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CHALLENGES IN MAINTENANCE FUNCTIONS

MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION LEVELS, CAPACITY UTILIZATION, EFFICIENT CAPITAL EMPLOYMENT AND REDUCED LOSSES ELECTRICAL JOBS RELATING TO ALL ELECTRIC PRIME MOVERS, POWER CONTROL, PLANNING LOAD DISTRIBUTION CIVIL AND ENVIRONMENTAL JOBS RELATING TO MAINTENANCE ELECTRONIC JOBS RELATED TO SOLID STATE DEVICES AND MICROPROCESSOR CONTROL

EXPECTATIONS

REDUCTION IN UNSCHEDULED BREAKDOWNS ELIMINATION OF TIME SCHEDULED OVERHAULS INCREASE IN OPERATING LIFE OF THE ASSETS REDUCTION IN DOWNTIME REDUCTION IN MAINTENANCE MANPOWER REDUCTION OF SPARES INVENTORY MAXIMIZING EQUIPMENT EFFECTIVENESS

TOTAL PREVENTIVE MAINTENANCE FAILURE MODE AND EFFECT ANALYSIS CRITICALITY ANALYSIS PRELIMINARY HAZARD ANALYSIS FAULT TREE ANALYSIS HAZOP STUDIES CAUSE-CONSEQUENCE-COST ANALYSIS INTEGRATING VARIOUS MAINTENANCE SYSTEMS DETEREMINING AREAS OF CONDITION MONITORING DOCUMENTATION PROCEDURES AND SYSTEMS

IDENTIFYING

LOSSES DUE TO FAILURES AND ADJUSTMENT OF SPEEDS AND MINOR STOPPAGES LOCATING DEFECT LOSSES HAVING PROPER LUBRICATION SYSTEM FOR ENERGY SAVINGS

EFFECTIVE MAINTENANCE

RESTORE SYSTEM PRODUCTIVITY IMPROVES EQUIPMENT RELIABILITY AVOID UNNECESSARY SHUTDOWNS INCREASE OF EQUIPMENT EFFICIENCY PROLONG SYSTEM LIFE IMPROVE OVERALL PLANT EFFECTIVENESS MAINTAIN PRODUCT QUALITY INCREASE PLANT PROFIT

NON-EFFECTIVE MAINTENANCE

INCREASED MAINTENANCE COST REDUCED SYSTEM / EQUIPMENT LIFE INDUCED / CREATED UNWANTED WASTE ADDITIONAL COST TO CLEAN THE EQUIPMENT CAN AFFECT PRODUCT QUALITY REDUCED PLANT PRODUCTIVITY DOWNGRADED SYSTEM EFFECTIVENESS DECREASED PLANT PROFIT POOR SKILL LEVEL REPITITIVE FAILURE

OVERALL EQUIPMENT EFFECTIVESSS


AVAILABILITY

PERFORMANCE
QUALITY

RATE

RATE MTBF , MTTR, MUT, MDT, MCT, MLDT INHERENT AVAILABILITY STEADY-STATE AVAILABILITY OPERATIONAL AVAILABILITY

KEY PERFORMANCE INDICATORS


INCREASE

EQUIPMENT RELIABILITY NUMBER OF UNITS REJECTED BY QUALITY INSPECTION ZERO DEFECTS SIX SIGMA ZERO ACCIDENTS MAXIMIZING O.E.E.

MAINTENANCE KEY PERFORMANCE INDICATORS


OVERTIME WORKED AGAINST PLAN PM SCHEDULE COMPLIANCE TIME TAKEN TO ATTEND MAINTENANCE CALLS BUDGET COMPLIANCE PM BACKLOG MANHOURS CRITICAL EQUIPMENT EFFECTIVESS NUMBER OF BREAKDOWNS PRODUCTION EQUIPMENT PERFORMANCE AVAILABILITY AND RELIABILITY

MAINTENANCE PERFORMANCE ANALYSIS


WORK

SAMPLING TECHNIQUES JOB AUDITING SWOT ANALYSIS EVALUATION BY REPORTS EVALUATION PROCESS OF PLANT ENGINEERING - BENCHMARKING

MANUFACTURING BASED MODEL

PLANT OUTPUT MAINTENANCE INPUTS

SERVICE BASED MODELS

QUALITY BASED PERFORMANCE PARAMETERS AVAILABILITY, RELIABILITY, WAITING TIME OPERATION BASED PERFORMANCE PARAMETERS OVERTIME, REPAIR MEAN TIME ETC.

MAINTENANCE PERFORMANCE MEASURE INDICATORS


QUALITY

BASED INDICES

AVAILABILITY EQUIPMENT RELIABILITY: MTBS, MTTF, MTTR, MTBM, FAILURE RATE EQUIPMENT MAINTAINABILITY: MTD EQUIPMENT UTILIZATION MANPOWER EFFICIENCY REACTIVE REPAIR RATIO

PERFORMANCE BASED INDICES


MAINTENANCE

COST PER UNIT

PRODUCTION MAINTENANCE COST / HOUR TOTAL PLANT MAINTENANCE PRODUCTIVITY % COST SCHEDULED MAINTENANCE % MAINTENANCE COST TO INVESTMENT

SCHEDULE COMPLIANCE SCHEDULE LOADING FACTOR WRENCH TIME MAINTENANCE WORK CAPACITY INDEX

MAINTENANCE OPERATION AUDIT


MAINTENANCE OPERATION PROCEDURE MAINTENANCE ORGANIZATION AND COMMUNICATION PLANNING AND SCHEDULING COMPLIANCE PLANT SHUTDOWN PROCEDURE MAINTENANCE PERSONNEL COMPLIANCE TO PROCEDURE, ROLES AND RESPONSIBILITIES INVENTORY MANAGEMENT COST COMPLIANCES TO APPROVED BUDGET CONTRACTOR PERFORMANCE REGULATORY AND STATUTORY COMPLIANCES

