WELCOME

Most people become engineers because they feel at least some affinity for things, be they Mechanical, Electrical or Structural
This affinity leads them to derive pleasure from assets in good condition, but to feel offended by assets in poor condition - John Moubray

MAINTENANCE
IN INDUSTRIES

HAT HY HEN HERE

WHAT ?

MAINTENANCE DEFINED

THE DICTIONARY MEANING

CAUSE TO CONTINUE (OXFORD) KEEP IN AN EXISTING STATE

(WEBSTER)

MODERN CONCEPT
Ensuring that physical assets continue to do

what their users want them to do

WHAT WE DO IN MAINTENANCE

MAINTENANCE TASKS

PREVENTIVE
ON RUN

FITCAL FITCAL REPAIR REPLACE

ON SHUTDOWN

Usually opportunities

Usually Planned S/D AS GOOD AS BEFORE AS GOOD AS NEW

CORRECTIVE
REPAIR REPLACE

GENERATIONS OF MAINTENANCE PRACTICE

REACTIVE INTERACTIVE

PROACTIVE

MAINTENANCE PRACTICE

REACTIVE
WAIT FOR BREAKDOWN RUN TO SET

HIGH COST DUE TO UNSCHEDULED PRODUCTION LOSS INCREASED EQUIPMENT DAMEGE SEVERETY
PRE WORLD WAR II

MAINTENANCE PRACTICE

INTERACTIVE
ACTION BEFORE FAILURE
PREVENTIVE ACTION BY CONSTANT

INTERACTION TIME BASED - SECOND GENERATION

DIFFICULTY IN DECIDING TIME HIGHER COST IMPLICATION WHEN TIME IS NOT OPTIMAL

CONDITION BASED THIRD GENERATION PREDICTION OF FAILURE BASED ON SIGNAL TECHNOLOGY BASED

MAINTENANCE PRACTICE

PROACTIVE
A MODERN APPROACH ELEMINATION OF MAINTENANCE NEED

BY DESIGN USE AND THROW CONCEPT LIMITED USE IN INDUSTRIES

WHEN & WHERE ?

PREVENTIVE REPAIR/ REPLACEMENTS

TIME BASED
Requires Engineering and Managerial skill to

decide the TIME

CONDITION BASED
Requires Technology support and/or Technical

Expertise

LIMITATION OF TIME BASED PREVENTIVE MAINTENANCE

Too short interval between shutdowns:

Costly maintenance due to erosion of machine

productive life.
Possibility of human error due to frequent

reassembly resulting in costly breakdowns.

Too long interval between shutdowns:

Increased instances of equipment failures

during operation.

TIME BASED PM SOME

ANSWERS

MANUFACTURERS RECOMMENDATIONS
EXPERIENCE QUANTITATIVE TECHNIQUES
PROBABILITY CURVE
RELIABILITY AND COST FUNCTION

WHERE PM ?

IS PM VIABLE IN ALL CASES? HOW ABOUT CHANGING A ELECTRONIC CARD - SAY EVERY YEAR ? DOES IT HAVE A PREDICTED LIFE ?

FAILURE RATE OF AN EQUIPMENT

PROBABILITY OF FAILING AT A GIVEN TIME

PROBABILITY MAY CHANGE WITH TIME

VIABLE PM

WHEN FAILURE RATE IS INCREASING WITH TIME CONSTANT FAILURE RATE NO PM ACTION BUT WAIT FOR B/D RUNNING COST IS ALSO A FACTOR

CONDITION BASED MAINTENANCE

ON-LINE OR OFF-LINE MONITORING FREQUENCY OF OFF-LINE MONITORING

THE DELAY TIME FAULT OCCURRENCE STATISTICS

TIMELY ACTION BASED ON OBSERVATION OF FAULT

WHY ?

WHY MAINTENANCE
The Simple answer is All systems exposed to real world Deteriorates Maintenance arrests deterioration

Still it is the most undesirable task!!

