 Bad state: Plant is frequently down because of equipment

failures.
 No-Demand losses. Plant is not responsible.
 Availability to operate when required.
 Production planning & Undertaking Shutdown Maintenance
when demand is low.
 If it isn’t broke, don’t fix it approach.
 Traditional approach. Unscientific cost
cutting.
 Active vs passive approach.
 Reactive, Preventative, Predictive
Maintenance.
 Proactive maintenance.
 MTBR and MTTR.
 Pareto analysis – 80 / 20 chart
 Checklist based Preventive Maintenance.
 CMMS/ SAP.
 Root cause analysis.
 68% equipment failure due to installation errors.
 Operating problems. Moisture. Overload, Loose objects,
Cylinder falling, Incorrect settings etc.
 Housekeeping. Tools, components, garbage.
 Operator care, ownership.
 Daily operator feedback.
 Team Building.
 Plant floor is hostile to management.
 Skill set mapping.
 Training – Internal/ External.
 When Maintenance become Proactive, Skill
Dependence will minimize.
 Getting overwhelmed by the magnitude of the job.
Divide & Conquer.
 Thinking of what is possible and not what is
impossible.
 Bill of material for each equipment and spare parts list.
 Spare part criticality assessment. Common failure mode,
frequency of failure, ease of detection, lead time,
consequence of failure.
 Standardisation of parts and awareness of
interchangeability.
 If reliability is improved, fewer spares are only required.
 If equipment condition monitoring and inspection is in
place, spare parts could be sourced.
 Standard parts, materials, spare parts, sub-assemblies,
special items.
Store layout. Quick availability of
spares.
Removal of obsolete parts from stores
Spares stored Not under the chair of
the officer and PMs totally inert and
indifferent. Absolute absence of
management.
 No constraint on cost. Only maintenance cost goes into
maintenance cost head.
 FM down. Why can’t we increase carousel speed?
 Scheduled and unscheduled downtime. Month end etc.
 Spare part procurement practice. Around 40% savings. OEM
service takes time
 Central inventory possible if same can be properly maintained.
 Central AMC contractor?
 Calibration cart. People working for themselves rather than the
organisation.
 Comprehensive Checklist based Preventive
Maintenance.
 99% plant availability with 1% unplanned and 4%
planned shutdowns
 Inventory targets. 0% stock outs of critical spares,
4% frequently required non-critical, 6%
infrequently required non-critical.