Maintenance Planning and Scheduling are key elements that influence the true success of any organization. Many times we have a planner or planner/scheduler, but do not know how to use him or her effectively or efficiently.
This document discusses maintenance management. It describes three types of maintenance - reactive, preventive, and predictive. Reactive maintenance involves fixing equipment after it breaks. Preventive maintenance is conducted on a schedule to prevent failures. Predictive maintenance uses condition monitoring to perform maintenance only when needed. The document outlines the advantages and disadvantages of each approach. It also discusses maintenance planning and scheduling, including developing repair plans, identifying tools and facilities needed, and estimating time requirements.
Maintenance policies and preventive maintenanceMudit M. Saxena
Here are the answers to the assignment questions:
Q1. Plant maintenance refers to the methods, strategies and practices used to keep an industrial plant running efficiently. The objectives of plant maintenance are to increase reliability, maximize equipment lifespan, maximize production capacity, minimize total production cost, minimize interruptions and enhance safety.
Q2. The importance of maintenance includes identifying failure causes, deciding maintenance actions, providing equipment life and reliability information, and enabling spare parts management.
Q3. The main types of maintenance are planned maintenance (preventive, predictive, corrective) and unplanned maintenance. Preventive maintenance is carried out according to schedules and aims to reduce failures. Corrective maintenance is carried out after failure. Predictive maintenance aims to
The document provides an overview of a presentation on maintenance systems. It discusses key topics like machinery failure, maintenance objectives, types of maintenance including breakdown, planned, preventive, and predictive maintenance. It covers maintenance cost analysis, availability calculation, integration of maintenance with other departments. Specific sections describe maintenance departments and roles, engineers' duties, use of computer systems, importance of maintenance records and overhaul management. The document aims to outline important aspects of effective maintenance systems for industrial operations.
Preventive maintenance involves maintaining equipment through scheduled work to prevent failures and extend equipment life. It is conducted before any problems occur. Corrective maintenance repairs equipment after a failure. Predictive maintenance uses direct measurements to predict failures. Preventive maintenance improves reliability, decreases costs and downtime, and reduces injuries. It can be planned maintenance based on schedules or condition-based maintenance that occurs when indicators show deterioration.
The document discusses principles and practices of maintenance planning in engineering systems. It describes key concepts like maintenance engineering, types of planning, objectives of planned maintenance, principles of maintenance systems, reliability measures like MTBF and MTTR, maintenance organization structures, and maintenance economics and costs. The overall goal of maintenance planning is to optimize equipment availability and performance at lowest cost through reliable maintenance strategies.
The document discusses key concepts in maintenance management. It emphasizes balancing equipment availability, costs, safety and compliance. Good maintenance management increases profits and competitiveness, while poor maintenance can threaten a company's survival. The document outlines ten areas for improvement in maintenance systems, including asset management, spare parts, planning, processes and data management. It stresses the importance of standardization, data quality and alignment with overall business strategy to optimize availability, costs, safety and compliance through continuous improvement.
Preventive maintenance is performing maintenance on equipment to minimize risk of failure by addressing issues before breakdowns occur. A preventive maintenance system helps maximize uptime and efficiency while reducing downtime through regular inspections and repairs. This prevents complete breakdowns, allows for early problem detection, and limits emergency repairs, unnecessary repairs, and delays from machinery issues.
Maintenance Planning and Scheduling are key elements that influence the true success of any organization. Many times we have a planner or planner/scheduler, but do not know how to use him or her effectively or efficiently.
This document discusses maintenance management. It describes three types of maintenance - reactive, preventive, and predictive. Reactive maintenance involves fixing equipment after it breaks. Preventive maintenance is conducted on a schedule to prevent failures. Predictive maintenance uses condition monitoring to perform maintenance only when needed. The document outlines the advantages and disadvantages of each approach. It also discusses maintenance planning and scheduling, including developing repair plans, identifying tools and facilities needed, and estimating time requirements.
Maintenance policies and preventive maintenanceMudit M. Saxena
Here are the answers to the assignment questions:
Q1. Plant maintenance refers to the methods, strategies and practices used to keep an industrial plant running efficiently. The objectives of plant maintenance are to increase reliability, maximize equipment lifespan, maximize production capacity, minimize total production cost, minimize interruptions and enhance safety.
Q2. The importance of maintenance includes identifying failure causes, deciding maintenance actions, providing equipment life and reliability information, and enabling spare parts management.
Q3. The main types of maintenance are planned maintenance (preventive, predictive, corrective) and unplanned maintenance. Preventive maintenance is carried out according to schedules and aims to reduce failures. Corrective maintenance is carried out after failure. Predictive maintenance aims to
The document provides an overview of a presentation on maintenance systems. It discusses key topics like machinery failure, maintenance objectives, types of maintenance including breakdown, planned, preventive, and predictive maintenance. It covers maintenance cost analysis, availability calculation, integration of maintenance with other departments. Specific sections describe maintenance departments and roles, engineers' duties, use of computer systems, importance of maintenance records and overhaul management. The document aims to outline important aspects of effective maintenance systems for industrial operations.
