Maintenance is important in any organization. Without proper maintenance, assets deteriorate over time reducing the quality of your output produced. It can also impact the safety of your asset or your people who operate it. Asset management focuses on assuring your people that parts and processes are optimized to improve asset performance. Reducing inventory, maintenance costs and the number of downtime events raises your productivity, while simultaneously driving financial performance and predictability. It also helps your employees with the right tools to make good decisions about driving your plant performance.
Proper Asset Maintenance Improves Safety, Reliability, and ProfitabilityUSC Consulting Group
Gain firsthand knowledge of strategies, processes, and methodologies used to develop an asset maintenance program for revenue-producing assets. This information can be applied to any industry with a reliance on heavy equipment and assets.
The preventive maintenance program is developed using a guided logic approach and is task oriented rather than maintenance process oriented. This eliminates the confusion associated with the various interpretations across different industries of terms such as condition monitoring, on condition, hard time, etc. By using a task oriented concept, it is possible to see the whole maintenance program reflected for a given item. A decision logic tree is used to identify applicable maintenance tasks. Servicing and lubrication are included as part of the logic diagram as this ensures that an important task category is considered each time an item is analyzed.
Maintenance Program Content
The content of the maintenance program itself consists of two groups of tasks.
• A group of preventive maintenance tasks, which include failure-finding tasks, scheduled to be accomplished at specified intervals, or based on condition. The objective of these tasks is to identify and prevent deterioration below inherent safety and reliability levels by one or more of the following means:
o Lubrication/servicing;
o Operational/visual/automated check;
o Inspection/functional test/condition monitoring;
o Restoration;
o Discard.
It is this group of tasks, which is determined by RCM analysis, e. it comprises the RCM based preventive maintenance program.
• A group of non scheduled maintenance tasks which result from:
• Findings from the scheduled tasks accomplished at specified intervals of time or usage;
• Reports of malfunctions or indications of impending failure (including automated detection).
The objective of this second group of tasks is to maintain or restore the equipment to an acceptable condition in which it can perform its required function.
An effective program is one that schedules only those tasks necessary to meet the stated objectives. It does not schedule additional tasks that will increase maintenance costs without a corresponding increase in protection of the inherent level of reliability. Experience has clearly demonstrated that reliability decreases when inappropriate or unnecessary maintenance tasks are performed, due to increased incidence of maintainer-induced faults.
Continued...
Maintenance is important in any organization. Without proper maintenance, assets deteriorate over time reducing the quality of your output produced. It can also impact the safety of your asset or your people who operate it. Asset management focuses on assuring your people that parts and processes are optimized to improve asset performance. Reducing inventory, maintenance costs and the number of downtime events raises your productivity, while simultaneously driving financial performance and predictability. It also helps your employees with the right tools to make good decisions about driving your plant performance.
Proper Asset Maintenance Improves Safety, Reliability, and ProfitabilityUSC Consulting Group
Gain firsthand knowledge of strategies, processes, and methodologies used to develop an asset maintenance program for revenue-producing assets. This information can be applied to any industry with a reliance on heavy equipment and assets.
The preventive maintenance program is developed using a guided logic approach and is task oriented rather than maintenance process oriented. This eliminates the confusion associated with the various interpretations across different industries of terms such as condition monitoring, on condition, hard time, etc. By using a task oriented concept, it is possible to see the whole maintenance program reflected for a given item. A decision logic tree is used to identify applicable maintenance tasks. Servicing and lubrication are included as part of the logic diagram as this ensures that an important task category is considered each time an item is analyzed.
Maintenance Program Content
The content of the maintenance program itself consists of two groups of tasks.
• A group of preventive maintenance tasks, which include failure-finding tasks, scheduled to be accomplished at specified intervals, or based on condition. The objective of these tasks is to identify and prevent deterioration below inherent safety and reliability levels by one or more of the following means:
o Lubrication/servicing;
o Operational/visual/automated check;
o Inspection/functional test/condition monitoring;
o Restoration;
o Discard.
