Plant Maintenance


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Managing Plant Maintenance

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Plant Maintenance

  1. 1. Plant Maintenance Managing Strategic Business Assets Anand Subramaniam
  2. 2. <ul><li>“ It's what you learn after you know it all that counts.&quot; </li></ul><ul><ul><li>- Earl Weaver </li></ul></ul>
  3. 3. Highlights <ul><li>Maintenance – Objectives & Types </li></ul><ul><li>Strategic Alignment </li></ul><ul><li>Maintenance Planning </li></ul><ul><li>Maintenance Control </li></ul><ul><li>Maintenance Terminology </li></ul>
  4. 4. Maintenance – Objectives & Types
  5. 5. Current Challenges <ul><li>People not trained </li></ul><ul><li>Production time loss </li></ul><ul><li>Product liability concerns </li></ul><ul><li>Cost of downtime unknown </li></ul><ul><li>Cause and Effects not fully understood </li></ul><ul><li>Cost of non-compliance with regulations </li></ul><ul><li>Threat of vandalism or corporate espionage </li></ul><ul><li>Obsolete configurations get mistakenly loaded or reloaded </li></ul><ul><li>Damage to life or property be caused by uncontrolled change </li></ul><ul><li>Configuration and changes to it, not documented or not controlled </li></ul>
  6. 6. Maintenance Objectives <ul><li>Prevent breakdown or failures </li></ul><ul><li>Maximise useful life of equipment </li></ul><ul><li>Minimise production loss from failures </li></ul><ul><li>Increase reliability of all operating systems </li></ul><ul><li>Minimise frequency and severity of interruptions </li></ul><ul><li>Maximise performance of production equipment </li></ul><ul><li>Keep equipment safe and prevent safety hazards </li></ul><ul><li>Maximise production capacity – throughput / utilisation </li></ul><ul><li>Improve product quality and customer satisfaction through adjusted and serviced equipment </li></ul>
  7. 7. Maintenance Types <ul><li>Corrective / Breakdown </li></ul><ul><li>Repairs made after the equipment has failed and can not perform its normal function anymore </li></ul><ul><li>Justified in small factories where - down times are non-critical : repair costs are less than other type of maintenance : where financial justification for scheduling not felt </li></ul><ul><li>Scheduled </li></ul><ul><li>It is a stitch-in-time procedure and incorporates – inspection, lubrication, repair and overhaul of equipments </li></ul><ul><li>If neglected can result in breakdown </li></ul><ul><li>Eg. overhaul of machines, change heavy equipment oils etc </li></ul><ul><li>Preventative </li></ul><ul><li>“ Prevention is better than cure” </li></ul><ul><li>Locates weak spots on machinery and equipment </li></ul><ul><li>Provides periodic/ scheduled inspections and minor repairs to reduce the danger of unanticipated breakdowns </li></ul><ul><li>Lower maintenance and repair costs </li></ul><ul><li>Increases plant life </li></ul><ul><li>Predictive </li></ul><ul><li>Machinery conditions are periodically monitored and this enables the maintenance crews to take timely action - machine adjustment, repair or overhaul </li></ul><ul><li>It makes use of human sense and other sensitive instruments - gauges, vibration analyser, pressure, temperature etc </li></ul>
  8. 8. Strategy Alignment
  9. 9. Align Business & Maintenance Goals Business Goals Compliance, safety, risk management Automation, scheduling Training, support, parts management, predictive maintenance Plant & line efficiency Logistics simulation Drive Regulatory Compliance Reduce Time to Market Improve Uptime Optimise Operations Supply chain Visibility Traceability Fulfill, Flexible Accurate Improve Capacity, quality Improve Asset, Performance Improve Visibility. Inventory
  10. 10. Maintenance Challenges Lack of management attention to maintenance Standards not used Difficulties in measuring performance Lack off participation by accounting in analysing and reporting costs Difficulties in applying quantitative analysis Difficulties in obtaining time and cost estimates for maintenance works Maintenance Challenges Inadequate control procedures for work order, service requests etc. Inadequate budgetary control Failure to develop written objectives and policy Absence of cost reports to aid maintenance planning & control system Lack of consistent production goals (cost, quality, delivery, safety) Lack of specific responsibilities Lack understanding on maintenance costs types Lack Team Collaboration
  11. 11. Maintenance Strategies Maintenance Strategies Replacement Statistic / Reliability Condition Based Opportunity Maintenance Overhaul Preventative Maintenance Design Modification Breakdown / Correction Fault Finding Off Line On Line Time Based Use Based
