redesign, etc.) to manage those failure modes.
• The goal is to maximize equipment reliability and availability while minimizing unnecessary
maintenance cost.
Example:
In a power plant, RCM might show that a critical pump needs vibration monitoring (predictive
maintenance) instead of a fixed-interval overhaul, while a non-critical valve can be run to failure
because the consequence is minor.

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