Preventive maintenance involves maintaining equipment through scheduled work to prevent failures and extend equipment life. It is conducted before any problems occur. Corrective maintenance repairs equipment after a failure. Predictive maintenance uses direct measurements to predict failures. Preventive maintenance improves reliability, decreases costs and downtime, and reduces injuries. It can be planned maintenance based on schedules or condition-based maintenance that occurs when indicators show deterioration.
The document discusses principles and practices of maintenance planning in engineering systems. It describes key concepts like maintenance engineering, types of planning, objectives of planned maintenance, principles of maintenance systems, reliability measures like MTBF and MTTR, maintenance organization structures, and maintenance economics and costs. The overall goal of maintenance planning is to optimize equipment availability and performance at lowest cost through reliable maintenance strategies.
The document discusses key concepts in maintenance management. It emphasizes balancing equipment availability, costs, safety and compliance. Good maintenance management increases profits and competitiveness, while poor maintenance can threaten a company's survival. The document outlines ten areas for improvement in maintenance systems, including asset management, spare parts, planning, processes and data management. It stresses the importance of standardization, data quality and alignment with overall business strategy to optimize availability, costs, safety and compliance through continuous improvement.
Preventive maintenance is performing maintenance on equipment to minimize risk of failure by addressing issues before breakdowns occur. A preventive maintenance system helps maximize uptime and efficiency while reducing downtime through regular inspections and repairs. This prevents complete breakdowns, allows for early problem detection, and limits emergency repairs, unnecessary repairs, and delays from machinery issues.
The document discusses preventive maintenance. It defines preventive maintenance as scheduled maintenance activities aimed at preventing mechanical breakdowns and failures. The primary goal of preventive maintenance is to prevent equipment failure before it occurs, maximizing the useful life of machines. Benefits include extended equipment life, savings on repairs, and minimized risk of failure. The document also outlines different types of maintenance cycles and lists the three B's of successful preventive maintenance as being based on time, performance, or condition.
The document discusses various aspects of maintenance management policies, including:
1. Policies around work allocation, such as determining the appropriate level of scheduling, selection of jobs to schedule, and balancing preventive and breakdown maintenance.
2. Policies regarding the workforce, including deciding whether to use an in-house workforce or outside contractors, and factors to consider in that decision.
3. General policies cover areas like interplant relations and control of the maintenance function.
Reliability centered maintenance (RCM) is a maintenance strategy that uses failure modes and effects analysis to determine the most cost-effective maintenance tasks. It aims to perform only necessary maintenance to preserve system functions and avoid unnecessary maintenance costs. RCM shifts maintenance from reactive to condition-based, using tools like vibration analysis and oil testing to predict failures. Initial costs for RCM are higher but maintenance costs decrease over time as failures are prevented.
The document discusses different types of maintenance activities. It defines maintenance and its objectives to keep equipment operational at minimum cost. It describes various types of maintenance including planned preventive maintenance to minimize breakdowns, and unplanned corrective maintenance after failures occur. Predictive maintenance uses condition monitoring to detect potential failures while preventive maintenance relies on routine inspections.
This document contains a summary of a presentation on best practices in maintenance and reliability by Ricky Smith. It discusses key topics like reliability definitions, failure patterns, predictive maintenance, FRACAS systems, and reliability metrics. It emphasizes that most equipment failures are self-induced due to issues like improper installation, maintenance, or lubrication. It also outlines steps for improving reliability like prioritizing assets, identifying maintenance strategies, and using failure data for continuous improvement. The goal is to move from reactive to proactive maintenance through practices like condition monitoring and root cause analysis.
Maintenance Strategy, Types of MaintenanceDhanesh S
The document discusses various maintenance strategies including breakdown maintenance, corrective maintenance, and preventive maintenance. It provides details on each strategy such as the approach, advantages, disadvantages, and components. Preventive maintenance involves periodic inspection, servicing, and repairs to equipment on a planned schedule to avoid breakdowns. The goals are to minimize failures, increase equipment life, and acquire maintenance history data. Sources for developing preventive maintenance procedures include vendor recommendations, plant experience, and generic approaches.
Plant maintenance is important for efficient production. It helps maintain and increase plant efficiency. There are different types of maintenance like planned, preventive, breakdown, and predictive maintenance. Planned maintenance involves prior planning and is done periodically. Preventive maintenance prevents failures through scheduled activities. Breakdown maintenance repairs equipment after failure. Predictive maintenance predicts and prevents failures through condition monitoring. The objectives of maintenance are to increase reliability, maximize equipment life, optimize production capacity and costs, and ensure safety.