MAINTENANCE PLAN AUDIT


WORK

REQUESTS / ORDERS EQUIPMENT FAILURE HISTORY EQUIPMENT LIFY CYCLE PROFILE FAILURE AND ROOT CAUSE ANALYSIS EQUIPMENT MAINTENANCE PLAN/SCHEDULE COMPLIANCE MAINTENANCE IMPROVEMENT PLAN ASSET CARE MANAGEMENT

TECHNICAL AUDIT
THERMAL

AUDIT ELECTRICAL AUDIT ENERGY AUDIT INDUSTRIAL WATER USAGE AUDIT COMPRESSED AIR AUDIT PLANT HYDRAULIC SYSTEM AUDIT PLANT CENTRALIZED LUBRICATION SYSTEM AUDIT

MAINTENANCE BENCHMARKING
STRATEGIC

BENCHMARKING PERFORMANCE BENCHMARKING PROCESS BENCHMARKING FUNCTIONAL BENCHMARKING INTERNAL BENCHMARKING EXTERNAL BENCHMARKING INTERNATIONAL BENCHMARKING

MAINTENANCE COSTS

FIXED AND VARIABLE COSTS FIXED COSTS: READY TO SERVE MEN AND FACILITIES VARIABLE COSTS: COST OF MAJOR REPAIRS AND OVERHAULS, SPARES, MATERIALS AND FACILITIES DIRECT COSTS APPARENT COSTS: BUDGETED COST AFFECTING THE CASH FLOW OF ORGN.

MATERIALS, MAINTENANCE LABOR, OVERTIME, CONTRACT SERVICES, OVERHEADS ETC.

INDIRECT COSTS HIDDEN COSTS


START-UP LOSSES MISSED SCHEDULES RIPPLE EFFECT ON PRODUCTION COST OF IDLING OR RUNNING AT REDUCED SPEED EXCESS INVENTORY WASTE GENERATION EMERGENCY PURCHASES EXTRA CLEAN UP CUSTOMER COMPLAINTS REGULATORY/STATUTORY FINES LOST BUSINESS ENVIRONMENTAL CONTROLS ACCIDENTS

REVENUE / CAPITAL COSTS


COST

COVERED BY REVENUE BUDGET ALLOCATED FOR VARIOUS NORMAL MAINTENANCE ACTIVITIES FOR A GROUP OF EQUIPMENT / SECTION / SHOP UNUTILISED BUDGET AMOUNT CANNOT BE CARRIED OVER TO NEXT YEAR

CAPEX CAPITAL EXPENDITURE

COVERED BY CAPITAL BUDGET SPECIFICALLY SANCTIONED FOR SPECIFIC JOBS, EQUIPMENT ADDITION, MODIFICATION, REPLACEMENT SCHEMES GENERALLY NOT TAKEN IN REGULAR COURSE OF MAINTENANCE NO ADJUSTMENT OF CAPITAL BUDGET PERMISSIBLE FROMMONE EQPT. TO ANOTHER OR FROM ONE JOB TO ANOTHER

MAINTENANCE COST COMPONENTS


READY TO SERVE CONDITION MONITORING FACILITIES PM, PdM, CBM CORRECTIVE MAINTENANCE MAJOR REPAIR, OVERHAULS, REVAMPING MATERIALS SPARES, CONSUMABLES, TOOLS, TACKLES DIAGNOSTIC AND MEASURING EQUIPMENT CAPTIVE SHOPS, CENTRAL SERVICES EXTERNAL AGENCIES TESTING, AUDIT ETC. CONTRACTORS , MAINTENANCE OUTSOURCINGS TRAINING AND DEVELOPMENT

REGULATORY

/ STATUTORY EXPENDITURES INSURANCE LIABILITES NON WORKING MAINTENANCE LABOR MAINTENANCE WORK DONE BY PRODUCTION EMPLOYEES NON CAPITAL PLANT IMPROVEMENTS

MAINTENANCE COST ANALYSIS


UNDERSTAND THE COSTS TO MAINTAIN EQUIPMENT IDENTIFY FAILURE MODELS IDENTIFY OPPORTUNITIES TO REDUCE COSTS VALUE Vs. COST OF SPARES INVENTORIES DEVELOP RELIABILITY MODEL DIRECTLY FROM MAINTENANCE RECORDS

COST CONTROL IN MAINTENANCE


KEEP BREAKDOWN COST DIFFERENT FORM PM, PdM, CBM COST-CONSCIOUS MAINTENANCE PERSONNEL MAINTENANCE PREVENTION USING COST REDUCTION TECHNIQUES REPAIR Vs REPLACE, LIFE CYCLE COSTING WASTE REDUCTION AND WASTE RECOVERY SALVAGING OF SPARES SUB-ASSEMBLIES

MAINTENANCE BUDGET
BUDGET

IS A FORECAST OF EXPENDITURES AND REVENUES APPROPRIATION BUDGETS: LUMPSUM AS THE MAX. AMOUNT THAT CAN BE SPENT FOR A GIVEN ITEM FIXED BUDGETS: SPECIFY ALLOWABLE AMOUNT OF COST FOR A PERIOD OF TIME FLEXIBLE BUDGET

PREPARATION OF MAINTENANCE BUDGET


ALLOCATE

REVENUE AND EXPENSES USING TOP DOWN / BOTTOM UP PRODUCTION MAINTENANCE SCHEDULE APPROACH LABOR ALLOCATION APPROACH INTEGRATED APPROACH