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CII Naoroj i Godrej Centre of Excellence

Workshop onPredictive & Preventive Maintenance

Basics & Practices

12 13 April 2013: Pune

Preventive Maintenance (Time based)Maintenance repairs are performed on a regular schedule to minimize component degradation and extend the life of equipment.

Preventive maintenance is performed after a set amount of elapsed calendar time or machine run time, regardless of whetherthe repair is needed. While more cost-effective than reactive maintenance, preventive maintenance still requires substantiahuman resources and replacement parts inventories.Preventive maintenance which was chosen as an improvement step over Breakdown Maintenance is of immense importance inindustries. The output & quality of next step process is quite dependent on previous process. Hence it is very important that allprocesses are managed efficiently. Preventive maintenance plays important role here in upkeep of all process equipments.

Predictive Maintenance (Condition based)

Predictive maintenance can be defined as measurements that detect the onset of degradation mechanism, thereby allowingcausal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Resultsindicate current and future functional capability. Basically, predictive maintenance differs from preventive maintenance by basingmaintenance need on the actual condition of the machine rather than on some preset schedule. Preventive maintenance is time-based. Activities such as changing lubricant are based on time, like calendar time or equipment run time. For example, mostpeople change the oil in their vehicles every 5,000 to 8,000 Kms travelled. This is effectively basing the oil change needs onequipment run time. No concern is given to the actual condition and performance capability of the oil. It is changed because it istime. This methodology would be analogous to a preventive maintenance task. If, on the other hand, the operator of the cardiscounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubricationproperties, he/she may be able to extend the oil change until the vehicle had travelled 15,000 Kms. This is the fundamentaldifference between predictive maintenance and preventive maintenance, whereby predictive maintenance is used to defineneeded maintenance task based on quantified material/equipment condition.

The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance programme will all but

eliminate catastrophic equipment failures. In fact, independent surveys indicate the following industrial average savings resultanfrom initiation of a functional predictive maintenance programme. Return on investment: 10 times Reduction in maintenance costs: 25% to 30% Elimination of breakdowns: 70% to 75% Reduction in downtime: 35% to 45% Increase in production: 20% to 25%.Advantages Increased component operational life/availability Allows for preemptive corrective actions Decrease in equipment or process downtime Better product quality Improved worker and environmental safety Improved worker morale

Energy savings. Estimated 8% to 12% cost savings over preventive maintenance programme

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Considering their unquestionable utility, ISO / TS 16949 standard includes Preventive & Predictive Maintenance inclause 7.5.1.4 which states that : The organisation shall identify key process equipments & provide resources formachine/ equipment maintenance & develop an effective planned total preventive maintenance system. Also itdescribes at least the inclusions like Planned Maintenance activities & use of Predictive Maintenance methods tocontinually improve effectiveness & efficiency of the production equipment.

Workshop Objectives :

To understand the concepts & methods of Preventive & Predictive Maintenance

To understand how to Implement Preventive & Predictive Maintenance

To understand how to gradually replace TBM activities by CBM activities

To appreciate use of modern technologies in equipment maintenanceWorkshop Contents : The workshop contains ten modules as follows.Module 1 Historical Background & Types of MaintenanceReactive(Panic), Preventive, Corrective & Predictive Maintenance, Reliability Centered, Proactive MaintenanceModule 2 Objectives of Maintenance & Documents of MaintenanceGeneral Objectives P,Q,C,D,S,M : MTTR, MTBF & MTBQFDocuments : Master List of Equipments, Equipment History Cards, Spare Parts Ledger, Preventive Maintenance Charts &SchedulesModule 3 Preventive MaintenanceCalculation of Maintenance Manpower, Load Leveling, Preparing & Monitoring of TBM SchedulesModule 4 Condition Based - Predictive MaintenanceSubstitute characters, Static & Dynamic Equipments, Approach & Contents of Predictive MaintenanceModule 5 Vibration AnalysisVibration analysis is used primarily with rotating equipment to find problems such as misalignment, out-of balance conditionsand bearing defects. Prior to using vibration analysis, maintenance technicians have to wait until a bearing failed to realize therewas a problemModule 6 UltrasoundUltrasound functions primarily for leak detection, particularly for steam and air leaks. These leaks can be expensive and manycompanies let them go unnoticedModule 7 Oil and Wear-Particle AnalysisSome people equate oil analysis and wear-particle analysis. Actually, they are two very different technologies. Oil analysisdetermines the condition of a lubricant. Wear-particle analysis determines the condition of equipment based on theconcentration of wear particles in the lubricantModule 8 ThermographyThermography serves primarily to find electrical components that are hotter than normal. Such a condition usually indicates wearor looseness. Thus, thermography allows technicians to perform maintenance on only the electrical components that needattention without requiring that all components get the same level of attentionModule 9 Additional Components

