Dubrovnik Airport Galiot Conference, Split 8/9. MAY 2014. Author: Tomislav Macan, DBV Airport Chief Technical Officer

GALIOT – MAINTENANCE

Dubrovnik Airport

Galiot Conference, Split 8/9. MAY 2014.

Author: Tomislav Macan, DBV Airport Chief Technical Officer

Maintenance function

All actions necessary for retaining an item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification

Increase availability of a system Keep system’s equipment in working

order



Question? Why do we need maintenance? What are the costs of doing

maintenance? What are the costs of not doing

maintenance? What are the benefits of maintenance? How can maintenance increase

profitability of company?



Purpose of Maintenance

Attempt to maximize performance of production equipment efficiently and regularly

Prevent breakdown or failures Minimize production loss from failures Increase reliability of the operating

systems



Principle Objectives in Maintenance To achieve product quality and

customer satisfaction through adjusted and serviced equipment

Maximize useful life of equipment Keep equipment safe and prevent

safety hazards Minimize frequency and severity of

interruptions Maximize production capacity –

through high utilization of facilityGaliot Conference, Split 8/9. MAY 2014.


Maintenance Objectives

Must be consistent with the goals of production (cost, quality, delivery, safety)

Must be comprehensive and include specific responsibilities



Maintenance Costs

Cost to replace or repair Losses of output Delayed shipment Scrap and rework



Maintenance types

Three types of maintenance

Breakdown maintenance – emergency or priority repairs on failed equipment

Preventive (scheduled) maintenance – routine inspection and servicing to keep facilities in good repair

Predictive (Condition-based) maintenance



Corrective or Breakdown Maintenance

Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed and can not perform its normal function anymore

Quite justified in small factories where: Down times are non-critical and repair costs are

less than other type of maintenanceFinancial justification for scheduling are not felt



Disadvantages of Corrective Maintenance Breakdown generally occurs inappropriate times

leading to poor and hurried maintenance Excessive delay in production & reduces output Faster plant deterioration Increases chances of accidents and less safety

for both workers and machines More spoilt materials Direct loss of profit Can not be employed for equipments regulated

by statutory provisions e.g. cranes, lift and hoists etc



Preventive Maintenance (PM) Principle – “Prevention is better than cure” Procedure - Stitch-in-time It

locates weak spots of machinery and equipments

provides them periodic/scheduled inspections and minor repairs to reduce the danger of unanticipated breakdowns



Implementing Preventive Maintenance Need to know when a system requires

service or is likely to fail High initial failure rates are known as

infant mortality Once a product settles in, MTBF

generally follows a normal distribution Good reporting and record keeping can

aid the decision on when preventive maintenance should be performed



Candidates for Preventive Maintenance

Mean Time Between Failure (MTBF)

Frequency of FailureGood candidates have more normal distribution with low variability



Advantages of PM Advantages:

Reduces break down and thereby down time Lass odd-time repair and reduces over time of crews

Greater safety of workersLower maintenance and repair costsLess stand-by equipments and spare partsBetter product quality and fewer reworks and scraps

Increases plant lifeIncreases chances to get production incentive bonus



Predictive (Condition-based) Maintenance In predictive maintenance, machinery

conditions are periodically monitored and this enables the maintenance crews to take timely actions, such as machine adjustment, repair or overhaul

It makes use of human sense and other sensitive instruments, such asaudio gauge, vibration analyzer, amplitude meter, pressure, temperature and resistance strain gauges etc.



Predictive Maintenance (Contd.)

Unusual sounds coming out of a rotating equipment predicts a trouble

An excessively hot electric cable predicts a trouble

Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble



Computerized Maintenance System

Output Reports

Inventory and purchasing reports

Equipment parts list

Equipment history reports

Cost analysis (Actual vs. standard)

Work orders– Preventive

maintenance– Scheduled

downtime– Emergency

maintenance

Data entry– Work requests– Purchase

requests– Time reporting– Contract work

Data Files

Personnel data with skills,

wages, etc.