The document outlines the seven steps of autonomous maintenance which involves operations maintaining their own equipment. The seven steps are: 1) initial clean-up, 2) stopping sources of defects, 3) formulating initial standards, 4) overall internal checkups, 5) autonomous checkups, 6) orderliness and tidiness, and 7) autonomous management. The goal is for operations to conduct routine maintenance and checks to improve reliability, minimize breakdowns, and achieve zero defects.
This document provides an introduction to maintenance. It discusses the importance of maintenance for safety, productivity, and avoiding costly failures. It outlines different types of maintenance including corrective, scheduled, preventive, and predictive maintenance. Preventive maintenance aims to perform minor repairs and inspections periodically to reduce unexpected breakdowns. The benefits of preventive maintenance include reducing downtime, repair costs, and improving safety, product quality, and plant life. The document also provides an example of calculating the number of repair crews needed based on machine breakdown and repair rates.
Maintenance management involves keeping equipment running at high capacity and low cost through a set of organized activities. The objectives of maintenance include efficient use of personnel, maximizing equipment life, reliability, quality, safety and minimizing costs and interruptions. There are various types of maintenance like preventive, corrective, and predictive. Preventive maintenance involves scheduled, running and shutdown maintenance to prevent failures. Corrective maintenance repairs equipment after failure through breakdown or shutdown maintenance. Predictive maintenance predicts failures through condition monitoring.
This document provides information about Total Productive Maintenance (TPM). It discusses TPM strategies and supporting strategies, including loss elimination, operator autonomous maintenance, initial control systems, zero defects, and education/training. Graphics show photos from clean-up activities and current conditions to improve like oil socks and workplace organization. Charts compare key indicators like costs and quality before and after implementing AMPS/TPM. The document also discusses TPM measurements, education and skills training, one point lessons for documenting issues and improvements, and addressing chronic losses.
The document provides an overview of reliability centered maintenance (RCM) concepts and process. It discusses the history and principles of RCM, failure patterns, and the RCM process steps. The process involves understanding the operating context and functions of equipment, identifying potential failures and their effects, and determining the most effective maintenance tasks. Understanding failure patterns is important for developing the proper maintenance strategy, such as on-condition tasks, restoration tasks, or redesign tasks. The document uses examples to illustrate RCM concepts.
This document discusses different types of maintenance for plants and equipment. It describes planned maintenance which includes preventive, corrective, and predictive maintenance. Preventive maintenance is carried out at predetermined intervals to reduce failures and includes running, scheduled, and shutdown maintenance. Corrective maintenance is performed after a failure to address the source of the problem. The key difference between preventive and corrective maintenance is timing - preventive is before and corrective is after a problem.
REPAIR METHODS FOR BASIC MACHINE ELEMENTSlaxtwinsme
Repair methods for beds, slide ways, spindles, gears, lead screws and bearings – Failure analysis –Failures and their development – Logical fault location methods – Sequential fault location
A complete guide on preparation, planning and execution of a computerized maintenance management system with examples and illustration of the program modules interaction and the way these programs operate.
The document discusses maintenance strategies, defining four main strategies: reactive, preventive, predictive, and proactive centered maintenance. It emphasizes that business objectives should drive the maintenance strategy, which then determines the technologies used. The document provides definitions and examples of each strategy and related terms like condition monitoring, reliability centered maintenance, and computerized maintenance management systems. It also outlines a process for selecting the right strategy that involves identifying asset criticality and potential failure modes.
Types of maintenance, maintenance in plant ,maintenance type suresh tusia
There are four main types of maintenance: breakdown, preventive, predictive, and corrective. Preventive maintenance includes periodic and predictive maintenance. Periodic maintenance is time-based while predictive maintenance is condition-based. Condition monitoring is part of predictive maintenance and involves determining equipment condition while in operation. The different types have advantages like increased equipment life and disadvantages like being labor intensive. Aircraft maintenance includes A, B, C, and D checks performed at increasing intervals. Nondestructive testing is important for aircraft maintenance to inspect for defects without damaging equipment.
The document discusses maintenance policies and work order processes. It provides details on different types of maintenance policies including failure based, time based, condition based, and risk based approaches. It then describes the purpose and benefits of work orders, including recording downtime data, ensuring repairs are completed properly, and providing a source for planning and key performance indicators. Guidelines are provided on the information included in work orders like inventory details, requestor information, work descriptions, and actual completion details. The work order system and typical flow from generation to completion is outlined.
Marts Conference 2012: Getting to the Root Cause of Your Maintenance Issues5S Supply
This slide deck is a recap of the session presented by Anthony Manos at the MARTS Conference March 13, 2012 covering how to get to the real root cause of your maintenance issues.
