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
NON-EFFECTIVE MAINTENANCENON-EFFECTIVE MAINTENANCE
INCREASED MAINTENANCE COSTINCREASED MAINTENANCE COST REDUCED SYSTEM / EQUIPMENT LIFEREDUCED SYSTEM / EQUIPMENT LIFE INDUCED / CREATED UNWANTED WASTEINDUCED / CREATED UNWANTED WASTE ADDITIONAL COST TO CLEAN THE EQUIPMENTADDITIONAL COST TO CLEAN THE EQUIPMENT CAN AFFECT PRODUCT QUALITYCAN AFFECT PRODUCT QUALITY REDUCED PLANT PRODUCTIVITYREDUCED PLANT PRODUCTIVITY DOWNGRADED SYSTEM EFFECTIVENESSDOWNGRADED SYSTEM EFFECTIVENESS DECREASED PLANT PROFITDECREASED PLANT PROFIT POOR SKILL LEVELPOOR SKILL LEVEL REPITITIVE FAILUREREPITITIVE FAILURE
OVERALL EQUIPMENT OVERALL EQUIPMENT EFFECTIVESSSEFFECTIVESSS
AVAILABILITYAVAILABILITY PERFORMANCE RATEPERFORMANCE RATE QUALITY RATEQUALITY RATE MTBF , MTTR, MUT, MDT, MCT, MLDTMTBF , MTTR, MUT, MDT, MCT, MLDT INHERENT AVAILABILITYINHERENT AVAILABILITY STEADY-STATE AVAILABILITYSTEADY-STATE AVAILABILITY OPERATIONAL AVAILABILITYOPERATIONAL AVAILABILITY
KEY PERFORMANCE KEY PERFORMANCE INDICATORSINDICATORS
INCREASE EQUIPMENT RELIABILITYINCREASE EQUIPMENT RELIABILITY NUMBER OF UNITS REJECTED BY NUMBER OF UNITS REJECTED BY
QUALITY INSPECTIONQUALITY INSPECTION ZERO DEFECTSZERO DEFECTS SIX SIGMASIX SIGMA ZERO ACCIDENTSZERO ACCIDENTS MAXIMIZING O.E.E.MAXIMIZING O.E.E.
MAINTENANCE KEY MAINTENANCE KEY PERFORMANCE INDICATORSPERFORMANCE INDICATORS
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
MAINTENANCE PERFORMANCE MAINTENANCE PERFORMANCE ANALYSISANALYSIS
WORK SAMPLING TECHNIQUESWORK SAMPLING TECHNIQUES JOB AUDITINGJOB AUDITING SWOT ANALYSISSWOT ANALYSIS EVALUATION BY REPORTSEVALUATION BY REPORTS EVALUATION PROCESS OF PLANT EVALUATION PROCESS OF PLANT
ENGINEERING - BENCHMARKINGENGINEERING - BENCHMARKING
MANUFACTURING BASED MANUFACTURING BASED MODELMODEL
PLANT OUTPUTPLANT OUTPUT MAINTENANCE INPUTSMAINTENANCE INPUTS
SERVICE BASED MODELSSERVICE BASED MODELS QUALITY BASED PERFORMANCE PARAMETERS – QUALITY BASED PERFORMANCE PARAMETERS –
AVAILABILITY, RELIABILITY, WAITING TIMEAVAILABILITY, RELIABILITY, WAITING TIME OPERATION BASED PERFORMANCE OPERATION BASED PERFORMANCE
PARAMETERS – OVERTIME, REPAIR MEAN TIME PARAMETERS – OVERTIME, REPAIR MEAN TIME ETC.ETC.