WHY MAINTENANCE IS NOT DESIRABLE

MACHINE DOES NOT PRODUCE WHEN BEING MAINTAINED COST INCURRED IS HIGH A SUNK COST? MAINTAINABILITY IS DOUBTFUL

IDLE ASSET IN SAIL

10 % NONAVAILABILITY OF ASSETS MEANS 1500 Crs. LOSS

HOURLY LOSS OF OPERATING PROFIT DUE TO STOPPAGE OF PRODUCTION IN MAJOR UNITS OF RSP
DEPARTMENT COKE OVENS SINTER PLANT II BLAST FURNACE STEEL MELTING SHOP-II PLATE MILL HOT STRIP MILL COLD ROLLING MILL SILICON STEEL MILL ERW PIPE PLANT LOSS PER HOUR ( Rs.) 2 LAKHS 10 THOUSANDS 1 LAKH 17 LAKHS 60 THOUSANDS 7 LAKHS 81 THOUSANDS 5 LAKHS 15 THOUSANDS 21 LAKHS 60 THOUSANDS 19 LAKHS 45 THOUSANDS 2 LAKHS 23 THOUSANDS 1 LAKH 38 THOUSANDS

IMPORTANCE OF MAINTENANCE IN STEEL PLANT

HEAVY, COSTLY AND COMPLEX EQUIPMENT SUBJECTED TO HEAVY LOAD, SHOCK, HEAT, DUST ETC. INTERDEPENDENT UNITS SERIES CONFIGURATION- SINGLE LINE DEMANDING PRODUCTION TARGETS MARKET COMPETITION

Response from a diverse group of plant managers Responsible for the costs that could be avoided .
Responsible for hindrance in exploiting opportunity for additional production (competitive advantage). Responsible for under utilization of asset and human resource.

FACTS ON MAINTENANCE ENGINEERING

NO SPECIFIC CURRICULUM IN COLLEGES

NEITHER IN ENGINEERING COURSE NOR IN MANAGEMENT STUDIES

WIDEST GAP BETWEEN THEORY AND PRACTICE IN THIS AREA LITTLE INPUTS AVAILABLE IN LITERATURE WORLD SUPPLIER HIDES MANY FACTS

Maintenance - Some more Perceptions

At the bottom of the management group.

Not highly valued. How good are maintenance budgets and how effectively are they utilized? How many organizations treat maintenance as a business centre and NOT as a simple cost centre?

THE PLIGHT OF A MANAGER

QUICK DELIVERY

QUALITY JOB

COST REDUCTION

SAFETY & ENVIRONMENT

MAINTENANCE SEEMS TO HAVE PROBLEMS EMBEDDED IN ITS HISTORY

BUT

Most people become engineers because they feel at least some affinity for things, be they Mechanical, Electrical or Structural
This affinity leads them to derive pleasure from assets in good condition, but to feel offended by assets in poor condition - John Moubray

The only Option for Maintenance fraternity

To be EFFICIENT and EFFECTIVE through a ROBUST MANAGEMENT SYSTEM

HOW ?

ANAGEMENT IN INDUSTRIES
MONEY
MAN
MACHINE

MATERIAL

PERSONNEL MANAGEMENT

MATERIALS MANAGEMENT

FINANCIAL MANAGEMENT

MANAGEMENT TOOLS FOR MAINTENANCE

PRIOR TO INSTALLATION: 10% OF LIFE CYCLE

ASSET MANAGEMENT / INVESTMENT MANAGEMENT

(MOSTLY A FINANCIAL MANAGEMENT ACTIVITY)

AFTER INSTALLATION: 90% OF LIFE CYCLE

MAINTENANCE MANAGEMENT
A LESS HEARD JARGON

TODAYS SCENARIO

Humanity continues to depend to an ever increasing extent on the wealth generated by highly mechanised and automated business. We also depend more and more on services such as:
Uninterrupted power supply Trains running on time

In short, this depends on continued integrity of physical assets. Equipment failure not only erodes wealth and interrupt services but threatens our survival with worst accidents and environmental incidents like:
Bhopal gas tragedy

TODAYS SCENARIO

There is a rapidly growing awareness of the extent

To which equipment failure affect Safety and

Environment The connection between Maintenance and product quality To achieve availability when user require it
To contain cost

