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