MAINTENANCE AND OCCUPATIONAL SAFETY BY ERINLE BABATUNDE.O

HOW RICH ARE YOU? Net worth: Value of machines minus

liability Spending: Cost of repair, cost of parts Savings: Income minus spending Maintenance should always be an active part in an organization so as to maintain spending margins and keep the company running effectively.

RICH AVERAGE BROKE0

5

10

15

20

25

SPENDINGS SAVINGS NET WORTH

Maintenance may be defined as the combination of all technical, administrative and managerial actions during the life cycle of an item, intended to retain it or restore it to a state in which it can perform it’s required function.

A maintenance function is critical t0 the

following; Ensuring continuous productivity Producing products of high quality Maintaining a company’s competitiveness

TYPES OF MAINTENANCE

The primary goal of maintenance is to mitigate the consequences of failure of equipment.

The types of maintenance includes: Preventive maintenance Corrective maintenance

PREVENTIVE MAINTENENCE

An operation carried out in an attempt to avoid failures, unnecessary production loss and safety voilations.It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail.

CORRECTIVE MAINTENANCE

An operation performed to identify, isolate and rectify a fault so that the failed equipment, machine or system can be restored to an operational condition within the tolerances or limits established for in-service operations.

DO WE REALLY NEED PM?

“Sure, I know preventive maintenance helps to avoid unplanned downtime and breakdowns. But PMs takes time excessively and cost a lot of money, and they don’t seem to make that much difference in the way our equipment runs. We’ve got excess capacity anyway, and we’re not running production on all shifts during the week. So, the downtime and repairs aren’t costing us that much in lost production. We’re able to keep up with customer orders. I really don’t see why we need to spend time and money on PM program.

COST!!, THEN WHY SHOULD PM BE PRACTICED?The general problem associated to preventive maintenance is cost.The system can seem difficult and time consuming, but there are solutions that can help; Utilizing computerized maintenance management

software Control monitoring

Remember, ”you cannot cut cost your way to profitability”.

"You need to be rich to buy cheap products. Why? Because you eventually have to buy twice to have the job done properly." -Tunde.

PREVENTIVE OVER CORRECTIVE MAINTENANCE Preventive maintenence makes good business sense. How? Saves costReduces spoilageDecreases downtimeDecreases revenue lossImprove reliability

On the other hand, reactive maintenance slumps a business contingency. How?

Difficult to control budgetTime consumingSafety issuesInterfers with planned workIssue repetition

Maintenance is not all about fixing things that break, it is all about preserving, protecting, safeguarding, and looking after the very machines that make business possible.

MAJOR PRODUCTION EQUIPMENT IN VITAFOAM NIG.

NO. OF MATTRESS PRODUCED PER DAY

1800

NO. OF TAPE EDGES

10

NO. OF SHIFTS 2

WORKING HOURS PER SHIFT

8HRS

TOTAL NUMBER OF WORKING HOURS

16HRS

ESTIMATED FAILURE RATE

65%

LIFE SPAN 10 YEARS

PMs CMsCLEANING

INSPECTION

LUBRICATION

×

OVERHAUL BEFORE FAILURE ×

DOWNTIME64%

CMs25%

PMs11%

DOWNTIMECMsPMs

YEAR 1 YEAR 2 YEAR 3 YEAR 40

1

2

3

4

5

6

7

8

9

10

Downtime

market

share holders

EFFECT OF EXCESSIVE DOWNTIME

Downtime market share holders

BUT, WHEN SHOULD CM BE USED?Reactive maintenance should only be performed on components that are inexpensive, easy to replace, where the failure does not cause collateral damage in the system or where the cost of reactive maintenance is not greater than preventative maintenance.

COST OF MAINTENANCE ON CAPITAL INVESTMENT RETURNThe cost of maintenance can send your business broke. If your annual maintenance cost is higher than 5% of your asset value you are in trouble.

Total Maintenance Cost per RAV (%) = [Total Maintenance Cost ($) × 100] ÷ Replacement Asset Value ($)

The total maintenance cost depends on the quality of the equipment used and how much maintenance it requires.

PROBLEMS OF MAINTENANCE OPERATIONS

Problems associated to maintenance operations includes; Poor schedule compliance Lack of management support Skill gap Insufficient detail on maintenance record

LIMITATIONS TO MAINTENANCE IN VITAFOAM NG. PLC

Problems associated with maintenance in vitafoam Ng. Plc includes; Wrong equipment selected Inconsistency Poor documentation after repair No changing/updating of maintenance

system Non availability of critical parts for

machines Privation of trained personnels

RECOMMENDATIONS

The following can be done to ensure proper maintenance exercise. Introduce 5-whys analysis Plan Set data operating instructions Use of computerized maintenance

management system (CMMS) Use of control monitoring Training and competence

CONCLUSION

In this tough economic times, it makes sound business sense to improve preventive maintenance effectiveness. Businesses that ignore the advantages and profitability of preventive maintenance will continue to struggle and miss their true potential in the marketplace.

YEAR 1 YEAR 2 YEAR 3 YEAR 40

5

10

15

20

25

IF VITAFOAM ABOLISH CORRECTIVE MAINTENANCE SYSTEM

CM PM SAVINGS PROFITABILITY

Vitafoam Nigeria plc, which is one of the leading manufacturing industries in Africa, should abolish the corrective maintenance system and implement the preventive maintenance system so as to hoist its productivity and compete in the international market.

SAFETYSafety is the state of being "safe“. This is the condition of being protected from harm or other non-desirable outcomes in order to achieve an acceptable level of risk.

OCCUPATIONAL HARZARDS AND INJURIES

OCCUPATIONAL HAZARDS IN VITAFOAM NIG. PLC.Maintenance workers are exposed to many and varied risk when carrying out their job due to very different activities of maintenance. These hazards includes the following;Physical hazards :Noise :Vibration :Musculoskeletal disorders (MSDs) Biological hazard :Exposure to legionnaires :Exposure to cancerous substances

SAFETY RECOMMENDATIONS IN VITAFOAM NIG. PLC.

The following can be done to ensure proper maintenance exercise.

Enforce protective equipment Risk assessment should be carried out Adequate information should be given Having programs to prevent MSDs

ALWAYS BE CAREFUL