1. A PRESENTATION ON
REINVENTING THE MAINTENANCE
TO INCREASE ITS EFFICIENCY AND
EFFECTIVENESS
BY
EKECHUKWU IKECHINEKE COLLINS
23 APRIL, 2015

2. INTRODUCTION TO KEY CONCEPTS
MAINTENANCE
Maintenance is defined as the combination of activities by which
equipment, assets or a system is kept or restored to a state in
which it can perform its designated function.
The maintenance of an industry, building, vehicle, workshop, or
machine is the process of keeping it in good condition by
regularly checking it and repairing it when necessary.

3. INTRODUCTION TO KEY CONCEPTS
WHY MAINTAIN?
Maintenance is carried out to extend the useful life of an asset.
Figure 1: Component failure rate over time

4. INTRODUCTION TO KEY CONCEPTS
TYPES OF MAINTENANCE
1
• Reactive Maintenance, whose cost is $18 per horsepower per year.
2
• Preventive Maintenance, whose cost is $13 per horsepower per year.
3
• Predictive Maintenance, whose cost is $9 per horsepower per year.
4
• Reliability Centered Maintenance, a combination of reactive, predictive
and preventive maintenance whose cost is $6 per horsepower per year.

5. INTRODUCTION TO KEY CONCEPTS
EFFICIENCY
• Efficiency is the extent to which time, effort, or cost is
well-used for the intended task or function.
• It is a measurable concept determined by a ratio of output
over input.
• It is doing things right.
EFFECTIVENESS
• Effectiveness is the capacity of producing the right result.
• It is doing the right things.

6. CHALLENGES OF THE MAINTENANCE
DEPARTMENT OF
OILSERV LIMITED
• Absence of workshop for heavy equipment
• Inadequate maintenance workshop layout
• Inadequate maintenance planning
• Lack of laid down procedure for carrying out
maintenance work
• Indeterminate mean time to repair (MTTR)
• Lack of training for maintenance personnel

7. REINVENTING THE MAINTENANCE DEPARTMENT
1. IMPROVED AND EFFECTIVE WORKSHOP AND LAYOUT
FOR HANDLING HEAVY EQUIPMENT
Plant layout specifies the position of the overall
arrangement of the various facilities such as equipment,
material, manpower, materials handling, service facilities,
and passage required to facilitate efficient operation of
production system of the plant within the area of the site
selected previously.

8. REINVENTING THE MAINTENANCE DEPARTMENT
The proposed layout of the maintenance workshop for the maintenance
department is shown below;

9. REINVENTING THE MAINTENANCE DEPARTMENT

10. REINVENTING THE MAINTENANCE DEPARTMENT
1. Vertical Milling Machine 2. Drilling Machine 3. Shaper Machine 4. Tool
Room Lathe 5. Automatic Bench Lathe 6. Machine Lathe 7. Planner
8. Working Table 9. Bench Vice 10. Universal Grinder 11. Hydraulic Press
12. Compressor 13. Scrap Pin 14. Hacksaw Machine 15. Bandsaw
Machine 16. Assembly Table 17. Surface Grinder 18. Gas Welding Kit 19.
Arc Welding Kit 20. Restroom 21. Workshop Superintendent Room 22.
Heat Exchanger Cleaning Kit 23. Air Compressor 24. Portable Grinder
and Surface Grinder 25. Gas Welding Kit 26. Working Table 27.
Monitoring Devices Room

11. REINVENTING THE MAINTENANCE DEPARTMENT
2. The proposed maintenance process flow chart

12. REINVENTING THE MAINTENANCE DEPARTMENT
3. Using Computerized Maintenance Management System for planning
A CMMS software package maintains a computer database of
information about an organization’s maintenance operations i.e.
CMMIS-computerized maintenance management information system
It performs the following functions
• Tracking Work Orders
• Scheduling Tasks
• Recording Assets History
• Managing Inventory
• Audit and Certification

13. REINVENTING THE MAINTENANCE DEPARTMENT
4. Training of Maintenance Personnel
To achieve mastery of any skill, three vital steps are required;
• Apprenticeship Phase
• Creative-Active Phase
• Mastery Phase
During the training (apprenticeship) of both the maintenance engineer
and technician, they are competent in the diagnostic tools for the
automobile and can readily solve breakdown problems.

14. REINVENTING THE MAINTENANCE DEPARTMENT
5. Introduce Operations and Maintenance (O&M) Best
Practices
This is done by writing down and following the right
procedures for carrying out maintenance work.
Example of maintenance best practices for changing v-belts is
shown in the table below

15. Maintenance Task Standard Required Best
Practices
Consequences for not
following Best
Practices
Probability of Future
Failures 〉 Number of
Self Induced failures,
versus following best
practices
V-Belts Measure the tension of
v-belts through tension
and deflection utilizing
a belt tension gage.
1. Identify the proper
tension and deflection
for the belt.
2. Set tension to
specifications
1. Premature belt
failures through rapid
belt wear or total belt
failure.
2. Premature bearing
failure of driven and
driver unit.
3. Belt creeping or
slipping causing speed
variation without
excessive noise.
4. Motor shaft
breakage.
100% 〉 20 vs. 1
REINVENTING THE MAINTENANCE DEPARTMENT

16. BENEFITS OF REINVENTING THE MAINTENANCE
DEPARTMENT
• Improving the layout of the maintenance department to increase the
efficiency of the department.
• Optimizing the cost of maintenance.
• Reducing down-time due to failure of equipment.
• Increasing the effectiveness of the department.
• Improving the safe working environment for personnel.
• Reducing the mean time to repair (MTTR) equipment.
• Smoothening workflow.
• Reducing material handling.
• Reducing work in progress inventory.
• CMMS creates efficient and effective planning of maintenance jobs.
• Introducing Operations and Maintenance (O&M) best practices.

17. CONCLUSION
IT IS NOT THE EMPLOYER WHO PAYS WAGES- HE
ONLY HANDLES THE MONEY. IT IS THE PRODUCT
THAT PAYS WAGES.
-HENRY FORD

18. THAT
IS
ALL