It is this group of tasks, which is determined by RCM analysis, e. it comprises the RCM based preventive maintenance program.
• A group of non scheduled maintenance tasks which result from:
• Findings from the scheduled tasks accomplished at specified intervals of time or usage;
• Reports of malfunctions or indications of impending failure (including automated detection).
The objective of this second group of tasks is to maintain or restore the equipment to an acceptable condition in which it can perform its required function.
An effective program is one that schedules only those tasks necessary to meet the stated objectives. It does not schedule additional tasks that will increase maintenance costs without a corresponding increase in protection of the inherent level of reliability. Experience has clearly demonstrated that reliability decreases when inappropriate or unnecessary maintenance tasks are performed, due to increased incidence of maintainer-induced faults.
Continued...
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
Massive Advantage in Mining - Using Scrapers for Efficient Material Transport...K-Tec Earthmovers Inc
As Presented By K-Tec Earthmovers at MinExpo 2016:
Scrapers are a valuable, yet underrated asset in mines and quarries. A scraper can pick-up, transport, and eject material with a single operator and power-unit. Find out how in some applications, the elimination of both an excavator and a dozer from a jobsite is possible, while obtaining a higher production output with a single scraper unit! This presentation will reveal jobsite scenarios to portray the labor, maintenance, and fuel efficiency savings, and corresponding cycle-times of using earthmoving scrapers for a successful mining application and wise return on investment.
Scrapers have been proven to work effectively in gravel quarries, coal & gypsum mines, while also being key for removing overburden and maintaining haul roads.
This presentation will also investigate new industry trend and technologies where, mining companies have been using Articulated Dump Trucks as the power-units to pull scrapers. The removal of the dump box and attachment of the scraper to the truck chassis is a helpful way to get more versatility out of an existing fleet of mining equipment.
Learn how to incorporate your own massive advantage in your mining operation by incorporating scrapers into your fleet.
http://www.ktec.com
In this presentation you will learn:
- The 4 key documents and the benefits of the ISO 55000 standard
- To develop an Asset Management Policy & associated communication plan
- To identify the value of stakeholder analysis & leadership alignment
- To explain the critical foundational concepts in asset management systems
An overview of ISO 55000 designed to help you manage risk and realize the value of your organization's assets. Presented by Randy Heisler at the 2014 AREGC Conference in Louisville, KY.
Definition of RCM, principles and goals of RCM; Four major components of RCM: reactive maintenance, preventive maintenance, predictive testing and inspection and proactive maintenance; RCM strategies.
Explain the importance of maintenance in FM Field.
Describe the range of maintenance activities.
Discuss preventive maintenance and the key issues associated with it.
Discuss breakdown maintenance and the key issues associated with it.
Reliability and Maintenance in production ManagementNazneen sheikh
This ppt may help you to get a clear picture about reliability and maintenance in Production Management.
Feedback is a must!!!1
Regards.
Nazneen Sheikh
Boost Equipment Performance, Save Money With Proactive MaintenanceJames Fitzgerald
Proactive, timely maintenance of plant equipment is critical to enabling manufacturers to meet a dizzying number of demands, from pressure to achieve target output levels, minimize labor costs, control parts spending and ensure maximum uptime. Manufacturers rely on their maintenance departments to help achieve these goals on a daily basis. However, a great number of manufacturers still use maintenance on a reactive basis rather than viewing it as strategic to operations. Myrtle Consulting helps manufacturers convert maintenance into a proactive, scheduled operation that is used strategically to control costs, maximize uptime, and maintain critical equipment. By following a few fundamental principles, plants can begin to establish a maintenance improvement program that supports operations and improves plant performance.
2. ASSETMANAGEMENTPROGRAM
O&M Program
An effective O&M program is one of the most cost-effective methods for
ensuring reliability, safety, and energy efficiency.
