maintenance data analysis

8/3/2019 Maintenance Data Analysis

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Organized data can add to our understanding of ourasset performance

This is what GRIHA can do



Plant-wise AnalysisD at e P la nt E qu ip me nt I D L oc at io n ID E qu ip me nt D es cr ip ti on M ai nt en an ce

Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No

Supervisor Technicians Work Start

Time

Work Done Work Complete

Time

Spares Used To ols Used Safety lo ckout

Closed

work permit

closed

Reasonfor failure -indicate

failure code

Remarks

S. No. Plant Equipment ID Location ID

Plant-wise analy sis can give comparative maintenance

performance between plants.Repetitive failures of a particular t y pe can indicate

lack of trained personnel.Ke y Performance Indicators

Plant Availabilit y as %



Equipment performance analysis

D at e P la nt E qu ip me nt I D L oc at io n ID E qu ip me nt D es cr ip ti on Ma in te na nc e

Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time

Spares Used T oo ls Used Saf ety locko ut

Closed

work permit

closed


failure code

Remarks


Searches of one particular ID can add to our understanding

of the equipment behavior. Comparing similar equipmentcan give us insight into the problem area such as locationfaults, service faults, operational defects, lack of training

and othersKPI Overall Equipment Effectiveness - OEE



Can the location throw some light?



Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks

There are particular locations which prove to beadding additional problems to the equipment such

as dust y locations, presence of acidic vapors,inherited construction faults, and man y others



Descriptive fieldsD at e P la nt E qu ip me nt I D L oc at io n ID E qu ip me nt D es cr ip ti on Ma in te na nc e

Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks

This being a descriptive field does not aidanaly sis unless some standardized texts

are used

Equipment Description Equipment type Maintenance

Type



Analysis by equipment type can

give us many clues


Type


Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks

Equpt. T y pe code if not alread y available is addedb y GRIHA and failure analy sis t y pe-wise can add

valuable input to our trouble shooting capabilit y ,particularly with regard to skill levels of the workmen , equipment selection criteria and

others



Maintenance type can tell us if we

have too many breakdowns


Type


Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks

Maintenance t y pe like Preventive, Breakdown, corrective,condition based etc., are clear indicators of our maintenance

work performance. The ratios of one with the others sa y plent y on our abilit y to create an optimum AssetManagement Strateg y

KPI PM EffectivenessB/D Vs PM RatioCondition Monitoring Effectiveness



Training is most importantD at e P la nt E qu ip me nt I D L oc at io n ID E qu ip me nt D es cr ip ti on Ma in te na nc e

Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks


Time

Repetitive failuresunder a supervisoror technician canindicate training

needs

Repetitive failuresare sure indicators

of poor reliabilit y



Is our MTTR

(Mean Time To Repair)good?

Work Start

Time


Time


Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks

Duration of work computed from start and completion timeindicates the time to repair.MTTR,Mean Time To Repair is animportant performance measure. This can lead to strategicdecisions on improving repair facilities or adding Rotables

The average run time between failures is MTBF, a ver y important measure of the reliabilit y of the equipment



Crew Size and Cost of Maintenance

D a te P l an t E qu i pm en t ID L oc a ti o n I D E qu i pm en t De s cr i pt i on M ai n te na nc e

Type

Maintenance

Task ListNo.

Work Permit

No

Safety

Lockout

No


Time

Work Done Work

Complete

Time

Man Hours

and costof

labour

Sp ares Used a nd c o st To ta l C o stof M a intena n c e To ols U sed Sa fety lo c ko u t

Closed

work permit

closed

Remarks

Work Start

Time


Time

Man Hours and

cost of labour

Ke y input to determine the crew size and

reduce theMean Time To Repair MTTR Cost of labor is ke y to the economics of

asset managementForms a significant part of the total cost of

maintenance



Spares Consumption Analysis

Cost of Spares used is another significantfactor for the total cost of maintenance

Repetitive consumption of a particularcomponent can trigger investigations on

component life/ procurementsource/maintenance requirements

D at e P l an t E qu i pm en t ID L oc a ti o n ID E qu i pm en t De sc r ip ti o n M ai n te na nc e

Type

Maintenance

Task ListNo.

Work Permit

No

Safety

Lockout

No


Time

Work Done Work

Complete

Time

Man Hours

and costof

labour

Sp ares Used an d co st To ta l C osto f Ma in ten an c e To ols U sed Sa fety lo c ko u t

Closed

work permit

closed

Remarks

Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout

Closed



Total Life Cycle Cost and

Replacement Planning

HelpsPlanning

D at e P l an t E qu i pm en t ID L oc a ti o n ID E qu i pm en t De sc r ip ti o n M ai n te na nc e

Type

Maintenance

Task ListNo.

Work Permit

No

Safety

Lockout

No


Time

Work Done Work

Complete

Time

Man Hours

and costof

labour

Sp ares Used an d co st To ta l C osto f Ma in ten an c e To ols U sed Sa fety lo c ko u t

Closed

work permit

closed

Remarks

Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout

Closed

THEMost Important criteria for assessing cost effectiveness of maintenance

Will pla y a major part in the Total Life C y cle Costing of the assetReplacement decisions are based on this analy sis

KPI CostMaintenance Vs Budget Vs Replacement Cost of Equipment



Failure Analysis is key to successful

asset management

work permitclosed

Reason for failure - indicatefailure code

Remarks


Type

Maintenance

Task List No.

Work Permit

No

Safety

Lockout No


Time


Time


Closed

work permit

closed


failure code

Remarks

The single most important data for analy sis.M AINTENANCE IS NOT COMPLETE UNLESSWE KNOW WHY AN EQUIPMENT FAILED AND TAKE CORRECTIVE

MEA SURESTO AVOID RECURRENCEGRIHA uses standard failure codes

maintenance data analysis

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