CHALLENGES IN CHALLENGES IN MAINTENANCE MAINTENANCE FUNCTIONS FUNCTIONS MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION LEVELS, CAPACITY UTILIZATION, EFFICIENT CAPITAL EMPLOYMENT LEVELS, CAPACITY UTILIZATION, EFFICIENT CAPITAL EMPLOYMENT AND REDUCED LOSSES AND REDUCED LOSSES ELECTRICAL JOBS RELATING TO ALL ELECTRIC PRIME MOVERS, ELECTRICAL JOBS RELATING TO ALL ELECTRIC PRIME MOVERS, POWER CONTROL, PLANNING LOAD DISTRIBUTION POWER CONTROL, PLANNING LOAD DISTRIBUTION CIVIL AND ENVIRONMENTAL JOBS RELATING TO MAINTENANCE CIVIL AND ENVIRONMENTAL JOBS RELATING TO MAINTENANCE ELECTRONIC JOBS RELATED TO SOLID STATE DEVICES AND ELECTRONIC JOBS RELATED TO SOLID STATE DEVICES AND MICROPROCESSOR CONTROL MICROPROCESSOR CONTROL
28
Embed
CHALLENGES IN MAINTENANCE FUNCTIONS MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION LEVELS,
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
CHALLENGES IN CHALLENGES IN MAINTENANCE MAINTENANCE
FUNCTIONSFUNCTIONS MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION LEVELS, CAPACITY UTILIZATION, EFFICIENT CAPITAL EMPLOYMENT LEVELS, CAPACITY UTILIZATION, EFFICIENT CAPITAL EMPLOYMENT AND REDUCED LOSSESAND REDUCED LOSSESELECTRICAL JOBS RELATING TO ALL ELECTRIC PRIME MOVERS, ELECTRICAL JOBS RELATING TO ALL ELECTRIC PRIME MOVERS, POWER CONTROL, PLANNING LOAD DISTRIBUTIONPOWER CONTROL, PLANNING LOAD DISTRIBUTIONCIVIL AND ENVIRONMENTAL JOBS RELATING TO MAINTENANCECIVIL AND ENVIRONMENTAL JOBS RELATING TO MAINTENANCEELECTRONIC JOBS RELATED TO SOLID STATE DEVICES AND ELECTRONIC JOBS RELATED TO SOLID STATE DEVICES AND MICROPROCESSOR CONTROLMICROPROCESSOR CONTROL
EXPECTATIONSEXPECTATIONS
REDUCTION IN UNSCHEDULED REDUCTION IN UNSCHEDULED BREAKDOWNSBREAKDOWNS
ELIMINATION OF TIME SCHEDULED ELIMINATION OF TIME SCHEDULED OVERHAULSOVERHAULS
INCREASE IN OPERATING LIFE OF THE INCREASE IN OPERATING LIFE OF THE ASSETSASSETS
REDUCTION IN DOWNTIMEREDUCTION IN DOWNTIME REDUCTION IN MAINTENANCE MANPOWERREDUCTION IN MAINTENANCE MANPOWER REDUCTION OF SPARES INVENTORYREDUCTION OF SPARES INVENTORY MAXIMIZING EQUIPMENT EFFECTIVENESSMAXIMIZING EQUIPMENT EFFECTIVENESS
TOTAL PREVENTIVE MAINTENANCETOTAL PREVENTIVE MAINTENANCE FAILURE MODE AND EFFECT ANALYSISFAILURE MODE AND EFFECT ANALYSIS CRITICALITY ANALYSISCRITICALITY ANALYSIS PRELIMINARY HAZARD ANALYSISPRELIMINARY HAZARD ANALYSIS FAULT TREE ANALYSISFAULT TREE ANALYSIS HAZOP STUDIESHAZOP STUDIES CAUSE-CONSEQUENCE-COST ANALYSISCAUSE-CONSEQUENCE-COST ANALYSIS INTEGRATING VARIOUS MAINTENANCE SYSTEMSINTEGRATING VARIOUS MAINTENANCE SYSTEMS DETEREMINING AREAS OF CONDITION DETEREMINING AREAS OF CONDITION
