how do you reduce maintenance costs

8/22/2019 How Do You Reduce Maintenance Costs

1/14

How do you reduce maintenance costs?

posted 8 days ago 16votes

We replace upfront We replace afterwards During build of a new plant, we monitor Nothing

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We replace upfront2(0%)

We replace afterwards1(0%)

During build of a new plant, we monitor12(0%)

Nothing

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2/14

Hendra DjatiUnfollow Follow Hendra Djati

Hendra Djati Perbowo only by perfect OnM. Record daily OnM activities, monitor repeated

abnormalities and defects and solve it, choose the right parts and methods, record equipment

history, and all..

8 days ago Unlike Like

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GeorgeUnfollow Follow George

George Vela Maintenance is performed to improve reliability. This is accomplished throughtesting.

to reduce maintenance costs, more companies are relying on their engineers to solve issues andperform maintenance rather than call in the OEM. This can result in substantial savings.


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Hendra DjatiUnfollow Follow Hendra Djati
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3/14

Hendra Djati Perbowo agreed


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0

Donald AUnfollow Follow Donald A

Donald A Hughes Simple voting buttons are not going to help obtain the information yourequire to answer this question. First you need equipment history, then frequency of brake down,

and required maintenance; factor these into scheduled down time maintenance, and cost of repairto replace, to come up with the correct maintenance at the right time. Chronic equipment

problems will require engineering review to analyze the problem and come up with a equipment

replacement or improvement to reduce the maintenance on chronic equipment problems. Alsothe addition of permanent support, such as permanent platforms to scaffold, at location, electrical

disconnects, addition of vibration monitoring to detect problems before breakdown. You will

need to spend some money up front to save money in the end.



6

BillUnfollow Follow Bill

Bill Rose RTF then you change the equipment out falling back on BART and pull the moneyout of your capital budget. :) atleast thats what I'm seeing from one company. :(


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4/14


0

JeremyUnfollow Follow Jeremy

Jeremy Culberg None of the above - the quick answer is "it depends" Some equipment we

condition monitor, and either proactively replace, or get ready for replacement at time of failure(consequence of failure is the driver). Other equipment simply run to failure. Others use a time

based equation to replace. And yet other failures (or potential failures) we design out.

The maintenance is tailored to suit the risk profile of the equipment.

An example may be a motor - 5 installations of the same motor across site. In the first example,there are 3 compressors - plant only needs 2 operational. So those motors have the basic

lubrications and inspections done, but very little additional work (for the sake of the argument

these motors are inexpensive). Essentially run to failure. Next pair of identical motors run feedpumps. Both are required for full load - increased inspection regime, and typically earlier

intervention when degradation becomes evident.

Different strategies for the same motor, as the consequences of failure are different.



2

baboolalUnfollow Follow baboolal

baboolal vishwakarma interest that I read your recent posting in the THERMAL POWERPLANT ORIENT GREEN POWER BIOMASS CO.LTD. & coal based In response, I enclose

my resume for your consideration.

Review of my credentials will confirm that I am capable of serving as the catalyst for achievingrevenue objectives and organic growth through effective contributions. I am a result-oriented

with 37 years of enriched experience in Power Plants Operations, Project Management,

Installation & Commissioning and Operations & Maintenance.

presently working ORIENT GREEN POWER BIOMASS CO.LTD. with as General Manager
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5/14

OPERATION & MAINTENANCE Thermal Power Plant

I understand that working for your organization requires a candidate who is team oriented and is

able to deal with people in various departments. I am confident that I possess these skills, whichwill help me to perform the job efficiently and effectively.

My goal is to transit my enthusiasm, creativity and experience into a position, where I continue

to provide the strategic and tactical leadership critical to retaining valued customers of anorganization. I am certain that my presence in your team will prove to be beneficial to yourorganization. As such, I would welcome an opportunity to speak with you to evaluate your needs

and share my ideas.

Thanking you.

