Challenges in maintenance functions
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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

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Challenges in maintenance functions

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
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



Effective maintenance
EFFECTIVE MAINTENANCE AND MINOR STOPPAGES

  • 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
NON-EFFECTIVE MAINTENANCE AND MINOR STOPPAGES

  • 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
OVERALL EQUIPMENT EFFECTIVESSS AND MINOR STOPPAGES

  • AVAILABILITY

  • PERFORMANCE RATE

  • QUALITY RATE

  • MTBF , MTTR, MUT, MDT, MCT, MLDT

  • INHERENT AVAILABILITY

  • STEADY-STATE AVAILABILITY

  • OPERATIONAL AVAILABILITY


Key performance indicators
KEY PERFORMANCE INDICATORS AND MINOR STOPPAGES

  • INCREASE EQUIPMENT RELIABILITY

  • NUMBER OF UNITS REJECTED BY QUALITY INSPECTION

  • ZERO DEFECTS

  • SIX SIGMA

  • ZERO ACCIDENTS

  • MAXIMIZING O.E.E.


Maintenance key performance indicators
MAINTENANCE KEY PERFORMANCE INDICATORS AND MINOR STOPPAGES

  • 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
MAINTENANCE PERFORMANCE ANALYSIS AND MINOR STOPPAGES

  • WORK SAMPLING TECHNIQUES

  • JOB AUDITING

  • SWOT ANALYSIS

  • EVALUATION BY REPORTS

  • EVALUATION PROCESS OF PLANT ENGINEERING - BENCHMARKING


Manufacturing based model
MANUFACTURING BASED MODEL AND MINOR STOPPAGES

  • 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
MAINTENANCE PERFORMANCE MEASURE INDICATORS AND MINOR STOPPAGES

  • 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
PERFORMANCE BASED INDICES AND MINOR STOPPAGES

  • MAINTENANCE COST PER UNIT PRODUCTION

  • MAINTENANCE COST / HOUR

  • TOTAL PLANT MAINTENANCE PRODUCTIVITY

  • % COST SCHEDULED MAINTENANCE

  • % MAINTENANCE COST TO INVESTMENT


  • % SCHEDULE COMPLIANCE AND MINOR STOPPAGES

  • SCHEDULE LOADING FACTOR

  • WRENCH TIME

  • MAINTENANCE WORK CAPACITY INDEX


Maintenance operation audit
MAINTENANCE OPERATION AUDIT AND MINOR STOPPAGES

  • 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
MAINTENANCE PLAN AUDIT AND MINOR STOPPAGES

  • 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
TECHNICAL AUDIT AND MINOR STOPPAGES

  • THERMAL AUDIT

  • ELECTRICAL AUDIT

  • ENERGY AUDIT

  • INDUSTRIAL WATER USAGE AUDIT

  • COMPRESSED AIR AUDIT

  • PLANT HYDRAULIC SYSTEM AUDIT

  • PLANT CENTRALIZED LUBRICATION SYSTEM AUDIT


Maintenance benchmarking
MAINTENANCE BENCHMARKING AND MINOR STOPPAGES

  • STRATEGIC BENCHMARKING

  • PERFORMANCE BENCHMARKING

  • PROCESS BENCHMARKING

  • FUNCTIONAL BENCHMARKING

  • INTERNAL BENCHMARKING

  • EXTERNAL BENCHMARKING

  • INTERNATIONAL BENCHMARKING


Maintenance costs
MAINTENANCE COSTS AND MINOR STOPPAGES

  • 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
INDIRECT COSTS – HIDDEN COSTS AND MINOR STOPPAGES

  • 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
REVENUE / CAPITAL COSTS AND MINOR STOPPAGES

  • 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
CAPEX – CAPITAL EXPENDITURE AND MINOR STOPPAGES

  • 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
MAINTENANCE COST COMPONENTS AND MINOR STOPPAGES

  • 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 AND MINOR STOPPAGES

  • INSURANCE LIABILITES

  • NON WORKING MAINTENANCE LABOR

  • MAINTENANCE WORK DONE BY PRODUCTION EMPLOYEES

  • NON CAPITAL PLANT IMPROVEMENTS


Maintenance cost analysis
MAINTENANCE COST ANALYSIS AND MINOR STOPPAGES

  • 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
COST CONTROL IN MAINTENANCE AND MINOR STOPPAGES

  • 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
MAINTENANCE BUDGET AND MINOR STOPPAGES

  • 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
PREPARATION OF MAINTENANCE BUDGET AND MINOR STOPPAGES

  • ALLOCATE REVENUE AND EXPENSES USING TOP DOWN / BOTTOM UP

  • PRODUCTION MAINTENANCE SCHEDULE APPROACH

  • LABOR ALLOCATION APPROACH

  • INTEGRATED APPROACH


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