MONITORINGMONITORING DOCUMENTATION PROCEDURES AND SYSTEMSDOCUMENTATION PROCEDURES AND SYSTEMS
IDENTIFYING LOSSES DUE TO IDENTIFYING LOSSES DUE TO FAILURES AND ADJUSTMENT OF FAILURES AND ADJUSTMENT OF SPEEDS AND MINOR STOPPAGESSPEEDS AND MINOR STOPPAGES
LOCATING DEFECT LOSSESLOCATING DEFECT LOSSES HAVING PROPER LUBRICATION HAVING PROPER LUBRICATION
SYSTEM FOR ENERGY SAVINGSSYSTEM FOR ENERGY SAVINGS
EFFECTIVE MAINTENANCEEFFECTIVE MAINTENANCE
RESTORE SYSTEM PRODUCTIVITYRESTORE SYSTEM PRODUCTIVITY IMPROVES EQUIPMENT RELIABILITYIMPROVES EQUIPMENT RELIABILITY AVOID UNNECESSARY SHUTDOWNSAVOID UNNECESSARY SHUTDOWNS INCREASE OF EQUIPMENT EFFICIENCYINCREASE OF EQUIPMENT EFFICIENCY PROLONG SYSTEM LIFEPROLONG SYSTEM LIFE IMPROVE OVERALL PLANT EFFECTIVENESSIMPROVE OVERALL PLANT EFFECTIVENESS MAINTAIN PRODUCT QUALITYMAINTAIN PRODUCT QUALITY INCREASE PLANT PROFITINCREASE PLANT PROFIT
OVERTIME WORKED AGAINST PLANOVERTIME WORKED AGAINST PLAN PM SCHEDULE COMPLIANCEPM SCHEDULE COMPLIANCE TIME TAKEN TO ATTEND MAINTENANCE TIME TAKEN TO ATTEND MAINTENANCE
CALLSCALLS BUDGET COMPLIANCEBUDGET COMPLIANCE PM BACKLOG MANHOURSPM BACKLOG MANHOURS CRITICAL EQUIPMENT EFFECTIVESSCRITICAL EQUIPMENT EFFECTIVESS NUMBER OF BREAKDOWNSNUMBER OF BREAKDOWNS PRODUCTION EQUIPMENT PERFORMANCEPRODUCTION EQUIPMENT PERFORMANCE AVAILABILITY AND RELIABILITYAVAILABILITY AND RELIABILITY
WORK SAMPLING TECHNIQUESWORK SAMPLING TECHNIQUES JOB AUDITINGJOB AUDITING SWOT ANALYSISSWOT ANALYSIS EVALUATION BY REPORTSEVALUATION BY REPORTS EVALUATION PROCESS OF PLANT EVALUATION PROCESS OF PLANT
MAINTENANCE OPERATION PROCEDUREMAINTENANCE OPERATION PROCEDURE MAINTENANCE ORGANIZATION AND MAINTENANCE ORGANIZATION AND
COMMUNICATIONCOMMUNICATION PLANNING AND SCHEDULING COMPLIANCEPLANNING AND SCHEDULING COMPLIANCE PLANT SHUTDOWN PROCEDUREPLANT SHUTDOWN PROCEDURE MAINTENANCE PERSONNEL COMPLIANCE TO MAINTENANCE PERSONNEL COMPLIANCE TO
PROCEDURE, ROLES AND RESPONSIBILITIESPROCEDURE, ROLES AND RESPONSIBILITIES INVENTORY MANAGEMENTINVENTORY MANAGEMENT COST COMPLIANCES TO APPROVED BUDGETCOST COMPLIANCES TO APPROVED BUDGET CONTRACTOR PERFORMANCECONTRACTOR PERFORMANCE REGULATORY AND STATUTORY COMPLIANCESREGULATORY AND STATUTORY COMPLIANCES
MAINTENANCE PLAN AUDITMAINTENANCE PLAN AUDIT