The document discusses preventive maintenance. It defines preventive maintenance as scheduled maintenance activities aimed at preventing mechanical breakdowns and failures. The primary goal of preventive maintenance is to prevent equipment failure before it occurs, maximizing the useful life of machines. Benefits include extended equipment life, savings on repairs, and minimized risk of failure. The document also outlines different types of maintenance cycles and lists the three B's of successful preventive maintenance as being based on time, performance, or condition.
The document discusses various aspects of maintenance management policies, including:
1. Policies around work allocation, such as determining the appropriate level of scheduling, selection of jobs to schedule, and balancing preventive and breakdown maintenance.
2. Policies regarding the workforce, including deciding whether to use an in-house workforce or outside contractors, and factors to consider in that decision.
3. General policies cover areas like interplant relations and control of the maintenance function.
Reliability centered maintenance (RCM) is a maintenance strategy that uses failure modes and effects analysis to determine the most cost-effective maintenance tasks. It aims to perform only necessary maintenance to preserve system functions and avoid unnecessary maintenance costs. RCM shifts maintenance from reactive to condition-based, using tools like vibration analysis and oil testing to predict failures. Initial costs for RCM are higher but maintenance costs decrease over time as failures are prevented.
The document discusses different types of maintenance activities. It defines maintenance and its objectives to keep equipment operational at minimum cost. It describes various types of maintenance including planned preventive maintenance to minimize breakdowns, and unplanned corrective maintenance after failures occur. Predictive maintenance uses condition monitoring to detect potential failures while preventive maintenance relies on routine inspections.
This document contains a summary of a presentation on best practices in maintenance and reliability by Ricky Smith. It discusses key topics like reliability definitions, failure patterns, predictive maintenance, FRACAS systems, and reliability metrics. It emphasizes that most equipment failures are self-induced due to issues like improper installation, maintenance, or lubrication. It also outlines steps for improving reliability like prioritizing assets, identifying maintenance strategies, and using failure data for continuous improvement. The goal is to move from reactive to proactive maintenance through practices like condition monitoring and root cause analysis.
Maintenance Strategy, Types of MaintenanceDhanesh S
The document discusses various maintenance strategies including breakdown maintenance, corrective maintenance, and preventive maintenance. It provides details on each strategy such as the approach, advantages, disadvantages, and components. Preventive maintenance involves periodic inspection, servicing, and repairs to equipment on a planned schedule to avoid breakdowns. The goals are to minimize failures, increase equipment life, and acquire maintenance history data. Sources for developing preventive maintenance procedures include vendor recommendations, plant experience, and generic approaches.
Plant maintenance is important for efficient production. It helps maintain and increase plant efficiency. There are different types of maintenance like planned, preventive, breakdown, and predictive maintenance. Planned maintenance involves prior planning and is done periodically. Preventive maintenance prevents failures through scheduled activities. Breakdown maintenance repairs equipment after failure. Predictive maintenance predicts and prevents failures through condition monitoring. The objectives of maintenance are to increase reliability, maximize equipment life, optimize production capacity and costs, and ensure safety.
The document outlines the seven steps of autonomous maintenance which involves operations maintaining their own equipment. The seven steps are: 1) initial clean-up, 2) stopping sources of defects, 3) formulating initial standards, 4) overall internal checkups, 5) autonomous checkups, 6) orderliness and tidiness, and 7) autonomous management. The goal is for operations to conduct routine maintenance and checks to improve reliability, minimize breakdowns, and achieve zero defects.
This document provides an introduction to maintenance. It discusses the importance of maintenance for safety, productivity, and avoiding costly failures. It outlines different types of maintenance including corrective, scheduled, preventive, and predictive maintenance. Preventive maintenance aims to perform minor repairs and inspections periodically to reduce unexpected breakdowns. The benefits of preventive maintenance include reducing downtime, repair costs, and improving safety, product quality, and plant life. The document also provides an example of calculating the number of repair crews needed based on machine breakdown and repair rates.
Maintenance management involves keeping equipment running at high capacity and low cost through a set of organized activities. The objectives of maintenance include efficient use of personnel, maximizing equipment life, reliability, quality, safety and minimizing costs and interruptions. There are various types of maintenance like preventive, corrective, and predictive. Preventive maintenance involves scheduled, running and shutdown maintenance to prevent failures. Corrective maintenance repairs equipment after failure through breakdown or shutdown maintenance. Predictive maintenance predicts failures through condition monitoring.
This document provides information about Total Productive Maintenance (TPM). It discusses TPM strategies and supporting strategies, including loss elimination, operator autonomous maintenance, initial control systems, zero defects, and education/training. Graphics show photos from clean-up activities and current conditions to improve like oil socks and workplace organization. Charts compare key indicators like costs and quality before and after implementing AMPS/TPM. The document also discusses TPM measurements, education and skills training, one point lessons for documenting issues and improvements, and addressing chronic losses.