  12. 12. Collaborative Maintenance Strategies <ul><ul><li>Online condition monitoring </li></ul></ul><ul><ul><li>Real-time process monitoring </li></ul></ul><ul><ul><li>Customised employee training </li></ul></ul><ul><ul><li>Storeroom management </li></ul></ul><ul><ul><li>enterprise asset management integration tools </li></ul></ul><ul><ul><li>Direct access to technical assistance </li></ul></ul><ul><ul><li>Organisation or procedural changes </li></ul></ul><ul><ul><li>Onsite support </li></ul></ul><ul><ul><li>Coloration of people, process & systems </li></ul></ul><ul><ul><li>Supplier Colloboration </li></ul></ul>
  13. 13. Link Strategies to Maintenance Equipment MRO Process Management Condition Monitoring Network Services Spare Parts Agreements Scheduled & Emergency On-site Services Repair & Renewal Parts Services People Service Assessments Remote Monitoring & Diagnostics Instructor Led Training Self Paced Training Phone Support Predict Prevent React Eliminate Downtime Events Produce to Spec Stabilise Budget Reduce Downtime Duration Speed to Change
  14. 14. Maintenance Planning
  15. 15. Plant Lifecycle Customer Support Technology / Systems Design Install Operate Maintain Replace
  16. 16. Maintenance System Planning (Maintenance) Organising Feedback/Control <ul><li>Philosophy </li></ul><ul><li>Load Forecast </li></ul><ul><li>Capacity </li></ul><ul><li>Organisation </li></ul><ul><li>Scheduling </li></ul><ul><li>Job Design </li></ul><ul><li>Standards </li></ul><ul><li>Manage Projects </li></ul><ul><li>Measure Work </li></ul>Maintenance Process <ul><li>Work Control </li></ul><ul><li>Material Control </li></ul><ul><li>Cost Control </li></ul><ul><li>Manage Quality </li></ul><ul><li>Input </li></ul><ul><li>Facilities </li></ul><ul><li>Labour </li></ul><ul><li>Spares </li></ul><ul><li>Equipment </li></ul><ul><li>Management </li></ul><ul><li>Output </li></ul><ul><li>Operations </li></ul><ul><li>Machines </li></ul><ul><li>Equipment </li></ul>Variation in Maintenance Demand
  17. 17. Maintenance Load Forecasting Information on maintenance load demand/ backlog of maintenance work Maintenance Load Forecasting Control Maintenance System Maintenance Scheduling Maintenance Capacity Planning Output of Maintenance System
  18. 18. Maintenance Solution <ul><li>People </li></ul><ul><ul><ul><li>Diagnostics </li></ul></ul></ul><ul><ul><ul><li>Training </li></ul></ul></ul><ul><ul><ul><li>Emergency support </li></ul></ul></ul><ul><ul><ul><li>Meaningful Metrics </li></ul></ul></ul><ul><ul><ul><li>Investments in people aligned with the goals of the organisation </li></ul></ul></ul><ul><li>Equipment </li></ul><ul><li>Automation products </li></ul><ul><ul><ul><li>Condition Monitoring </li></ul></ul></ul><ul><ul><ul><li>Networks </li></ul></ul></ul><ul><ul><ul><li>Technical support </li></ul></ul></ul><ul><li>Mean Time between Failures Report (MTBF) </li></ul><ul><li>Establish predetermined expectations of performance and uptime requirements </li></ul><ul><li>Process </li></ul><ul><ul><ul><li>Assessments </li></ul></ul></ul><ul><ul><ul><li>MRO Process Mngt </li></ul></ul></ul><ul><ul><ul><li>Spare Parts </li></ul></ul></ul><ul><ul><ul><li>Repair processes </li></ul></ul></ul><ul><ul><li>Development </li></ul></ul><ul><ul><li>Documentation </li></ul></ul><ul><ul><li>Remove Bottlenecks </li></ul></ul><ul><ul><li>Ongoing commitment to Continuous improvement </li></ul></ul>Match Predictive, Preventive & Reactive Maintenance Needs
  19. 19. Maintenance Control
  20. 20. Control Activities <ul><li>Cost control </li></ul><ul><li>Work control </li></ul><ul><li>Inventory control </li></ul><ul><li>Quality control </li></ul>
  21. 21. Cost Types & Control Direct Cost of Periodic Inspection Service Cost Repair Cost, Overhaul Cost Standby Cost of Operating and Maintaining a Standby Unit Lost Production Cost due to Equipment down time Degrade Cost occurring due to deterioration of the life span of equipment due to no maintenance or inadequate maintenance
  22. 22. Quality Control <ul><li>“ Doing it right the first time&quot; </li></ul><ul><li>Awareness / need to improve </li></ul><ul><li>Selecting appropriate improvement techniques </li></ul><ul><li>Percentage of accepted maintenance jobs according to the standard adopted by the organisation </li></ul><ul><li>High Quality is usually assured by checking the critical maintenance jobs or by maintenance supervision </li></ul>
  23. 23. Inventory & Work Control <ul><li>For further details on the above, please visit my LinkedIn Profile </li></ul><ul><ul><li>“ Advance Planning & Scheduling” </li></ul></ul><ul><ul><li>“ Enterprise Asset Management” </li></ul></ul><ul><ul><li>“ Inventory Management” </li></ul></ul><ul><ul><li>“ Lean Transformation ~ A Journey” </li></ul></ul><ul><ul><li>“ Manufacturing Execution System” </li></ul></ul><ul><ul><li>“ Operations Strategy” </li></ul></ul><ul><ul><li>“ Value Stream Mapping Process” </li></ul></ul>
  24. 24. Maintenance Terminology
