Asset Management,A Maintenance Perspective
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Asset Management,A Maintenance Perspective

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Asset Management,A Maintenance Perspective Presentation Transcript

  • 1. ASSET MANAGEMENT
    A Maintenance perspective…..
  • 2. CHALLENGES –Maintenance Industry
    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
    Cost-effective and enduring Solutions
    Ensure Zero Surprises
    Organization Culture
    Understanding Change
    Increasing Production Demands
  • 3. Maintenance Management
    • Maintenance, as apart of the wider scope asset management, is of central importance for an efficient operation of Industry.
    • 4. Modern organizations must move toward improving the maintenance process.
    • 5. Preserving assets while fulfilling the overall mission of the company is key to any maintenance effort.
    • 6. Development of new applicable maintenance techniques is the need of the Hour
  • Symptoms to Recognize
    Too many emergencies. Everything is Priority One.
    High Inventory Costs
    Fixing the same thing over and over
    Frequent Downtime
    Late product or service delivery due to equipment problems
  • 7. Growing expectations of Maintenance
  • 8. Changing Maintenance Techniques
  • 9. Asset Management-Presume
    Machinery and Equipments must be preserved and Productive Life must be Extended
    Maintenance & OE Norms must be challenged
    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
    Concept of Making Maintenance a Profit Centre
    Use of Specialty Consumables with a view to Extend Useful Life of Productive Assets
    Productive Assets must be monitored in Real Time
  • 10. Methodology
    • Benchmarking Survey
    • 11. Assessment of maintenance practices and production processes
    • 12. Evaluation of Machinery and Parts
    • 13. Identification of Critical Machineries
    • 14. Assessment of Spare part Inventories & Costs
    • 15. Collection and collation of DATA BEFORE application
    • 16. Predictive Maintenance Techniques
  • Methodology
    • Discover and Identify Application
    • 17. Introduction of Specialty Products & Solutions
    • 18. Continuous monitoring wherever product is supplied.
    • 19. Use of Ultrasound, Vibration, Leak and Diagnostic tools ‘before’ and ‘post’ application
    • 20. Submit Reports that CONFIRM cost effectiveness as a result of Specialty Product usage as per recommendations
  • Case study-A Reputed Cigarette maf., Co.,
    Audit and Survey of Critical Plant Machinery in Primary & Secondary Manufacturing
    Ultrasound Diagnosis of critical parts and components before Application
    Evaluation of Maintenance Downtime and Spare part costs
    Consumables replaced with Specialty equivalents
    Extension of maintenance intervals
    Reduction in Downtime and Spare Part costs
    Post Application Audit of selected Applications
    Leak & Energy Audits using Ultrasound Tools
    Savings in Energy,Downtime & Production costs
    Long Term Condition Monitoring, Maintenance & Leak Detection Contract
  • 21. Case study-A Reputed Cigarette maf., Co
  • 22. CASE STUDY-A Reputed Automotive giant
    Audit and Survey of Entire Plant
    Study of Processes
    Identification of Specific Departments & Key Applications
    Cause and effect Study of Specific Applications
    Use of Ultrasound and Vibration Tools for Diagnosis and Quantification
    Introduction of a suite of Solutions across all the Applications covering Lubricants, Alloys ,Chemicals, Coatings
    Introduction of Energy Audits and Leak detection services
    Continuous Monitoring & Evaluation of selected Applications
    Maintenance Intervals extended & Better Productivity Quantified
  • 23. Case Study-A reputed Paper and Pulp Industry
  • 24. The Way Forward
    Use of Specialty Products to Extend Maintenance Intervals & Reduce Downtime
    Condition Based Monitoring & Scheduling
    Predictive maintenance Techniques
    Information based Management
    Reliability Centered Maintenance
    Change from ‘Reactive’ to ‘Proactive’ Maintenance
    Real time Non Invasive Diagnosis
    Change the Organization Culture
    Ensure Zero Surprises
  • 25. Sunil V Rao, Director,Strategic Accounts
    TCS,Bangalore,India
    suneilrao@gmail.com