The document provides an overview of reliability centered maintenance (RCM) concepts and process. It discusses the history and principles of RCM, failure patterns, and the RCM process steps. The process involves understanding the operating context and functions of equipment, identifying potential failures and their effects, and determining the most effective maintenance tasks. Understanding failure patterns is important for developing the proper maintenance strategy, such as on-condition tasks, restoration tasks, or redesign tasks. The document uses examples to illustrate RCM concepts.
This document discusses different types of maintenance for plants and equipment. It describes planned maintenance which includes preventive, corrective, and predictive maintenance. Preventive maintenance is carried out at predetermined intervals to reduce failures and includes running, scheduled, and shutdown maintenance. Corrective maintenance is performed after a failure to address the source of the problem. The key difference between preventive and corrective maintenance is timing - preventive is before and corrective is after a problem.
REPAIR METHODS FOR BASIC MACHINE ELEMENTSlaxtwinsme
Repair methods for beds, slide ways, spindles, gears, lead screws and bearings – Failure analysis –Failures and their development – Logical fault location methods – Sequential fault location
A complete guide on preparation, planning and execution of a computerized maintenance management system with examples and illustration of the program modules interaction and the way these programs operate.
The document discusses maintenance strategies, defining four main strategies: reactive, preventive, predictive, and proactive centered maintenance. It emphasizes that business objectives should drive the maintenance strategy, which then determines the technologies used. The document provides definitions and examples of each strategy and related terms like condition monitoring, reliability centered maintenance, and computerized maintenance management systems. It also outlines a process for selecting the right strategy that involves identifying asset criticality and potential failure modes.
Types of maintenance, maintenance in plant ,maintenance type suresh tusia
There are four main types of maintenance: breakdown, preventive, predictive, and corrective. Preventive maintenance includes periodic and predictive maintenance. Periodic maintenance is time-based while predictive maintenance is condition-based. Condition monitoring is part of predictive maintenance and involves determining equipment condition while in operation. The different types have advantages like increased equipment life and disadvantages like being labor intensive. Aircraft maintenance includes A, B, C, and D checks performed at increasing intervals. Nondestructive testing is important for aircraft maintenance to inspect for defects without damaging equipment.
The document discusses maintenance policies and work order processes. It provides details on different types of maintenance policies including failure based, time based, condition based, and risk based approaches. It then describes the purpose and benefits of work orders, including recording downtime data, ensuring repairs are completed properly, and providing a source for planning and key performance indicators. Guidelines are provided on the information included in work orders like inventory details, requestor information, work descriptions, and actual completion details. The work order system and typical flow from generation to completion is outlined.
Marts Conference 2012: Getting to the Root Cause of Your Maintenance Issues5S Supply
This slide deck is a recap of the session presented by Anthony Manos at the MARTS Conference March 13, 2012 covering how to get to the real root cause of your maintenance issues.
The document discusses various maintenance strategies including reactive, preventive, predictive, proactive, and reliability centered maintenance. Reactive maintenance involves repair after failure, while preventive maintenance uses scheduled inspections and repairs. Predictive maintenance utilizes condition monitoring to detect failures before they occur. Proactive maintenance focuses on identifying and correcting abnormal causes of failure. The goal is to preserve asset functions throughout their lives in the most cost effective way.
When working for Petrobras at PRSI (Pasadena Refining System Inc.) I had this opportunity to share my experience as a Maintenance Manager in Brazil with PRSI operators and maintenance crew.
The document provides an overview of quality assurance and reliability (QAR). It discusses key concepts like quality control, statistical quality control, quality assurance, reliability, and the responsibilities of different departments in ensuring quality. Statistical tools for quality control include control charts, sampling distributions, measures of central tendency and dispersion. The document also covers cost of quality, hidden costs, quality losses, and techniques to reduce quality issues like following the Rule of Tens.
Este documento discute os desafios de implementar métodos ágeis no mundo real. Apresenta os principais pontos como: 1) métodos ágeis são populares, mas muitas vezes mal compreendidos; 2) na prática, a teoria é diferente e há desafios como equipes burocráticas e backlogs infinitos; 3) os princípios como interações individuais, software funcionando e colaboração com o cliente são mais importantes do que processos e ferramentas.
The document discusses various topics in a disorganized manner with many repeated phrases and symbols. It touches on industry trends in the early 2000s, including the growth of outsourcing and its impact on manufacturing jobs. It also mentions workforce training programs and the need to retrain displaced workers.
The document discusses transferring a team to a new distributed setup within 3 months. It describes holding initial meetings in Xi'an, Sydney, and Melbourne to bring the new team together and establish practices. It notes the challenges of building an effective team remotely but emphasizes focusing on delivering software through pairing, storytelling and other techniques.
