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

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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


Challenges in maintenance functions

  • 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


Challenges in maintenance functions

  • IDENTIFYING LOSSES DUE TO FAILURES AND ADJUSTMENT OF SPEEDS AND MINOR STOPPAGES

  • LOCATING DEFECT LOSSES

  • HAVING PROPER LUBRICATION SYSTEM FOR ENERGY SAVINGS


Effective maintenance

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

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

OVERALL EQUIPMENT EFFECTIVESSS

  • AVAILABILITY

  • PERFORMANCE RATE

  • QUALITY RATE

  • MTBF , MTTR, MUT, MDT, MCT, MLDT

  • INHERENT AVAILABILITY

  • STEADY-STATE AVAILABILITY

  • OPERATIONAL AVAILABILITY


Key performance indicators

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

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

MAINTENANCE PERFORMANCE ANALYSIS

  • WORK SAMPLING TECHNIQUES

  • JOB AUDITING

  • SWOT ANALYSIS

  • EVALUATION BY REPORTS

  • EVALUATION PROCESS OF PLANT ENGINEERING - BENCHMARKING


Manufacturing based model

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

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

PERFORMANCE BASED INDICES

  • MAINTENANCE COST PER UNIT PRODUCTION

  • MAINTENANCE COST / HOUR

  • TOTAL PLANT MAINTENANCE PRODUCTIVITY

  • % COST SCHEDULED MAINTENANCE

  • % MAINTENANCE COST TO INVESTMENT


Challenges in maintenance functions

  • % SCHEDULE COMPLIANCE

  • SCHEDULE LOADING FACTOR

  • WRENCH TIME

  • MAINTENANCE WORK CAPACITY INDEX


Maintenance operation audit

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

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

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

MAINTENANCE BENCHMARKING

  • STRATEGIC BENCHMARKING

  • PERFORMANCE BENCHMARKING

  • PROCESS BENCHMARKING

  • FUNCTIONAL BENCHMARKING

  • INTERNAL BENCHMARKING

  • EXTERNAL BENCHMARKING

  • INTERNATIONAL BENCHMARKING


Maintenance costs

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

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

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

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

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


Challenges in maintenance functions

  • REGULATORY / STATUTORY EXPENDITURES

  • INSURANCE LIABILITES

  • NON WORKING MAINTENANCE LABOR

  • MAINTENANCE WORK DONE BY PRODUCTION EMPLOYEES

  • NON CAPITAL PLANT IMPROVEMENTS


Maintenance cost analysis

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

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

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

PREPARATION OF MAINTENANCE BUDGET

  • ALLOCATE REVENUE AND EXPENSES USING TOP DOWN / BOTTOM UP

  • PRODUCTION MAINTENANCE SCHEDULE APPROACH

  • LABOR ALLOCATION APPROACH

  • INTEGRATED APPROACH


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