Sincerely,

BABOOLAL VISHWAKARMA

Enclosure: Resume

CONTACT:- 9425885234

[email protected]

baboolal vishwakarma Hello Dear

* I understand that working for your organization requires a candidate who is team oriented andis able to deal with people in various departments. I am confident that I possess these skills,

which will help me to perform the job efficiently and effectively.plz see link as bellow.

baboolal vishwakarma "http://www.siliconindia.com/profiles/Baboolal-nil-vishwakarma-LBqwD1i0.html"

* I am seeking job for GM(O&M) thermal power plant FBC,CFBC,PFBC,BOILER ,TURBINEexpert & given details as below :-

total exp = 37 years in powercurrent ctc = 18,30,000 p.a

exp ctc = as per company norms (negotiations)

notice period = immediate

availability of interview = as per your schedule

thanks & regards

B.L VISHWAKARMA

Gm. thermal power plant


Reply privately
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6/14


0

CarlosUnfollow Follow Carlos

Carlos de Vos Thanks for all comments so far! Of course I realize simple voting buttons will

not be enough to get all information. But it helps to start this very interesting discussion withexperienced engineers!



0


baboolal vishwakarma Preview: BABOOLAL VISHWAKARMA

Contact: +918989139763

E-Mail: [email protected]

Dated: 17/1/13

Dear Sir/ Madam,It was with great interest that I read your recent posting in the THERMAL POWER PLANT

ORIENT GREEN POWER BIOMASS CO.LTD. & coal based In response, I enclose my resume

for your consideration.

Review of my credentials will confirm that I am capable of serving as the catalyst for achievingrevenue objectives and organic growth through effective contributions. I am a result-oriented

with 37 years of enriched experience in Power Plants Operations, Project Management,

Installation & Commissioning and Operations & Maintenance.presently working ORIENT GREEN POWER BIOMASS CO.LTD. with as General Manager

OPERATION & MAINTENANCE Thermal Power Plant

I understand that working for your organization requires a candidate who is team oriented and is

able to deal with people in various departments. I am confident that I possess these skills, which
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will help me to perform the job efficiently and effectively.

My goal is to transit my enthusiasm, creativity and experience into a position, where I continue

to provide the strategic and tactical leadership critical to retaining valued customers of anorganization. I am certain that my presence in your team will prove to be beneficial to your

organization. As such, I would welcome an opportunity to speak with you to evaluate your needs

and share my ideas.

Thanking you.

Sincerely,

BABOOLAL VISHWAKARMAEnclosure: Resume

CONTACT:- 918989139763

[email protected]

baboolal vishwakarma Hello Dear* I understand that working for your organization requires a candidate who is team oriented and

is able to deal with people in various departments. I am confident that I possess these skills,

which will help me to perform the job efficiently and effectively.plz see link as bellow.

baboolal vishwakarma "http://www.siliconindia.com/profiles/Baboolal-nil-vishwakarma-

LBqwD1i0.html"

* I am seeking job for GM(O&M) thermal power plant FBC,CFBC,PFBC,BOILER ,TURBINE

expert & given details as below :-

total exp = 37 years in power

current ctc = 18,30,000 p.a

exp ctc = as per company norms (negotiations)notice period = immediate

availability of interview = as per your schedule

thanks & regardsB.L VISHWAKARMA

Gm. thermal power plant


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8/14

0

MohUnfollow Follow Moh

Moh Ali Get the experiences engineer and teams, put them in the right position ... may be help



0

Phillip W.Unfollow Follow Phillip W.

Phillip W. Davis Get to the basics. Eliminate errors which includes human errors. Get all

personnel involved. Let the men doing the work talk to you about waste that can be quicklyeliminated.



0

josephUnfollow Follow joseph

joseph hanna Nothing means nothing of the above.

Watching, collecting data, analyzing then decide how and when to interfere.this is about reliability.
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9/14



1

UdhayakumarUnfollow Follow Udhayakumar

Udhayakumar Venkataraman Use Standard Guide lines as per OEM, proactive maintenance,

avoid repetitive failurs by root cause analysis, best planning of all resources like right man

power, spares consumables, verification of quality, Effective operation with prudent practiceswith SOPs etc will help. regards



1

LuisUnfollow Follow Luis

Luis Rodriguez There are several ways to reduce maintenance costs. 1) Implementing anagressive inspection program. This program should feed the daily or weekly maintenance jobs;

2) Your should concentrate your efforts in those equipment that represent the major impact in

your plant reliability, it does not matter their size; 3) Work orders priorities are very important

aspect in this matter; 4) The Operations Department should participate in the discussions when

the maintenance jobs are being schedule in order to help identifying which of the discussedaspects could affect the plant or equipment reliability; 5) The outside contractors should be

screened and well selected. Many of the maintenance costs are coming from re_works from

external contractors; 6) The maintenance people should know the maintenance progress or delaysto encourage them to be responsible for their results and discussing how to prevent them. You

could implement a monthly recognition program to the most excellent employee chosen by a

committee; 7) You could reduce costs when a budget controlling culture is spread in all themaintenance staff. There are many works that are being done as extra budget that could be
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10/14

planned for the future.

