Preventive Maintenance in construction, Mining and Transportation

1. Preventive Maintenance in construction, Mining and Transportation Preventive Maintenance 1.IMPLEMENTING PREVENTIVE MAINTENANCE IN YOUR SITE MAINTENANCE Fleet managers who run a planned maintenance-based program may view preventive maintenance as an overhead cost that is, at first, difficult to justify. But all it takes is one serious accident or significant period of downtime to demonstrate how important it is to undertake a program of proactive maintenance strategies. The most successful fleet maintenance strategies value preventive maintenance as its main focus. By staying ahead on fleet maintenance and repair of heavy vehicles and construction equipment, your department will realize major cost savings and higher tool reliability. With the right tools and resources, fleet managers can use PM to transform the way they care for their equipment and grounds. Here are five reasons why adopting a preventive maintenance plan can benefit your fleet maintenance and your industry. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 1

2. 2.ADVANTAGES:- Advantage #1: You’ll save money and waste less energy. Costly repairs and replacements occur less often when vehicle is maintained. While it’s nearly impossible to prevent all reactive planned maintenance, the likelihood of a major breakdown is minimal when a fleet department employs a preventive maintenance program. Regular fleet maintenance can also lead to reduced energy bills. vehicle that works as expected is more likely to run efficiently and use less energy than unmaintained vehicle. Advantage #2:You’ll extend the useful life of critical vehicle Excavator, Dumper, graders, wheel Tractor Scraper are just a few examples of assets in a road commercial heavy vehicles and construction equipment that require consistent vehicle fleet maintenance for optimal performance. Checking equipment regularly means they’ll last longer, since issues are spotted early and can be dealt with as needed. vehicle also remains in its best shape, therefore extending its useful lifetime. Advantage #3: You’ll create a safer work environment for your site maintenance team. A majority of fleet managers would agree that maintaining safety in their buildings is a top priority. A preventive maintenance plan can keep buildings safer and more secure. Equipment that meets safety standards is less likely to pose risk or cause serious harm to operators. With regular maintenance, dangerous and catastrophic equipment failures are reduced, making your service a safer place for staff and occupants alike. Advantage #4: You’ll significantly reduce unexpected disruptions and asset breakdown. Regular equipment checks mean you won’t be caught off guard if something goes wrong or breaks down. A preventive maintenance plan will indicate when parts need to be replaced. This means that there will be little-to-no unexpected downtime, since you’ll have replacement parts and service technicians on hand for timely repairs. Replacing parts before they are damaged also means there will be less wear-and-tear compared to machines that are serviced using run- to-failure maintenance. Advantage #5: You’ll be able to plan ahead and budget for upcoming site maintenance. Repairs are planned in advance, so all costs associated with replacement parts and repair personnel are factored into the department’s budget. A preventive maintenance plan will also help you keep track of asset names, parts and contact information for repair personnel. As maintenance is performed throughout the year, you’ll know exactly what annual expenses to calculate for upcoming site maintenance. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 2

3. 2 types of asset breakdown maintenance :- asset breakdown maintenance Planned maintenance- • Planned maintenance means that the organization is prepared for a breakdown and even expects it to happen. The equipment runs until it breaks, which initiates a run to failure (RTF) trigger. While RTF triggers can be unplanned, breakdown maintenance plans use RTF as a way of lowering the cost of maintenance. This kind of plan needs to be rigorously documented and controlled, especially for heavy vehicles. Employees should be clear on exactly which parts could break down and which parts will be maintained normally via preventive maintenance. Without these checks, a breakdown maintenance plan can be exploited or run awry. •Unplanned breakdown maintenance:- Unplanned breakdown maintenance, on the other hand, occurs when a piece of equipment fails or breaks unexpectedly—also called an unplanned downtime event. While some services may not utilize a planned maintenance plan, nearly every service needs resources in place for unplanned maintenance. After all, every piece of equipment will break or fault at some point in its life. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 3

4. 5 examples of breakdown maintenance:- It is unique in its applications because it cannot be used with certain industries or products, especially ones that involve health and safety. This means that it is most frequently used when parts are inexpensive or nonessential. Here are some examples in which asset breakdown maintenance is applicable:- Equipment can’t be repaired at all (inaccessible, designed to not be repaired) Asset consists of inexpensive or easy-to-replace parts Non-critical pieces of equipment (like hand tools) Objects/equipment that are disposable or meant to be replaced at the end of their lifespan Short-life assets (batteries, high flow pumps) • • • • • As you can see from these examples, it becomes viable when there’s no inherent safety risk to letting a part or piece of equipment break. As an example, consider a service’s light bulbs. If a light bulb is not linked to a safety feature, it doesn’t make financial sense to replace it before it has burned out. However, it is absolutely not viable when people’s lives can be endangered by a part or product breaking. For example, the aviation industry cannot rely on parts breaking down to fix them because doing so could threaten the personal wellbeing and safety of people on planes. This is also true for tire manufacturers who are responsible for road safety. When it comes to people’s lives, preventive and predictive maintenance are the right choice. Breakdown vs. corrective maintenance:- Some may wonder what the difference is between breakdown and corrective maintenance. Both work with equipment that is faulty, less than optimized, and/or broken. However, the two terms are not necessarily the same thing. Breakdown maintenance is performed on equipment that is broken, faulted, or otherwise stopped in such a manner as to make the equipment non-operational. Corrective maintenance is focused on rectifying and repairing faulty equipment. Breakdown maintenance is obviously not for every industry. In particular, industries that are directly responsible for people’s safety should never use breakdown-maintenance. However, it can be useful when working with disposable, cheap parts or equipment that cannot be repaired by normal means. The bottom line for vehicle maintenance is that it requires planning and coordination—an organization should never allow the vehicle maintenance to be exploited or used improperly. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 4