Equipment file with parts list

Maintenanceand work order

schedule

Inventory of spare parts

Repair history file



Maintenance Costs The traditional view attempted to

balance preventive and breakdown maintenance costs

Typically this approach failed to consider the true total cost of breakdowns Inventory Employee morale Schedule unreliability



Maintenance Costs – traditional view

Total costs

Breakdown maintenance costs

Cos

ts

Maintenance commitment

Preventive maintenance costs

Optimal point (lowestcost maintenance policy)



Maintenance Costs – Full cost view

Cos

ts

Maintenance commitmentOptimal point (lowest

cost maintenance policy)

Total costs

Full cost of breakdowns

Preventive maintenance costs



How Maintenance is Performed

Operator Maintenance department

Manufacturer’s field service

Depot service(return equipment)

Preventive maintenance costs less and is faster the more we move to the left

Competence is higher as we move to the right



Total Productive Maintenance (TPM) Designing machines that are reliable, easy

to operate, and easy to maintain Emphasizing total cost of ownership when

purchasing machines, so that service and maintenance are included in the cost

Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot service

Training workers to operate and maintain their own machines



Categorization of facilities, equipment and systems



DUBROVNIK AIRPORT MAINTENANCE CONCEPT

Documents : Zakon o zračnom prometu 69/09 (čl. 79) Pravilnik o aerodromima NN 64/12 Pravilnik o održavanju i pregledanju aerodroma te mjerama potrebnim

za njegovu sigurnu uporabu, NN 65/05 ICAO Annexes and Airport service manuals (Annex 9)

Brochures and practices: Strategic Approach to Facilities Life Cycle Management Product technical sheets “Best practice”

• the result is



Aerodromski priručnik poglavlje 4.7.

INTERNI PRIRUČNIK ZA ODRŽAVANJE

1. OPREMA ZA PRIHVAT I OTPREMU ZRAKOPLOVA I PUTNIKA

2. VOZILA IZVAN PLATFORME

3. ELEKTRO OPREMA

4. ELEKTRONIČKA OPREMA

5. STROJARSKA OPREMA

6. OBJEKTI I INFRASTRUKTURA

7. RTG UREĐAJI

8. INFORMATIKAGaliot Conference, Split 8/9. MAY 2014.


GALIOT Device structure



Galiot Device structure layers

Categories: 96 (GSE 19)

Devices: 600 (GSE 300)

Procedures: 400



GALIOT Departments



ImplementationYear of admin. % of admin. in 2013.

GSE equipment 2003. 100

Public vehicles 2003. 100

Electro eq. 2005. 100

Electronics 2009. 50

Mechanic eq. 2009. 50

Infrastructure 2005. 90

Security eq. 2006. 100

IT 2010. 50



GALIOT History at DBV Airport 2003. - Maintenance of GSE equipment 2004. – UKMP, Accident report, NOTAM, RIFF,

Update with lighting equip. 2005. – update with electrical equip. and infrastrucutre 2006. – reporting, messaging, alarm, scheduling,

update with security equip. 2008. – Emergency module 2009. – update with Airport manual (incl. electronic

and mechanic equip.). Iphone application for Emergency module

2010.-2013. full integration of Galiot based at Airport Manual including new module structure.



GALIOT Maintenance 2014.



Izbornik 1



Izbornik 2



Report – GSE Maintenance



Report – Lighting Maintenance



Report – GSE repair



Statistics and Audits2013.

Preventive maintenance

Repairs Upgrade and new

Outsourcing

GSE equipment (aprox. 120 selfpropelled + 200 towed units)

517 (without weekly overhaul by operators)

580 18 8

AUDITS by Airlines, Agency and others Authorities: Total 15-20 yearly checking procedured and SLA of which 3-5 checking in detail GSE maintenance and 2-3 checking in detail operational surfaces, pavements,

strips, lighting, signage and markings.



GALIOT – Maintenance conclusion

easy planning and control automatic counting and scheduling self-made procedures easy administration useful reports and notifications important warnings by levels history



GALIOT – Maintenance module

THANKS TO MER SYSTEMS

for development of the module according to best practice and

custom made by DBV Airport inside National and EU regulatory frame

&

keep it up to date.



THANK YOU

Tomislav Macan, DBV Airport Chief Technical [email protected]

mailto:[email protected]