Key Terms
Operations and Maintenance: The decisions and actions regarding
the control and upkeep of property and equipment. These are
inclusive, but not limited to, the following: 1) actions focused on
scheduling, procedures, and work/systems control and optimization;
and 2) performance of routine, preventive, predictive, scheduled
and unscheduled actions aimed at preventing equipment failure or
decline with the goal of increasing efficiency, reliability, and safety.
Operational Efficiency: The life-cycle, cost-effective mix of
preventive, predictive, and reliability-centered maintenance
technologies, coupled with equipment calibration, tracking, and
computerized maintenance management capabilities all targeting
reliability, safety, occupant comfort, and system efficiency.
3. KEYPHASES
O&M Key Phases
Plan
• Objective (Must be aligned with Corporate Goals)
• Schedule
• Budget
• Procurement
Initiate
• Preventative Maintenance
• Predictive Maintenance
• Corrective Maintenance
• Monitoring
• Training
Measure
• Overview Indicators
•Organizational Indicators
• Maintenance Parts Management Indicators
• Routine Maintenance Indicators
• Equipment Performance Indicators
Analyze
• Failure Mode Effect Analysis
(FMEA)
• Standard Process Control (SPC)
• Overall Equipment Efficiency
(OEE)
Adjust
• Continuous Improvement
4. KEYINDICATORS
Maintenance Parts IndicatorsOverview Indicators
•Overall Equipment Effeteness (OEE)
•Equipment Downtime
•Equipment Capacity, Utilization, and Performance Efficiency
•Mean Time Between Failure (MTBF)
•List of Worst Performing Equipment
•Monthly Cost per Equipment Type
•Monthly Cost per Asset Center
Equipment Performance Indicators
• Budget Compliance (Actual vs. Forecast)
• Facility wide Overall Equipment Effectiveness (OEE)
• Costs as a percent of Operating Costs
•Maintenance Dollars per SQFT
•Safety and Environmental Performance/Compliance
Routine Maintenance Indicators
•Work Input Level (By craft, Priority and Type)
•Backlog Level (By craft, Priority and Type)
•Standing Work Orders
•Man Hours per Work order
•Schedule Completion
•PM Completion
•Percentage of Maintenance Rework
•Percentage of Overtime and Total Call outs.
•Inventory Accuracy and Frequency
•Percentage in Stock
•Inventory Turnover
•Materials vs. Labor Ratio
Dashboard should be created to track Key Performance Indicators (KPI’S).
5. TYPESOFMAINTENANCEPROGRAM
Preventive Maintenance (PM)Reactive Maintenance (CM)
Reliability Center Maintenance, emphasizes the use of predictive
maintenance (PdM) techniques in addition to traditional
preventive measures. When properly implemented, RCM provides
companies with a tool for achieving lowest asset Net Present Costs
(NPC) for a given level of performance and risk
Reliability Center Maintenance (RCM)
Maintenance performed only after a machine fails or experiences
problems
Predictive Maintenance (PdM)
Predictive Maintenance (PdM), or condition-based
maintenance, attempts to evaluate the condition of equipment
by performing periodic or continuous (online) equipment
condition monitoring . The ultimate goal of PdM is to perform
maintenance at a scheduled point in time when the
maintenance activity is most cost-effective and before the
equipment loses performance within a threshold. This is in
contrast to time- and/or operation count-based maintenance,
where a piece of equipment gets maintained whether it needs
it or not. Time-based maintenance is labor intensive, ineffective
in identifying problems that develop between scheduled
inspections, and is not cost-effective.
Preventive maintenance is a schedule of planned maintenance
actions aimed at the prevention of breakdowns and failures. The
primary goal of preventive maintenance is to prevent the failure
of equipment before it actually occurs.
