CHALLENGES IN MAINTENANCE FUNCTIONS

1. 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

2. 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

3. 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

4. IDENTIFYING LOSSES DUE TO FAILURES AND ADJUSTMENT OF SPEEDS AND MINOR STOPPAGES • LOCATING DEFECT LOSSES • HAVING PROPER LUBRICATION SYSTEM FOR ENERGY SAVINGS

5. 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

6. 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

7. OVERALL EQUIPMENT EFFECTIVESSS • AVAILABILITY • PERFORMANCE RATE • QUALITY RATE • MTBF , MTTR, MUT, MDT, MCT, MLDT • INHERENT AVAILABILITY • STEADY-STATE AVAILABILITY • OPERATIONAL AVAILABILITY

8. KEY PERFORMANCE INDICATORS • INCREASE EQUIPMENT RELIABILITY • NUMBER OF UNITS REJECTED BY QUALITY INSPECTION • ZERO DEFECTS • SIX SIGMA • ZERO ACCIDENTS • MAXIMIZING O.E.E.

9. 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

10. MAINTENANCE PERFORMANCE ANALYSIS • WORK SAMPLING TECHNIQUES • JOB AUDITING • SWOT ANALYSIS • EVALUATION BY REPORTS • EVALUATION PROCESS OF PLANT ENGINEERING - BENCHMARKING

11. 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.

12. 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

13. PERFORMANCE BASED INDICES • MAINTENANCE COST PER UNIT PRODUCTION • MAINTENANCE COST / HOUR • TOTAL PLANT MAINTENANCE PRODUCTIVITY • % COST SCHEDULED MAINTENANCE • % MAINTENANCE COST TO INVESTMENT

14. % SCHEDULE COMPLIANCE • SCHEDULE LOADING FACTOR • WRENCH TIME • MAINTENANCE WORK CAPACITY INDEX

15. 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

16. 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

17. TECHNICAL AUDIT • THERMAL AUDIT • ELECTRICAL AUDIT • ENERGY AUDIT • INDUSTRIAL WATER USAGE AUDIT • COMPRESSED AIR AUDIT • PLANT HYDRAULIC SYSTEM AUDIT • PLANT CENTRALIZED LUBRICATION SYSTEM AUDIT

18. MAINTENANCE BENCHMARKING • STRATEGIC BENCHMARKING • PERFORMANCE BENCHMARKING • PROCESS BENCHMARKING • FUNCTIONAL BENCHMARKING • INTERNAL BENCHMARKING • EXTERNAL BENCHMARKING • INTERNATIONAL BENCHMARKING

19. 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.

20. 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

21. 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

22. 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

23. 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

24. REGULATORY / STATUTORY EXPENDITURES • INSURANCE LIABILITES • NON WORKING MAINTENANCE LABOR • MAINTENANCE WORK DONE BY PRODUCTION EMPLOYEES • NON CAPITAL PLANT IMPROVEMENTS

25. 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

26. 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

27. 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

28. PREPARATION OF MAINTENANCE BUDGET • ALLOCATE REVENUE AND EXPENSES USING TOP DOWN / BOTTOM UP • PRODUCTION MAINTENANCE SCHEDULE APPROACH • LABOR ALLOCATION APPROACH • INTEGRATED APPROACH