WORK REQUESTS / ORDERSWORK REQUESTS / ORDERS EQUIPMENT FAILURE HISTORYEQUIPMENT FAILURE HISTORY EQUIPMENT LIFY CYCLE PROFILEEQUIPMENT LIFY CYCLE PROFILE FAILURE AND ROOT CAUSE ANALYSISFAILURE AND ROOT CAUSE ANALYSIS EQUIPMENT MAINTENANCE EQUIPMENT MAINTENANCE
PLAN/SCHEDULE COMPLIANCEPLAN/SCHEDULE COMPLIANCE MAINTENANCE IMPROVEMENT PLANMAINTENANCE IMPROVEMENT PLAN ASSET CARE MANAGEMENTASSET CARE MANAGEMENT
TECHNICAL AUDITTECHNICAL AUDIT
THERMAL AUDITTHERMAL AUDIT ELECTRICAL AUDITELECTRICAL AUDIT ENERGY AUDITENERGY AUDIT INDUSTRIAL WATER USAGE AUDITINDUSTRIAL WATER USAGE AUDIT COMPRESSED AIR AUDITCOMPRESSED AIR AUDIT PLANT HYDRAULIC SYSTEM AUDITPLANT HYDRAULIC SYSTEM AUDIT PLANT CENTRALIZED LUBRICATION PLANT CENTRALIZED LUBRICATION
MAINTENANCE COSTSMAINTENANCE COSTS FIXED AND VARIABLE COSTSFIXED AND VARIABLE COSTS FIXED COSTS: READY TO SERVE MEN AND FIXED COSTS: READY TO SERVE MEN AND
FACILITIESFACILITIES VARIABLE COSTS: COST OF MAJOR VARIABLE COSTS: COST OF MAJOR
REPAIRS AND OVERHAULS, SPARES, REPAIRS AND OVERHAULS, SPARES, MATERIALS AND FACILITIESMATERIALS AND FACILITIES
DIRECT COSTS – APPARENT COSTS: DIRECT COSTS – APPARENT COSTS: BUDGETED COST AFFECTING THE CASH BUDGETED COST AFFECTING THE CASH FLOW OF ORGN.FLOW OF ORGN. MATERIALS, MAINTENANCE LABOR, OVERTIME, MATERIALS, MAINTENANCE LABOR, OVERTIME,
CONTRACT SERVICES, OVERHEADS ETC.CONTRACT SERVICES, OVERHEADS ETC.
START-UP LOSSESSTART-UP LOSSES MISSED SCHEDULESMISSED SCHEDULES RIPPLE EFFECT ON PRODUCTIONRIPPLE EFFECT ON PRODUCTION COST OF IDLING OR RUNNING AT REDUCED SPEEDCOST OF IDLING OR RUNNING AT REDUCED SPEED EXCESS INVENTORYEXCESS INVENTORY WASTE GENERATIONWASTE GENERATION EMERGENCY PURCHASESEMERGENCY PURCHASES EXTRA CLEAN – UPEXTRA CLEAN – UP CUSTOMER COMPLAINTSCUSTOMER COMPLAINTS REGULATORY/STATUTORY FINESREGULATORY/STATUTORY FINES LOST BUSINESSLOST BUSINESS ENVIRONMENTAL CONTROLSENVIRONMENTAL CONTROLS ACCIDENTSACCIDENTS
REVENUE / CAPITAL COSTSREVENUE / CAPITAL COSTS
COST COVERED BY REVENUE COST COVERED BY REVENUE BUDGET ALLOCATED FOR VARIOUS BUDGET ALLOCATED FOR VARIOUS NORMAL MAINTENANCE ACTIVITIES NORMAL MAINTENANCE ACTIVITIES FOR A GROUP OF EQUIPMENT / FOR A GROUP OF EQUIPMENT / SECTION / SHOPSECTION / SHOP
UNUTILISED BUDGET AMOUNT UNUTILISED BUDGET AMOUNT CANNOT BE CARRIED OVER TO NEXT CANNOT BE CARRIED OVER TO NEXT YEARYEAR
CAPEX – CAPITAL CAPEX – CAPITAL EXPENDITUREEXPENDITURE
COVERED BY CAPITAL BUDGETCOVERED BY CAPITAL BUDGET SPECIFICALLY SANCTIONED FOR SPECIFIC SPECIFICALLY SANCTIONED FOR SPECIFIC