6. TYPESOFMAINTENANCEPROGRAM
Preventive MaintenanceReactive Maintenance
Advantages:
•Properly implemented can be most efficient
•Lower over all cost by eliminate unnecessary maintenance of
expensive overhauls
•Minimizes frequency of major overhauls
•Focus manpower on critical components
•Increase equipment reliability
•Root Cause Analysis
Disadvantages:
•High start-up cost
Reliability Center Maintenance
Advantages:
•Low first look Cost
•Less Staff
Disadvantages:
•Increased cost due to unplanned downtime of equipment
•Increased Labor cost, especially OT
•High Cost involved with repair and replacement of equipment
possible secondary equipment or process damage form
equipment failure
•Inefficient use of staff
Predictive Maintenance
Advantages:
•Increased component operation life/availability
•Proactive Corrective Actions
•Decrease in Equipment Downtime/Increase in reliability
•Decrease in cost of labor and parts over the life of the
equipment
•Cost savings of 12 to 18% over the lifecycle of the equipment
over just preventative maintenance
Disadvantages:
•Increased upfront investment in diagnostic equipment
•Increase investment in staff training
•Savings potential is hard to initially show upper management
Advantages:
•Cost effective
•Flexible
•Increased Component Life Cycle
•Energy Saving
•Cost savings of 12 to 18% over the lifecycle of the equipment
over reactive maintenance
Disadvantages:
•Catastrophic failure still high risk
•Labor intensive
•Performance of unneeded maintenance
•Potential of incidental damage to components in conducting
unecessary maintenance
8. ASSETMANAGEMENTPROGRAMBENIFITS
O&M
Maintenance is no longer just fixing broken equipment it is a mix of
processes that increases the reliability of a facility.
Benefits
•Risk Mitigation
•Failure Avoidance
•Customer Satisfaction
•Increased Reliability
•Control of Operating Cost
•Increased Equipment Life
9. ASSETMANAGEMENTRETRO-COMMISSIONING
Retro-Commissioning
.
The analytics from the indicators will trigger Retro-Cx events, where Retro-commissioning is
the process of systematically evaluating existing buildings and systems to ensure:
•Original Design Intent
•Current Operational Needs
•Energy Conservation Opportunities (ECO)
Retro-Cx focuses on the following:
•Instrument Calibration
•HVAC & Lighting Control Sequences
•Mechanical Systems & Components
Retro-Cx can be triggered by an unexplained increases in bldg energy usage or a major
equipment repair or change in functionality of an area.
•A significant rise in occupant comfort complaints
•Undocumented changes to building systems & structure
•Maintenance staff overwhelmed with emergency calls.
10. ASSETMANAGEMENTCONTINIOUS-COMMISSIONING
Continuous Commissioning
Commissioning and Retro-commissioning can loose its initial effectiveness over time due to the
following factors:
•Inability of Operations and Maintenance staff to continually monitor monitory building
performance and make needed adjustments as problems arise.
•Lack of tracking of adjustments made
•Failures of equipment and control devices
•Controls Changes that negate optimum performance
•Lack of proper training (Cause and Effect)
•Managements change in priorities.
This can be resolved by implementing a continuous commissioning program.
The key from the owners side is to sell the
benefits to upper management to get buy in
to the processes to ensure long term cost
control.
11. ASSETMANAGEMENTCONTINIOUS-COMMISSIONING
Continuous Commissioning
Continuous commissioning is an ongoing process to resolve operating problems, improve
comfort, optimize energy use and control costs.
•Identify and quantify potential measures and cost controls
•Develop performance baselines for energy, comfort and cost
•Examine the building in detail—to the air-handling-unit (AHU) and/or terminal-box
level—to identify operating and comfort problems, component failures or degradation,
and causes of system inefficiency
•Implement Continuous Commissioning measures.
•Identify changes in operating procedures for the building staff, and document energy
savings and comfort improvements
•Train the building staff
•Track/verify energy, comfort, equipment efficiency and cost performance
Continuous Commissioning goes a step further, involving the continuous collection and
analysis of energy data via an existing Building Management System (BMS) in conjunction
with stand-alone metering equipment.