My Project

A PRESENTATION ON

REINVENTING THE MAINTENANCE DEPARTMENT

TO INCREASE ITS EFFICIENCY AND EFFECTIVENESS

BY

EKECHUKWU IKECHINEKE COLLINS

23 APRIL, 2015

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.

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

INTRODUCTION TO KEY CONCEPTSTYPES 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.

INTRODUCTION TO KEY CONCEPTSEFFICIENCY• 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.

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

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.

REINVENTING THE MAINTENANCE DEPARTMENT

The proposed layout of the maintenance workshop for the maintenance department is shown below;

REINVENTING THE MAINTENANCE DEPARTMENT

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

Accommodate Interrupt Schedule

=

ContinuousImprovement

PlanJobs

Schedule Jobs

for theNext Period

AuthorizeCosts

CollectCosts &

JobFeedback

Allocate and Do the

Work

PrioritizeWork

Review and Approve Requests

Non Routine Work Flow

Unplanned Jobs

Routine Work Flow

REINVENTING THE MAINTENANCE DEPARTMENT

2. The proposed maintenance process flow chart

REINVENTING THE MAINTENANCE DEPARTMENT

3. Using Computerized Maintenance Management System for planningA CMMS software package maintains a computer database of

information about an organization’s maintenance operations i.e. CMMIS-computerized maintenance management information systemIt performs the following functions• Tracking Work Orders• Scheduling Tasks• Recording Assets History• Managing Inventory• Audit and Certification

REINVENTING THE MAINTENANCE DEPARTMENT

4. Training of Maintenance PersonnelTo 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.

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

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

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.

CONCLUSION

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

-HENRY FORD

THAT IS

ALL