This document discusses improving reliability and maintenance through organizational culture change. It introduces Ian Knight from the Reliability Institute in the Netherlands who has 35 years of experience in condition monitoring, lubrication, and equipment reliability. Knight discusses examples of implementing change programs focused on maintenance, reliability, and production. He emphasizes that changing organizational culture is key to successful and sustainable change efforts, and outlines a framework for assessing culture and driving change through initiatives, activities, and ongoing evaluation.
Hoshin promotion demystifying the x-matrix - manos5S Supply
The document summarizes a presentation on demystifying the Hoshin Kanri or policy deployment X-matrix. It discusses how to properly complete an X-matrix including filling out the main sections of initiatives/projects, targets/metrics, focus strategies, and key players/interactions. It provides an example of a high-level X-matrix and explains how the sections are related and how drilling down into lower level X-matrices can help implement strategies and tactics.
This document discusses why most organizations are not learning enough and changing effectively. It argues that true change requires moving away from top-down, uniform change programs towards independent, business-aligned teams with decision autonomy, visibility, knowledge sharing, and an emphasis on learning through trying new things. The key is shifting from a focus on control to one of openness, meritocracy, flexibility and collaboration both within and across teams.
Here are the calculations for an OEE goal of 80% and 85%:
OEE Goal of 80%:
- Good Production Hours Needed: 96 hrs
- Scheduled Hours: 96/0.8 = 120 hrs
- Loss Hours: 120 - 96 = 24 hrs
OEE Goal of 85%:
- Good Production Hours Needed: 96 hrs
- Scheduled Hours: 96/0.85 = 112.5 hrs ~= 112 hrs
- Loss Hours: 112 - 96 = 16 hrs
So at an OEE of 80%, the loss hours would be 24 hrs. At an OEE of 85%, the loss hours would be 16 hrs.
The HYL process uses natural gas to directly reduce iron ore into DRI through a gas-based reduction process. It was developed in the 1950s in Mexico. The HYL process uses fixed bed reactors that are heated to reduce iron ore pellets or lumps into sponge iron using a mixture of carbon monoxide and hydrogen produced from the reforming of natural gas. Later developments included moving to a single rotating shaft furnace (HYL III) and allowing production of DRI, HBI, or hot briquetted iron.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
Slides from a presentation given by Georgiana Mannion to a meeting of IIBA UK's North branch on 25 November 2014.
Georgiana explores some of the ways we can align play to lean process improvement and problem identification.
Short introduction to Innovation Games® and examples of their application in Lean and Lean StartUps: Reduce Waste, Value Stream Mapping, and Minimum Viable Product.
Reliability and Maintenance Conference - 7-9 April 2014, Al Khobar, Kingdom o...Ricky Smith CMRP, CMRT
Despite the best efforts and precautions, equipment
failures do occur hampering the equipment performance
and adversly impacting the profitibility of the business.
Rotating Equipment Reliability and Maintenance
Conference aims to create a learning platform for all the
maintenance and reliability professionals to share the
best maintenance practices and discuss the strategies to
improve reliability.
This three day conference will cover all aspects of
reliability and maintenance including reliability centered
maintenance, availability, machinery failures, risk
assessment, spare parts optimization, techniques to
facilitate equipment maintenance, root cause analysis,
condition monitoring, maintenance planning and
scheduling.
This document provides an overview of a training on industrial plant machineries troubleshooting and maintenance taking place on February 8, 2023 in Lagos, Nigeria. The training will cover preventive maintenance management and machinery/equipment overview. Module one will discuss maintenance concepts, solving equipment failures/losses, and presenting maintenance challenges. The goals are to explain maintenance management, solve manufacturing process problems, and submit a maintenance management report.
The document discusses maintenance management. It defines maintenance as keeping equipment operational or repairing it. The objectives of maintenance are increased availability, safety, and optimized costs. Maintenance management involves managing maintenance functions. Common maintenance strategies discussed are breakdown, preventive, predictive, opportunity, and design-out maintenance. Functions of the maintenance department include maintaining equipment, installations, preventive maintenance, condition monitoring, modifications, inventory management, and record keeping. Elements of effective maintenance management discussed are maintenance policy, materials control, work orders, job planning, data recording, and performance measurement.
Lecture-3-Introduction to Maintenance Management.pptThushan9
This document discusses operations and maintenance (O&M) of facilities and equipment. It covers:
1) The importance of effective O&M for reliability, safety, and efficiency through technical systems, competent personnel, and continuous improvement.
2) Definitions of key terms including maintenance, operations and maintenance, and operational efficiency.
3) The five distinct functions that should make up an O&M organization: operations, maintenance, engineering, training, and administration.
