This document discusses plant maintenance strategies, challenges, aspects of effectiveness, evaluation, and costs. It outlines approaches to maintenance including employee involvement, procedures, and reliability practices. It also discusses challenges, expectations for improvement, and methods for analyzing maintenance data. Key performance indicators and factors that determine effectiveness or ineffectiveness are provided. The document also covers maintenance costs, budgeting, and performance analysis.

1. PLANT MAINTENANCE
STRATEGY, CHALLENGES, ASPECTS,
EFFECTIVENESS, EVALUATION
AND COSTS
Manohar Tatwawadi
total output power solutions
Pune, 411045
03-Aug-19 total output power solutions 1

2. Maintenance Strategy
Employee Involvement
Information sharing
Skill training
Reward system
Employee empowerment
Maintenance and Reliability
Procedures
Clean and lubricate
Monitor and adjust
Make minor repair
Keep computerized records
Results
Reduced inventory
Improved quality
Improved capacity
Reputation for quality
Continuous improvement
Reduced variability

3. 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
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4. 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
AND RELIABILITY
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5. Data Analysis for Expectations……..
• 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
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6. Data Analysis….and observations
• IDENTIFYING LOSSES DUE TO FAILURES AND
ADJUSTMENT OF SPEEDS AND MINOR
STOPPAGES
• LOCATING DEFECT LOSSES
• HAVING PROPER LUBRICATION SYSTEM FOR
ENERGY SAVINGS
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7. 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
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8. 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
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9. OVERALL EQUIPMENT EFFECTIVESSS
• AVAILABILITY
• PERFORMANCE RATE
• QUALITY RATE
• MTBF , MTTR, MUT, MDT, MCT, MLDT
• INHERENT AVAILABILITY
• STEADY-STATE AVAILABILITY
• OPERATIONAL AVAILABILITY
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10. KEY PERFORMANCE INDICATORS
• INCREASE EQUIPMENT RELIABILITY
• NUMBER OF UNITS REJECTED BY QUALITY
INSPECTION
• ZERO DEFECTS
• SIX SIGMA
• ZERO ACCIDENTS
• MAXIMIZING O.E.E.
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11. 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
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12. MAINTENANCE PERFORMANCE ANALYSIS
• WORK SAMPLING TECHNIQUES
• JOB AUDITING
• SWOT ANALYSIS
• EVALUATION BY REPORTS
• EVALUATION PROCESS OF PLANT
ENGINEERING - BENCHMARKING
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13. 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.
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14. 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
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15. PERFORMANCE BASED INDICES
• MAINTENANCE COST PER UNIT PRODUCTION
• MAINTENANCE COST / HOUR
• TOTAL PLANT MAINTENANCE PRODUCTIVITY
• % COST SCHEDULED MAINTENANCE
• % MAINTENANCE COST TO INVESTMENT
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16. Indices……
• % SCHEDULE COMPLIANCE
• SCHEDULE LOADING FACTOR
• WRENCH TIME
• MAINTENANCE WORK CAPACITY INDEX
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17. 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
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18. 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
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19. TECHNICAL AUDIT
• THERMAL AUDIT
• ELECTRICAL AUDIT
• ENERGY AUDIT
• INDUSTRIAL WATER USAGE AUDIT
• COMPRESSED AIR AUDIT
• PLANT HYDRAULIC SYSTEM AUDIT
• PLANT CENTRALIZED LUBRICATION SYSTEM
AUDIT
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20. MAINTENANCE BENCHMARKING
• STRATEGIC BENCHMARKING
• PERFORMANCE BENCHMARKING
• PROCESS BENCHMARKING
• FUNCTIONAL BENCHMARKING
• INTERNAL BENCHMARKING
• EXTERNAL BENCHMARKING
• INTERNATIONAL BENCHMARKING
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21. 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.
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22. 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
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23. 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
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24. 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
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25. 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
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26. Maintenance Costs….other
• REGULATORY / STATUTORY EXPENDITURES
• INSURANCE LIABILITES
• NON WORKING MAINTENANCE LABOR
• MAINTENANCE WORK DONE BY PRODUCTION
EMPLOYEES
• NON CAPITAL PLANT IMPROVEMENTS
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27. 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
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28. 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
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29. 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
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30. 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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