SEMINAR ONMAINTENANCE STRATEGIES FOR

IMPROVEMENT OF PRODUCTIVITY AT INDUSTRY

By

GREEJESH PRAKASH

Key Phrases

■ Maintenance, Maintenance Strategy, Types of Maintenance, Maintenance System,

Productivity, Maintenance Engineering, Maintenance Cost

Objectives

■ To highlight the benefits of maintenance strategy

■ To study the new strategy of maintenance for better productivity

■ Approaches for the better maintenance strategy leading in to better profitability

What is Maintenance Strategy?

“Management method used in order to achieve the maintenance

objectives.”

Maintenance Objectives?

■ The targets assigned to or accepted by the management and maintenance

department.

■ Targets may include availability, cost reduction, product quality, environment

preservation, safety

Introduction

■ Maintenance is an activity carried out for any equipment to ensure its reliability to

perform its functions

■ It is any activity carried out on an asset in order to ensure that the asset continues

to perform its intended functions

■ To repair any equipment that has failed

■ To keep the equipment running, or to restore to its favorable operating condition

Another Perspective

■ Maintenance function is not only to maintain

■ Its also to enhance the process or the plant operation system

■ With the turnaround planning.

■ Most management now saw maintenance efficiency as

■ A factor that can affect the all business effectiveness and risk-safety,

■ Environmental integrity

■ Energy efficiency

■ Product quality and customer service and not contained only to plant availability and cost.

Another Perspective

Maintenance

Environmental integrity

Energy efficiency

Product quality

customer service

Plant

Availability

and

Cost

Methodologies

Direct Participation

Technical Experience

Primary Sources

Internet Studies

Books

Interviews

Secondary Sources

Literature Review

FIRST GENERATION SECOND GENERATION THIRD GENERATION

Fix it when it broke Scheduled overhauls

Systems for planning and controlling work

Low-tech computerization

Condition monitoring

Design for reliability and maintainability

Hazard studies

High-tech computers

Failure Modes & effect analysis

Expert Systems

Multi-tasking and team work

1930 1940 1950 1960 1970 1980 1990 2000 NOW

Literature Review

Fourth Generation of Maintenance

Definite negotiation of risk

Coherence between functional demand, equipment design and maintenance

Development in information

technology to detect, predict, diagnose and

prevent

Literature Review

Fourth

Generation

Different Strategies

Maintenance Strategy Maintenance Approach Signification

Breakdown Maintenance Fix-it when broke Large maintenance budget

Preventive MaintenanceScheduled Maintenance

Periodic component

replacement

Predictive Maintenance Condition-based MonitoringMaintenance decision based on

equipment condition

Proactive Maintenance Detection of Sources of Failures Monitoring and correcting failing

root causes

Different Strategies

■ Reliability Centered maintenance

■ Root Cause Failure Analysis

Discussion

■ In the maintenance enterprise state, presentation assurances and constant

upgrading goals deliver better switch over maintenance outcomes

■ Guarantee manufacture goals which are actuality stretched

■ The assortment of a precise equipment of low installed budget helps to decrease

budget

■ Driving up maintenance budget and downtime which is not promising to the vender

maintenance team

■ Therefore an enhanced solution should be a combined and aligned method

Finding

■ Maintenance should be initiated when the facility or system is just a proposal, which

is even earlier the preparation stage

■ And lasts up until it is time to for the facility to de-commissioning

Finding

Proposal Construction Commissioning

Operation Decommissioning

Integrated and aligned approach of maintenance program

Findings

■ By dropping the direct and indirect cost of system failure, the perception of

productive, effective and cost-effective can be attained

■ Return of Assets = Revenue -------------------------------- (1)

(Asset Value)

■ Revenue = Price x Volume -------------------------------- (2)

■ Volume = Max. Capacity x Overall Equipment Effectiveness ------------- (3)

Effective maintenance has a constructive result on calculation (1), (2) and (3).

Enhanced maintenance assistances to improve efficiency by dropping the need for

costly capital advancements to upturn output.

Effective Maintenance Vs Non Effective Maintenance

Conclusion

■ fix-it-when-it-broke to a more complex approach

■ adopted maintenance strategy of a more integrated approach and alignment

■ maintenance will also be part of the investment decision-making

Improved Maintenance

Effectiveness

Productivity

Profitability

Recommendation

■ Any industry should use effective strategy in order to improve efficiency

■ Reducing the direct and indirect cost of maintenance using preventive and

predictive maintenance will remarkably reduce the maintenance cost

■ Maintenance actions could be started when the facility or system is just a proposal.

Proposal Construction Commissioning Operation

Decommissioning

References

■ HISHAM BIN JABAR, Segi Perkasa Sdn Bhd, PLANT MAINTENANCE STRATEGY: KEY

FOR ENHANCING PROFITABILITY

■ General Electric (www.ge.com)

■ Dhillon, S. B. (2006). (2006) Maintainability, Maintenance, and Reliability for

Engineers

■ Mobley, K. (2004). Maintenance Fundamentals (2nd edition). Elsevier Inc.

■ Moubray JM. (2000). Maintenance Management – A New Paradigm. Retrieved from

Maintenance Resources.Com