JOBS, EQUIPMENT – ADDITION, JOBS, EQUIPMENT – ADDITION, MODIFICATION, REPLACEMENT SCHEMES MODIFICATION, REPLACEMENT SCHEMES GENERALLY NOT TAKEN IN REGULAR GENERALLY NOT TAKEN IN REGULAR COURSE OF MAINTENANCECOURSE OF MAINTENANCE
NO ADJUSTMENT OF CAPITAL BUDGET NO ADJUSTMENT OF CAPITAL BUDGET PERMISSIBLE FROMMONE EQPT. TO PERMISSIBLE FROMMONE EQPT. TO ANOTHER OR FROM ONE JOB TO ANOTHERANOTHER OR FROM ONE JOB TO ANOTHER
TACKLESTACKLES DIAGNOSTIC AND MEASURING EQUIPMENTDIAGNOSTIC AND MEASURING EQUIPMENT CAPTIVE SHOPS, CENTRAL SERVICESCAPTIVE SHOPS, CENTRAL SERVICES EXTERNAL AGENCIES – TESTING, AUDIT ETC.EXTERNAL AGENCIES – TESTING, AUDIT ETC. CONTRACTORS , MAINTENANCE OUTSOURCINGSCONTRACTORS , MAINTENANCE OUTSOURCINGS TRAINING AND DEVELOPMENTTRAINING AND DEVELOPMENT
UNDERSTAND THE COSTS TO MAINTAIN UNDERSTAND THE COSTS TO MAINTAIN EQUIPMENTEQUIPMENT
IDENTIFY FAILURE MODELS IDENTIFY FAILURE MODELS IDENTIFY OPPORTUNITIES TO REDUCE IDENTIFY OPPORTUNITIES TO REDUCE
COSTSCOSTS VALUE Vs. COST OF SPARES INVENTORIESVALUE Vs. COST OF SPARES INVENTORIES DEVELOP RELIABILITY MODEL DIRECTLY DEVELOP RELIABILITY MODEL DIRECTLY
FROM MAINTENANCE RECORDSFROM MAINTENANCE RECORDS
COST CONTROL IN COST CONTROL IN MAINTENANCEMAINTENANCE
KEEP BREAKDOWN COST DIFFERENT FORM KEEP BREAKDOWN COST DIFFERENT FORM PM, PdM, CBM PM, PdM, CBM
MAINTENANCE PREVENTIONMAINTENANCE PREVENTION USING COST REDUCTION TECHNIQUES – USING COST REDUCTION TECHNIQUES –
REPAIR Vs REPLACE, LIFE CYCLE COSTING REPAIR Vs REPLACE, LIFE CYCLE COSTING WASTE REDUCTION AND WASTE WASTE REDUCTION AND WASTE
RECOVERYRECOVERY SALVAGING OF SPARES SUB-ASSEMBLIESSALVAGING OF SPARES SUB-ASSEMBLIES
MAINTENANCE BUDGETMAINTENANCE BUDGET
BUDGET IS A FORECAST OF BUDGET IS A FORECAST OF EXPENDITURES AND REVENUESEXPENDITURES AND REVENUES
APPROPRIATION BUDGETS: LUMPSUM APPROPRIATION BUDGETS: LUMPSUM AS THE MAX. AMOUNT THAT CAN BE AS THE MAX. AMOUNT THAT CAN BE SPENT FOR A GIVEN ITEMSPENT FOR A GIVEN ITEM
FIXED BUDGETS: SPECIFY FIXED BUDGETS: SPECIFY ALLOWABLE AMOUNT OF COST FOR A ALLOWABLE AMOUNT OF COST FOR A PERIOD OF TIMEPERIOD OF TIME
FLEXIBLE BUDGETFLEXIBLE BUDGET
PREPARATION OF PREPARATION OF MAINTENANCE BUDGETMAINTENANCE BUDGET
ALLOCATE REVENUE AND EXPENSES ALLOCATE REVENUE AND EXPENSES USING TOP DOWN / BOTTOM UPUSING TOP DOWN / BOTTOM UP
PRODUCTION MAINTENANCE PRODUCTION MAINTENANCE SCHEDULE APPROACHSCHEDULE APPROACH