As has been shown, a Predictive maintenance programme is not a stand alone strategy, but needs to be integrated into anoverall asset management strategyModule 10 How to Develop a Predictive Maintenance SystemTeams work to develop TBM & CBMs for select equipments using learning in Workshop

Quiz Test

Methodology : Classroom sessions & Videos with many examples of industrial life. All methods of Preventive & PredictiveMaintenance will be discussed with their comparative strengths & weaknesses. There are three tests & discussions betweenmodules to reinforce learning, exercises, experience sharing & case studies followed by Quiz Test at the end to reinforceunderstanding. It is expected that participants bring data from their workplace for critical equipments so as to develop TBM &CBM schedules.

Who Should Attend: Managers, Engineers, Supervisors, Process Specialists, Senior Technicians involved in Maintenance

Process Control and Improvement activities.

Faculty : Mr Shekhar Deshpande, Director, Shilpa ConsultantsHe is an MBA in Operations Management + Industrial + Electrical Engineer with more than 34 years experience in reputedcompanies like L & T, ABB, Crompton Greaves, Associated Capsules Group & EIPL. He has conducted more than 200 resultoriented programmes on Tools of Lean i.e. 5S, Kaizen, TPM, SMED, VSM, Poka Yoke, and Quality Management tools such asSPC, FMEA, MSA, GDT, for organizations like Bajaj Auto, TitanTime Products, Hindustan Coca Cola, LG Electronics, AsianPaints, Hindustan Lever, Siemens, Kirloskar Brothers, Videocon International, Fairfield Atlas, Tata Motors etc.

He has hands on experience in shop floor improvements on six sigma projects & time & method studies.

Dates / Schedule of Sessions : 12 13 April 201312 April 2013 Registration - 9:15am to 9:30 am 12 13 April 2013 Sessions - 9:30am to 5:00pm

Venue : Orbett Hotels, 1238/2, Apte Road , Deccan Gymkhana, Pune - 411 004 Tel: 020-30244800/01/02




Participation Fees (on non-residential basis) :

Type of Organisation Fees per Participant Service Tax (12.36%) Total Participation Fees Payable

CII Members (Large &Medium)

Rs 9500/- Rs 1174/- Rs 10674/-

CII SSI Members Rs 7500/- Rs 927/- Rs 8427/-

Non Member Companies Rs 10500/- Rs 1298/- Rs 11798/-

Fees include participation, course material (hard copies), breakfast, working lunch and tea / coffee. Advance payment of fees is to bedrawn in favour ofConfederation of Indian Industry payable at Mumbai. A discount of 10% on fees will be admissible on threeor more nominations from an organisation only where payment is received in advance (on or before 4 April 2013). Participation

fees is non-refundable / non-adjustable against any other programme of CII, but change in nomination(s) is accepted.

Registration:Prior registration for participation by the sponsoring companies is necessary. Number of admissions will be limited to 25.

Certificate of Participation will be given to the participants.

Nominations & Enquiries : S D Puranik, Executive DirectorCII Naoroji Godrej Centre of ExcellenceGodrej Station-Side Colony Tel : (022) 2574 5146 / 5148Opp Railway Station, Vikhroli (East) Fax : (022) 2574 3361Mumbai 400 079 Email : [email protected] / [email protected]

Residential Facilities : Although the programme is being held on non-residential basis, residential facilities are available at OrbettHotels, the venue of this workshop, at reasonable tariff. Those interested may get in touch with

Mr Sanjay TipnisOrbett Hotels1238/2, Apte RoadDeccan GymkhanaPune - 411 004Tel: 020 30244800 / 01 / 02Cell : 09922773699Email : [email protected]

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CII Naoroji Godrej Centre of Excellence

Workshop onPredictive & Preventive Maintenance

Basics & Practices

12 13 April 2013 : Pune

We nominate the followingmanager/s to attend the Workshop

Name Designation Email / Telephone

1

2

3

Our Cheque / Demand Draft dated __________ No. _________ for Rs. ________________ drawn in favour of Confederation ofIndian Industry payable at Mumbai is enclosed.

Name:______________________________________________ Designation : ____________________________

Organisation : ________________________________________________________________________________

Address : ____________________________________________________________________________________

____________________________________________________________________________________________CII Membership No : _________________________ Telephone : _______________________________________

Fax : _______________________________Email : __________________________________________________

Signature & Stamp of the Nominating Authority : _____________________________________________

Participation fee is non refundable / non-transferable against any other programme of CII. However change in nomination(s) is accepted.

Workshop is non residential.