5. Tips to reduce Downtime in your Industry :- Industry breakdown 1. Perform risk audits:- It’s not fun to do, but it needs to be done nonetheless. Risk auditing is the fastest and most effective way to reduce downtime losses that may occur in the future. An example of a risk audit is identifying real-time obsolete equipment. Even in the most modern companies, it is common to find equipment that is 10-20 years old. Furthermore, the equipment spare parts are often difficult to find because it is no longer produced by the Industry where you bought it. If the equipment is broken, there are many possible consequences, such as the safety of the workers around the engine, the quality of the products produced by the engine, and the long downtime due to difficulties in finding spare parts. With risk audit, you will be able to see problems that might arise, so that when downtime occurs, you won’t panic. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 5

6. 2. Use latest cloud based CMMS and operators Apps:- Bring the speed of technology “cloud based CMMS “by using Mobile app based software. Software can connect all your team members in real-time Cloud based CMMS so it becomes very easy to track progress of vehicle maintenance. A breakdown can be reported immediately via app with breakdown images and voice notes. All team members stay informed on the breakdown and corrective action. Cloud based CMMS is a must have tool to stay competitive maintenance. 3. Calculating losses that occur during downtime:- In the area of heavy vehicles and construction equipment, the biggest mistake of a industry fleet manager is not counting how much money the industry losses during downtime. Even five minutes of downtime can potentially harm you in large numbers! These downtime losses include no productivity from employees, no items are produced, potential working hours that must be rescheduled, equipment repair costs, time wasted serving customer complaints, and damage to the industry image. Downtime must always be calculated in the form of currency. In this way, you as a industry fleet manager can focus on preventing losses when downtime occurs. 4. Install sensors to early detect potential equipment breakdowns:- Signs of equipment breakdown can generally be seen in three aspects. The vibration produced by the device is greater than usual. The tool gets hot faster than before, or the engine noise is louder than usual. These signs may difficult to see with a naked eye, but the sensor can detect those irregularities easily. Fortunately, sensors like this are relatively inexpensive and not too large in size. Don’t hesitate to buy sensors like this to avoid equipment damage that potentially causes losses on a greater scale. 5. Get help with your system and equipment:- Let’s face it, every software or hardware used by your industry comes from a variety of different companies. No matter how reliable your technician is, you will certainly have difficulties when your technician required to handle two different devices when it is broken at the same time, or when you have to troubleshoot two software which functions differently. That’s why you need help. Make sure you have at least the contact number of the technician from every equipment and software in your industry. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 6

7. 6. Train and empower your fleet employees:- After hardware error, an operational error is the second most common cause of downtime. A good operator is the one who has the ability to detect whether the machine they handle showing signs of error. Even better if the operator knows when it should undergo vehicle maintenance. This is why employee training is very important in the area of heavy vehicles and construction equipment industry. In addition to mastering the equipment, the production will be even more efficient if the operator can solve the problem of the equipment by himself, thus the potential for downtime can be minimized. 7. Schedule your regular maintenance regularly:- For those of you who have a motorbike or an automobile, you certainly know when you have to change the oil and perform routine maintenance at the nearest workshop. Apply the same thing in your industry . Just like your motorbike/car, regular maintenance reduces the possibility of breakdown and the possibility of downtime, and also increasing safety and productivity. Unfortunately, there are still quite a number of companies out there who don’t care about this. They continuously run their machines without any vehicle maintenance at all. In fact, just like a motorbike that is not maintained, we do not know when the engine suddenly broke down and made the loss bigger. 8. Do documentation:- Make notes of the condition of each equipment and make this a corporate culture. By recording when the last time a machine undergo vehicle maintenance, which parts that have been replaced, what are the signs of damage seen in the sensor, it will make vehicle maintenance easier and downtime easier to avoid. Growing a culture like this might be difficult at first. But with real-time and discipline, this is not impossible to implement The worst thing that might happen from the situation above is you have to recreate the software, delay the production process for two weeks. Nightmare! This is the reason why a backup process is an important thing that must be done regularly, besides regular maintenance. 9. Be proactive! As a fleet manager or leader, you must have a proactive mindset. Which means; do not wait for a disaster to happen, but actively identify where potential disaster might occur so that damage can be reduced, and downtime avoided. One of the proactive steps is making your industry environmentally friendly. An environmentally friendly industry is not only effective in reducing downtime, but also enhancing your industry’s image in the surrounding community, reducing waste, and ultimately increasing the profit the industry gets. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 7

8. HTTPS://WWW.HEAVYVEHICLEINSPECTION.COM/ 8