MAINTENANCE GOALS

MAXIMIZATION OF AVAILABILITY REDUCTION IN MAINTENANCE COST ENSURING QUALITY PRODUCTION SAFETY AND ENVIRONMENT

MAINTENANCE OBJECTIVES

STRATEGIC OBJECTIVES

To extend the useful life of Capital Assets

CRITICAL OBJECTIVES

To ensure safety of personnel & Equip. To control / reduce maintenance cost To ensure Quality in equipment performance

MAINTENANCE OBJECTIVES

MEDIUM TERM OBJECTIVE

To ensure maximum availability of equipments to achieve target production To execute necessary repairs & to carryout systematic maintenance to ensure the health of equipment To plan & make available required spares and consumables of right quality in right quantity at right time To eliminate unscheduled stoppages and break downs To ensure operational readiness of standby equipment

SHORT TERM OBJECTIVES

MAINTENANCE SYSTEMS

CENTRALIZED SYSTEM

DECENTRALIZED SYSTEM MIXED SYSTEM

CENTRALIZED SYSTEM

ADMINISTRATIVE CONTROL WITH

CHIEF OF MAINT. OF PLANT

FLEXIBLE RESOURCE MOBILIZATION

BETTER INVENTORY CONTROL

STANDARDIZED/ UNIFORM POLICY

DECENTRALIZED SYSTEM

RESPONSIBILITY WITH HEAD OF DEPTT. BETTER CO-ORDINATION BETWEEN OPERATION OWNINGNESS SPECIALIZED JOBS THROUGH CONTRACTS NO EXPERTISE

MAINTENANCE ORGANISATION AT SAIL

MIXED SYSTEM OWNING AND RESPONSIBILITY OF EQUIPMENT WITH DEPARTMENTS

OVERALL FUNCTIONAL RESPONSIBILITY WITH

CHIEF OF MAINTENANCE SYSTEMS, POLICIES

SUPPORT OF CENTRALIZED EXPERTISE AND SERVICES

DECENTRALIZED ORGANIZATION

DEPARTMENT LEVEL MAINTENANCE MAINTENANCE ( MECH & ELECT.) UNDER HEAD OF THE DEPTT. SEPARATE GROUPS UNDER HEAD OF MECH & ELECT. PLANNING GROUP INSPECTION GROUP REPAIR GROUP

CENTRALIZED SERVICES IN MAINTENANCE

CENTRALISZD SERVICES / SUPPORT GROUPS UNDER GM(MECH), GM(ELECT.), GM(CIVIL)

EXAMPLES :

DESIGN DEPARTMENT CRANE / ROTATING EQUIP MAINT. DEPT ENGINEERING SHOPS/ REPAIR SHOPS CBMS/CMMS INSTRUMENTATION AIR CONDITIONING ELECTRONICS CIVIL MAINT STRUCTURAL INSPECTION

SYSTEMATIC MAINTENANCE APPROACH

DEFINED MAINTENANCE POLICIES PLANNED ACTIVITIES ROBUST LINKAGES BETWEEN ACTIVITIES DOCUMENTATION OF ACTIVITIES AND HAPPENINGS TRANSPARENT ORGANIZATION

EQUIPMENT DEFINED

MAINTENANCE JOB CATALOGUE

SMP

PREVENTIVE MAINT. JOBS TIME BASED JOBS REPAIR & REPLACEMENT JOBS

CORRECTIVE MAINT. JOBS CONDITION BASED JOBS

BREAKDOWN RECORDING

INSPECTION JOBS

MIS

INSPN. SCHEDULE

DEFECT RECORDING

MIS

ANALYSIS FOR AVAILABILITY ROOT CAUSE REPETITION

JOB EXECUTION & HISTORY RECORDING

DEFECT BASED JOB LISTING

EXECUTION PLAN PM1c

SHUTDOWN PLAN (WEEKLY/ MONTHLY/ ANNUAL)

RE-DESIGN DECISION

TILL NEXT SESSION ..