I hope these observations could help you. There are many other things that should be taken inaccount, but the space is limited (i.e. materials purchase process that include the PO,

specifications and reception).



1

CHANDRA PRAKASHUnfollow Follow CHANDRA PRAKASH

CHANDRA PRAKASH PANDEY Maintenance cost is directly related with availability of

equipment. Hence availabilty is to increase. Verious supports are available. Fast wearing parts bereplaced instead of repair.

Vibration analysis is done regularly of moving parts.New technology & on line repairs be

preferred while running of unit. Repair/ replacement be clubbed together to avoid down time.



0


baboolal vishwakarma Repair becomes a significant percentage of the cost of replacement, itbecomes economically favorable to simply order a replacement part. In such cases, the part is

said to be "beyond economic repair

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11/14


0

GaryUnfollow Follow Gary

Gary Melrose Stop doing pointless (often destructive) tasks and concentrate on criticality andrisk optimised maintenance which are directly aligned with corporate strategy.

Refer to the Physical Asset Management Handbook by John S Mitchell, the Institute of Asset

Management website (http://theiam.org/) and the John Woodhouse Partnership white papers

section (http://www.twpl.co.uk/) for further details.

1 day ago Unlike Like


0


baboolal vishwakarma utilized many factor for reducing the cost of manufacturing kindly

contact as privately



0
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12/14

N.K.Unfollow Follow N.K.

N.K. Agarwal Hi Carlos,

Pl donot make it sound as simple as you have put in to vote the factor to reduce maintenance

cost. There is no one factor which is responsible of which will give you a reduced maintenancecost. It is a strategy combining all the above and many more factors which help in reducing

maint costs. Starting with, to create a maintenance culture in the organisation which involves

doing the job without any mistakes, so that the fault does not repeat. This saves unnecessary

manhours in repeating repairs on the same equipment. Avoid unnecessary maint by adoptingcondition based maint so that you do maint only when needed. Use of genuine spare parts which

is possible only if you plan properly and organise the spares supply in advance. Last minute rush

always end up in duplicate spares. Reducing spare parts inventory reduces the total maint costsubstantially. Doing Route Cause Analysis for establishing route cause of the problem always

helps in avoiding the unnecessary efforts of doing the same job over and over again. Maintain

history cards for all the jobs done on major equipments to know the background before

attempting any work on the same. Allow sufficient time for training of manpower for the variousjobs.These are few of the many aspects that a maintenance team has to look into in order to

reduce the cost of maintenance. And ultimately, for all maint activities follow, STAR

philosophy.



1

abdelaaliUnfollow Follow abdelaali

abdelaali badache To reduice maintenance cost you should have the following organisation .1/ high level competence or skilled employees

2/ well planned, EPC and commissioning welle monitored

3/ High level of O&M4/ data base of all equipement

5/ act just at the right time to avoid failure
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13/14



0

true 24 24 groupItem?seeM


baboolal vishwakarma To operations and maintenancebudgets are among the first to be cut.

Fewer personnel working fewerhours are expected to operate and maintain more equipment atlower

cost

14 hours ago Unlike Like


0

DavidUnfollow Follow David

David Garbe As far as we are concerned in our field of expertize, we provide online cleaning of

fired heaters, boilers (fire-side) and fin fan of air coolers for major oil refineries.

Our dry chemical process allows to optimize the energy efficiency of production units without

the need of a shutdown, nor waste management (see www.furnace-solutions.com).Our customers are able to anticipate online cleaning campaigns on a yearly basis, according to

their energy performance analysis.

This is one example of preventive maintenance with a viable and safe solution, representing huge

savings for our customers.

Thanks to the other people who posted very interesting information in this subject.
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how do you reduce maintenance costs

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