4) Potential benefits of O&M including energy savings, hazard mitigation, improved indoor air quality, and achieving design life of equipment.
This document discusses maintenance engineering. It defines maintenance as processes that keep equipment functioning normally to deliver expected performance without breakdowns. Maintenance aims to reduce business risks and maximize asset life at optimal cost. It involves basic functions like repairing, overhauling, and inspecting equipment, as well as composite functions like protecting facilities, reducing downtime, and analyzing repetitive failures. Maintenance objectives center around maintaining high equipment efficiency, minimizing deterioration costs, and helping management with replacement decisions. Responsibilities include caring for equipment availability and maintainability, identifying chronic problems, and implementing effective preventative programs. Benefits of maintenance include lower costs, extended asset life, reduced risks, and improved safety.
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.
The document discusses strategies for achieving world class maintenance in an organization. It describes total productive maintenance (TPM) which focuses on improving equipment efficiency through five pillars: increasing equipment effectiveness, training, autonomous maintenance, early equipment management, and planned and preventive maintenance. It also discusses reliability centered maintenance (RCM) which aims to optimize maintenance programs and offers different risk management strategies. Effective asset management is also described as a process to deploy, operate and maintain assets cost-effectively. Challenges in implementing these strategies include resistance to change, lack of knowledge, and misaligned production and maintenance goals.
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.
The document discusses key concepts in operations management including process mapping, performance measurement, types of processes, and factors affecting plant location and layout. It defines process mapping as creating diagrams that illustrate business processes. Performance can be measured through metrics like workload, efficiency, effectiveness, and productivity. The types of processes include job shop, batch, mass and continuous production. Important considerations for plant location are proximity to materials, markets, labor, utilities and transportation. Plant layout options include product, process, fixed position and combination layouts.
The document discusses the importance and objectives of maintenance management. Modern maintenance aims to keep equipment running at high capacity and producing quality products at the lowest possible cost. It also aims to minimize unplanned downtime and maximize availability. Preventive maintenance is important as it can reduce breakdowns, repairs and costs while increasing availability and efficiency. Condition-based maintenance allows failures to be detected early and repairs to be planned in advance. The goals of maintenance are to maintain availability at the lowest cost while ensuring safety.
Maintenance management involves keeping production equipment in good operating condition on a daily basis. This includes maintaining existing plant and equipment, inspecting and lubricating machinery, and installing new equipment. The main goals of maintenance are to maximize equipment uptime and efficiency while minimizing repair costs and production downtime through activities like preventative maintenance, equipment inspections, and reliability engineering. An effective maintenance program requires planning work activities, scheduling tasks, and controlling costs.
This document provides an overview of maintenance management. It defines various types of maintenance including breakdown, preventive, predictive, and reliability-centered maintenance. It discusses the evolution of maintenance concepts from breakdown-based to more modern condition-based approaches. The responsibilities of the maintenance department include personnel management, scheduling, inventory control, and financial management. Effective maintenance requires establishing objectives, planning and executing maintenance activities, and providing feedback and control.
Development Of An Effective Industrial Maintenance Practice For Plant Optimum...IJERA Editor
Plant optimization is a sound fiscal decision and this is a key attribute of good operational management. The
decision to adhere strictly to the maintenance measurements, controls and efficiencies necessary for optimum
performance not only enhances the plant operations, it quite often produces a safer operating facility and
protects plant asset or investment. Plant operations rely on dependable acquired knowledge, skills, equipment
and maintenance programs for an assured performance whiles strategies are required to be in place for
equipment optimum availability to ensure system operational integrity in order to reduce costs which affect
production. This optimized system would ideally give meaning to effective maintenance practice of plant
equipment and accepted best maintenance management system. This paper presents a comprehensive review of
characteristics of plant equipment and maintenance strategies and proposes sustainable maintenance
management performance criteria. Thereby improving business, safety, equipment efficiency and sustain the
environment. The goal is to achieve optimum availability and optimum operating condition of the equipment
life cycle in a cost optimized approach.
The document presents a maintenance delivery improvement process by Industrial Aids and Services. It discusses the need for a preventive maintenance program to improve reliability, quality, and reduce costs. The maintenance delivery improvement realization process involves equipment criticality analysis, failure mode analysis, maintenance strategy development, and preventive maintenance scheduling. It also includes training, performance monitoring, and knowledge management. The implementation approach involves reviewing current practices, pilot testing, field implementation, and sustaining the system. The deliverables are preventive maintenance checklists, equipment strategies, and schedules. The benefits are reliable equipment, consistent quality, low maintenance costs, and knowledge management.