  25. 25. Terms <ul><li>Availability </li></ul><ul><ul><li>The ability of an equipment to successfully perform its required function at a stated instant of time or over a stated period of time. </li></ul></ul><ul><li>Breakdown </li></ul><ul><ul><li>Failure resulting in the non-availability of an equipment . </li></ul></ul><ul><li>Condition-based maintenance </li></ul><ul><ul><li>The preventive maintenance initiated as a result of knowledge of the condition of an equipment observed through routine or continuous monitoring. </li></ul></ul><ul><li>Condition monitoring </li></ul><ul><ul><li>The continuous or periodic measurement and interpretation of data to infer the condition of an equipment to determine its need for maintenance. </li></ul></ul>
  26. 26. Terms (Contd.) <ul><li>Corrective maintenance </li></ul><ul><ul><li>The maintenance carried out after a failure has occurred and intended to restore an equipment to a state in which it can perform its required function. </li></ul></ul><ul><li>Emergency maintenance </li></ul><ul><ul><li>Maintenance which is necessary in order to avoid serious consequences, such as loss of production time and unsafe conditions. </li></ul></ul><ul><li>Failure </li></ul><ul><ul><li>The termination of the ability of an equipment to perform its required function. </li></ul></ul><ul><li>Fault </li></ul><ul><ul><li>An unexpected deviation from requirements which require corrective action. </li></ul></ul>
  27. 27. Terms (Contd.) <ul><li>Feedback </li></ul><ul><ul><li>A report on the success or failure of an action to achieve its desired objectives and which can be used to improve a process. </li></ul></ul><ul><li>Forced outage </li></ul><ul><ul><li>Outage due to the unscheduled stopping of equipment. </li></ul></ul><ul><li>Inspection </li></ul><ul><ul><li>The process of measuring, examining, testing, gauging or otherwise detecting any deviations from specifications. </li></ul></ul><ul><li>Maintainability </li></ul><ul><ul><li>The ability of an equipment, under stated conditions of use, to be retained in, or restored to, a state in which it can perform its required function, when maintenance is performed under stated conditions and using prescribed procedures and resources. </li></ul></ul>
  28. 28. Terms (Contd.) <ul><li>Maintenance </li></ul><ul><ul><li>The combination of all technical and associated actions by which an equipment or a system is kept or restored to a state in which it can perform its designated functions. </li></ul></ul><ul><li>Maintenance history </li></ul><ul><ul><li>A history record showing repair, spares, etc. used to assist maintenance planning . </li></ul></ul><ul><li>Maintenance schedule </li></ul><ul><ul><li>A comprehensive list of items and the maintenance tasks required, including the intervals at which maintenance should be performed. </li></ul></ul><ul><li>Planned maintenance </li></ul><ul><ul><li>The maintenance organised and carried out with forethought, control, and the use of records to meet a predetermined plan. </li></ul></ul>
  29. 29. Terms (Contd.) <ul><li>Overhaul </li></ul><ul><ul><li>A comprehensive examination and restoration of an equipment, or a major part thereof, to an acceptable condition. </li></ul></ul><ul><li>Preventive maintenance </li></ul><ul><ul><li>The maintenance carried out at predetermined intervals or intended to minimise the probability of failure or the performance degradation of equipment. </li></ul></ul><ul><li>Refurbishment </li></ul><ul><ul><li>Extensive work intended to bring equipment up to acceptable functional conditions, often involving improvements. </li></ul></ul><ul><li>Repair </li></ul><ul><ul><li>To restore an item to an acceptable condition by the renewal, replacement or replacement of damaged or worn parts. </li></ul></ul>
  30. 30. Terms (Contd.) <ul><li>Restoration </li></ul><ul><ul><li>Maintenance actions intended to bring back equipment to its original conditions. </li></ul></ul><ul><li>Running maintenance </li></ul><ul><ul><li>Maintenance which can be carried out whilst the equipment is in service . </li></ul></ul><ul><li>Shut down maintenance </li></ul><ul><ul><li>Maintenance which can only be carried out when the equipment is out of service. </li></ul></ul><ul><li>Spare stock </li></ul><ul><ul><li>Items which are available for maintenance purposes or for the replacement of defective parts . </li></ul></ul>
  31. 31. Terms (Contd.) <ul><li>Work order </li></ul><ul><ul><li>A written instruction giving detail of work to be carried out including detail of spares, manpower, etc. </li></ul></ul><ul><li>Work requisition </li></ul><ul><ul><li>A document requesting work to be carried out. </li></ul></ul><ul><li>Work specification </li></ul><ul><ul><li>A document describing the way in which the work is to be carried out. It may define the materials, tools, time standards, and procedures. </li></ul></ul>
  32. 32. <ul><li>“ The pursuit of perfection often impedes improvement. &quot; </li></ul><ul><ul><li>- George Will </li></ul></ul>
  33. 33. <ul><li>Good Luck </li></ul><ul><li> </li></ul>