Solutions for Industrial Services

Maintenance is a topic for the top management: from reactive fault repair to a value adding factor

Tobias Zaers

Maintenance is a topic for the top management

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Costs:• Personnel• Depreciation• Operation supply material• Maintenance (DIN 31051:2003)

• Maintenance• Inspection• Repair• Improvement

Effizienz einer Anlage

CostsReliabilityAvailability

Reactive fault repair

Efficiency

Maintenance is a topic for the top management

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Impacts of reactive fault repair to efficiency

Efficiency ist the top target for the operation of production equipment. This means to guarantee high reliability and availability for lowest cost.

Within DIN 31051 reactive failure repair is defined as apart of the whole maintenance subject. Repair in this context is defined as „the measures that are leading a specific element back to the operational condition, except improvement measures.“

Reactive fault repair is not leading to an increase of reliablity and availability and therefore can not contribute to an increase of efficiency.

Maintenance is a topic for the top management

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Increase of reliability and availability

ReliabilityAvailability

WorkOptmisation

Reduction of down times

Reduction of reaktive work

Tools, Methods & Techniques

Tools, Methods & Techniques

Tools, Methods & Tecniques Tools, Methods &

Techniques

Execution Efficiency

Improvemnt of planning

Plannable efforts

Improvement

Reduction of reactive work

Quality improvement in execution

Reduction ofimmediate

assignments

Maintenance is a topic for the top management

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Increase of reliability and availability

A reduction of downtimes is only available by preventive maintenance or improvement of the equipment. Repairs are only leading back to the operational condition, causes of failure howevere are not eliminated.

An improvement of the equipment will allow to reduce future reactive assignments.

An improvement of the planning allows efficient maintenance execution as efforts can be optimised and cost could be saved.

To be able to realise these measures tools, methods and techniques are necessary. To using these, specific training or consultancy is required.

The use of sophisticated technologies for condition monitoring can further increase reliability and availability as imminent failures can be predicted with higher accuracy. Wearing parts can be used to their maximum lifetime. Unusual equipment conditions can quickly be recognised.

Maintenance is a topic for the top management

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Maintenance potentials

1.500

7.500

Direct

Indirect

Maintenance cost in Europe (in Mrd. €)

Personnel, operating supplies, spare partsmaintenance systems

DowntimesQuality failuresLegal consequencesLoss of imageStorage costInvestment for replacement

Estimated potential 5-25%

Source: Trends, Potenziale und Handlungsfelder Nachhaltiger Instandhaltung Ergebnisbericht der vom BMBF geförderten Untersuchung „Nachhaltige Instandhaltung“; FVI – Forum Vision Instandhaltung e.V.

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Requirements for maintenance management

Exploitation ofMaintenanceOpportunities

Economy

Information Technology

Technology

OrganisationLegal Requirements

Produktion PlanningPurchasing

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Requirements to the Maintenance Management

To exploit maintenance opportunities diverse areas have to be oncorporated Economics (e.g. for investments) Technology developments Organisation Production Planning (Integration of maintenance planning) Purchasing and materials management (optmised storage and procurement

prcesses) Legal requirements …

The common competence of maintenance managers is not allowing to deal with the requirements in a comprehensive way. The realisation of successful concepts requires strategic decisions and support by the top level.

Therefore it is of utmost importance for the top management to know the potentials to be able to make successful implementation maintenance concepts a part of the company strategy and to initiate the work on those concepts.

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Lifecycle

Further optimisation of maintenance can be supported by specialised service

partners or groups whose core competency is the develoment and realisation of maintenance strategies.

Maintenance is a topic for the top management

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Maintain 2007

The Maintain 2007 offers top managers a forum to broadly inform themselves on the topic maintenance.

Big companies as well as small and medium sized companies are offered the opportunity to collect information and share experience.

Solutions for Industrial Services

Thanks for your attention!