The document discusses Total Productive Maintenance (TPM), which aims to maximize equipment effectiveness by improving maintenance and involving operators. TPM covers the entire life of equipment and aims to eliminate waste and reduce costs through preventative maintenance. It differs from total quality management by focusing on equipment inputs rather than just output quality. The pillars of TPM include 5S, autonomous maintenance by operators, continuous improvement through kaizen, planned maintenance, and quality maintenance.
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.
The document discusses maintenance management. It describes how maintenance has become more important as production equipment has become more advanced and impacts productivity and quality. Modern maintenance aims to keep equipment running at high capacity and producing quality products at the lowest cost. It also discusses total productive maintenance and different maintenance procedures like condition-based maintenance.
This presentation provides an introduction to Total Productive Maintenance (TPM). It discusses the history and origins of TPM in Japan and defines TPM as keeping equipment at its highest level of performance through cooperation across all areas of an organization. The presentation outlines the eight pillars of TPM that are implemented in organizations, including 5S, autonomous maintenance, planned maintenance, quality maintenance, and safety/environment. It also discusses the goals of TPM as achieving zero breakdowns, accidents, and defects through improved performance, safety, and quality.
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3. Objectives
■ To highlight the benefits of maintenance strategy
■ To study the new strategy of maintenance for better productivity
■ Approaches for the better maintenance strategy leading in to better profitability
4. What is Maintenance Strategy?
“Management method used in order to achieve the maintenance
objectives.”
5. Maintenance Objectives?
■ The targets assigned to or accepted by the management and maintenance
department.
■ Targets may include availability, cost reduction, product quality, environment
preservation, safety
6. Introduction
■ Maintenance is an activity carried out for any equipment to ensure its reliability to
perform its functions
■ It is any activity carried out on an asset in order to ensure that the asset continues
to perform its intended functions
■ To repair any equipment that has failed
■ To keep the equipment running, or to restore to its favorable operating condition
7. Another Perspective
■ Maintenance function is not only to maintain
■ Its also to enhance the process or the plant operation system
■ With the turnaround planning.
■ Most management now saw maintenance efficiency as
■ A factor that can affect the all business effectiveness and risk-safety,
■ Environmental integrity
■ Energy efficiency
■ Product quality and customer service and not contained only to plant availability and
cost.
10. Literature Review
FIRST GENERATION SECOND GENERATION THIRD GENERATION
Fix it when it broke Scheduled overhauls
Systems for planning and
controlling work
Low-tech computerization
Condition monitoring
Design for reliability and
maintainability
Hazard studies
High-tech computers
Failure Modes & effect
analysis
Expert Systems
Multi-tasking and team
work
1930 1940 1950 1960 1970 1980 1990 2000 NOW
15. Discussion
■ In the maintenance enterprise state, presentation assurances and constant
upgrading goals deliver better switch over maintenance outcomes
■ Guarantee manufacture goals which are actuality stretched
■ The assortment of a precise equipment of low installed budget helps to decrease
budget
■ Driving up maintenance budget and downtime which is not promising to the vender
maintenance team
■ Therefore an enhanced solution should be a combined and aligned method
16. Finding
■ Maintenance should be initiated when the facility or system is just a proposal, which
is even earlier the preparation stage
■ And lasts up until it is time to for the facility to de-commissioning
18. Findings
■ By dropping the direct and indirect cost of system failure, the perception of
productive, effective and cost-effective can be attained
■ Return of Assets = Revenue -------------------------------- (1)
(Asset Value)
■ Revenue = Price x Volume -------------------------------- (2)
■ Volume = Max. Capacity x Overall Equipment Effectiveness ------------- (3)
Effective maintenance has a constructive result on calculation (1), (2) and (3).
Enhanced maintenance assistances to improve efficiency by dropping the need for
costly capital advancements to upturn output.
20. Conclusion
■ fix-it-when-it-broke to a more complex approach
■ adopted maintenance strategy of a more integrated approach and alignment
■ maintenance will also be part of the investment decision-making
Improved
Maintenance
Effectiveness
Productivity
Profitability
21. Recommendation
■ Any industry should use effective strategy in order to improve efficiency
■ Reducing the direct and indirect cost of maintenance using preventive and
predictive maintenance will remarkably reduce the maintenance cost
■ Maintenance actions could be started when the facility or system is just a proposal.
Proposal Construction Commissioning Operation
Decommissioning
22. References
■ HISHAM BIN JABAR, Segi Perkasa Sdn Bhd, PLANT MAINTENANCE STRATEGY: KEY
FOR ENHANCING PROFITABILITY
■ General Electric (www.ge.com)
■ Dhillon, S. B. (2006). (2006) Maintainability, Maintenance, and Reliability for
Engineers
■ Mobley, K. (2004). Maintenance Fundamentals (2nd edition). Elsevier Inc.
■ Moubray JM. (2000). Maintenance Management – A New Paradigm. Retrieved from
Maintenance Resources.Com