MAINTENANCE PERFORMANCE MAINTENANCE PERFORMANCE MEASURE INDICATORSMEASURE INDICATORS
QUALITY BASED INDICESQUALITY BASED INDICES AVAILABILITYAVAILABILITY EQUIPMENT RELIABILITY: MTBS, MTTF, EQUIPMENT RELIABILITY: MTBS, MTTF,
MTTR, MTBM, FAILURE RATEMTTR, MTBM, FAILURE RATE EQUIPMENT MAINTAINABILITY: MTDEQUIPMENT MAINTAINABILITY: MTD EQUIPMENT UTILIZATIONEQUIPMENT UTILIZATION MANPOWER EFFICIENCYMANPOWER EFFICIENCY REACTIVE REPAIR RATIOREACTIVE REPAIR RATIO
PERFORMANCE BASED INDICESPERFORMANCE BASED INDICES
MAINTENANCE COST PER UNIT MAINTENANCE COST PER UNIT PRODUCTIONPRODUCTION
MAINTENANCE COST / HOURMAINTENANCE COST / HOUR TOTAL PLANT MAINTENANCE TOTAL PLANT MAINTENANCE
PRODUCTIVITYPRODUCTIVITY % COST SCHEDULED MAINTENANCE% COST SCHEDULED MAINTENANCE % MAINTENANCE COST TO % MAINTENANCE COST TO
INVESTMENTINVESTMENT
% SCHEDULE COMPLIANCE% SCHEDULE COMPLIANCE SCHEDULE LOADING FACTORSCHEDULE LOADING FACTOR WRENCH TIMEWRENCH TIME MAINTENANCE WORK CAPACITY MAINTENANCE WORK CAPACITY
INDEXINDEX
MAINTENANCE OPERATION MAINTENANCE OPERATION AUDITAUDIT
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
SYSTEM AUDITSYSTEM AUDIT
MAINTENANCE BENCHMARKINGMAINTENANCE BENCHMARKING
STRATEGIC BENCHMARKINGSTRATEGIC BENCHMARKING PERFORMANCE BENCHMARKINGPERFORMANCE BENCHMARKING PROCESS BENCHMARKINGPROCESS BENCHMARKING FUNCTIONAL BENCHMARKINGFUNCTIONAL BENCHMARKING INTERNAL BENCHMARKINGINTERNAL BENCHMARKING EXTERNAL BENCHMARKINGEXTERNAL BENCHMARKING INTERNATIONAL BENCHMARKINGINTERNATIONAL BENCHMARKING
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.
INDIRECT COSTS – HIDDEN INDIRECT COSTS – HIDDEN COSTSCOSTS
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
MAINTENANCE COST MAINTENANCE COST COMPONENTSCOMPONENTS
READY TO SERVEREADY TO SERVE CONDITION MONITORING – FACILITIESCONDITION MONITORING – FACILITIES PM, PdM, CBMPM, PdM, CBM CORRECTIVE MAINTENANCECORRECTIVE MAINTENANCE MAJOR REPAIR, OVERHAULS, REVAMPINGMAJOR REPAIR, OVERHAULS, REVAMPING MATERIALS – SPARES, CONSUMABLES, TOOLS, MATERIALS – SPARES, CONSUMABLES, TOOLS,
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
REGULATORY / STATUTORY REGULATORY / STATUTORY EXPENDITURESEXPENDITURES
INSURANCE LIABILITESINSURANCE LIABILITES NON WORKING MAINTENANCE LABORNON WORKING MAINTENANCE LABOR MAINTENANCE WORK DONE BY MAINTENANCE WORK DONE BY
PRODUCTION EMPLOYEESPRODUCTION EMPLOYEES NON CAPITAL PLANT IMPROVEMENTSNON CAPITAL PLANT IMPROVEMENTS
MAINTENANCE COST ANALYSISMAINTENANCE COST ANALYSIS
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
COST-CONSCIOUS MAINTENANCE COST-CONSCIOUS MAINTENANCE PERSONNELPERSONNEL
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
LABOR ALLOCATION APPROACHLABOR ALLOCATION APPROACH INTEGRATED APPROACHINTEGRATED APPROACH