CHALLENGES –Maintenance Industry<br />To select the most appropriate techniques to deal with each type of failure process in order to fulfill all the expectations of the owners & users of the assets<br />Cost-effective and enduring Solutions <br />Ensure Zero Surprises<br />Organization Culture<br />Understanding Change<br />Increasing Production Demands<br />
Maintenance Management<br /><ul><li>Maintenance, as apart of the wider scope asset management, is of central importance for an efficient operation of Industry.
Modern organizations must move toward improving the maintenance process.
Preserving assets while fulfilling the overall mission of the company is key to any maintenance effort.
Development of new applicable maintenance techniques is the need of the Hour</li></li></ul><li>Symptoms to Recognize<br />Too many emergencies. Everything is Priority One.<br />High Inventory Costs<br />Fixing the same thing over and over<br />Frequent Downtime<br />Late product or service delivery due to equipment problems <br />
Growing expectations of Maintenance<br />
Changing Maintenance Techniques<br />
Asset Management-Presume<br />Machinery and Equipments must be preserved and Productive Life must be Extended<br />Maintenance & OE Norms must be challenged<br />The original composition & performance of machinery and its components change due to a multitude of factors that include age, temperature, vibration, duration of operation, corrosion and other environmental factors<br />Concept of Making Maintenance a Profit Centre<br />Use of Specialty Consumables with a view to Extend Useful Life of Productive Assets<br />Productive Assets must be monitored in Real Time<br />
Methodology<br /><ul><li>Benchmarking Survey
Assessment of maintenance practices and production processes
Evaluation of Machinery and Parts
Identification of Critical Machineries
Assessment of Spare part Inventories & Costs
Collection and collation of DATA BEFORE application
Predictive Maintenance Techniques</li></li></ul><li>Methodology<br /><ul><li>Discover and Identify Application
Introduction of Specialty Products & Solutions
Continuous monitoring wherever product is supplied.
Use of Ultrasound, Vibration, Leak and Diagnostic tools ‘before’ and ‘post’ application
Submit Reports that CONFIRM cost effectiveness as a result of Specialty Product usage as per recommendations</li></li></ul><li>Case study-A Reputed Cigarette maf., Co.,<br />Audit and Survey of Critical Plant Machinery in Primary & Secondary Manufacturing <br />Ultrasound Diagnosis of critical parts and components before Application<br />Evaluation of Maintenance Downtime and Spare part costs <br />Consumables replaced with Specialty equivalents<br />Extension of maintenance intervals<br />Reduction in Downtime and Spare Part costs <br />Post Application Audit of selected Applications<br />Leak & Energy Audits using Ultrasound Tools<br />Savings in Energy,Downtime & Production costs<br />Long Term Condition Monitoring, Maintenance & Leak Detection Contract <br />
Case study-A Reputed Cigarette maf., Co<br />
CASE STUDY-A Reputed Automotive giant<br />Audit and Survey of Entire Plant<br />Study of Processes <br />Identification of Specific Departments & Key Applications<br />Cause and effect Study of Specific Applications<br />Use of Ultrasound and Vibration Tools for Diagnosis and Quantification<br />Introduction of a suite of Solutions across all the Applications covering Lubricants, Alloys ,Chemicals, Coatings<br />Introduction of Energy Audits and Leak detection services<br />Continuous Monitoring & Evaluation of selected Applications <br />Maintenance Intervals extended & Better Productivity Quantified <br />
Case Study-A reputed Paper and Pulp Industry<br />
The Way Forward<br />Use of Specialty Products to Extend Maintenance Intervals & Reduce Downtime<br />Condition Based Monitoring & Scheduling<br />Predictive maintenance Techniques<br />Information based Management<br />Reliability Centered Maintenance <br />Change from ‘Reactive’ to ‘Proactive’ Maintenance<br />Real time Non Invasive Diagnosis<br />Change the Organization Culture<br />Ensure Zero Surprises<br />
Sunil V Rao, Director,Strategic Accounts<br />TCS,Bangalore,India<br />firstname.lastname@example.org<br />