...MAINTENANCE MANAGEMENT Prof. O.P. Gandhi ITMMEC, IIT Delhi The term ‘maintenance’ means to keep the equipment in operational condition or repair it to its operational mode. Main objective of the maintenance is to have increased availability of production systems, with increased safety and optimized cost. Maintenance management involves managing the functions of maintenance. Maintaining equipment in the field has been a challenging task since the beginning of industrial revolution. Since then, a significant of progress has been made to maintain equipment effectively in the field. As the engineering equipment becomes sophisticated and expensive to produce and maintain, maintenance management has to face even more challenging situations to maintain effectively such equipments in industrial environment. This brief lecture on maintenance management includes maintenance strategies, functions of maintenance department, maintenance organization and elements of maintenance management. MAINTENANCE STRATEGIES OR OPTIONS A maintenance strategy or option means a scheme for maintenance, i.e. an elaborate and systematic plan of maintenance action. Following are the maintenance strategies [1] that are commonly applied in the plants. • Breakdown Maintenance or Operate to Failure or Unplanned Maintenance • Preventive or Scheduled Maintenance • Predictive or Condition Based Maintenance • Opportunity Maintenance • Design out Maintenance The equipment...
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...(1)http://www.leanexpertise.com/TPMONLINE/articles_on_total_productive_maintenance/tpm/tpmroberts.htm TPM TOTAL PRODUCTIVE MAINTENANCE History and Basic Implementation Process by Jack Roberts, Ph.D. Jack_Roberts@TAMU-Commerce.edu Department of Industrial and Engineering Technology Texas A&M University-Commerce Abstract: Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. The TPM program closely resembles the popular Total Quality Management (TQM) program. Many of the same tools such as employee empowerment, benchmarking, documentation, etc. are used to implement and optimize TPM. This paper will define TPM in some detail, evaluate its strengths and weaknesses as a maintenance philosophy, and discuss implementation procedures. Examples of successfully implemented programs will be presented. I. What is Total Productive Maintenance? Total Productive Maintenance (TPM) is a maintenance program concept. Philosophically, TPM resembles Total Quality Management (TQM) in several aspects, such as (1)total commitment to the program by upper level management is required, (2) employees must be empowered to initiate corrective action, and (3) a long range outlook must be accepted as TPM may take a year or more to implement and is an on-going...
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...cost of the maintenance programmes but to improve the functional performance of the plant equipment. Enhanced reliability and efficiency will in turn contribute to improved economic and safety performance of the plant equipment. 245.2. Cost Benefits Cost reduction benefits are not the primary goal of the RCM process however, EdF estimate that the application of RCM to their maintenance programmes will produce a maintenance cost reduction of 7 Million Euros over a period of 2004-2007 when applied to a large standardised fleet. Conversely, the experience in the Czech Republic where RCM was applied to a small number of systems at the Dukovany NPP the experience proved to be maintenance cost neutral. The experience of cost savings through the application of RCM in France, Spain, UK and Czech Republic are detailed in the Attachments to this TECDOC. Many are quoted in the form of task and man-hour reductions. 5.3. Contribution to Long Term Operation RCM is a systematic approach to the identification and execution of maintenance activities designed to support plant performance. The associated condition monitoring programmes and analytical techniques ensure excellent knowledge of plant condition and can provide early warning of plant aging and obsolescence issues which are vital for asset management. The data collected and the maintenance practices developed are conducive to long term asset management strategies. 5.4. Soft 5.4.1. Operations and Maintenance interaction...
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...MAINTENANCE MANAGEMENT The term ‘maintenance’ means to keep the equipment in operational condition or repair it to its operational mode. Main objective of the maintenance is to have increased availability of production systems, with increased safety and optimized cost. Maintenance management involves managing the functions of maintenance. Maintaining equipment in the field has been a challenging task since the beginning of industrial revolution. Since then, a significant of progress has been made to maintain equipment effectively in the field. As the engineering equipment becomes sophisticated and expensive to produce and maintain, maintenance management has to face even more challenging situations to maintain effectively such equipments in industrial environment. This brief lecture on maintenance management includes maintenance strategies, functions of maintenance department, maintenance organization and elements of maintenance management. MAINTENANCE STRATEGIES OR OPTIONS A maintenance strategy or option means a scheme for maintenance, i.e. an elaborate and systematic plan of maintenance action. Following are the maintenance strategies [1] that are commonly applied in the plants. • Breakdown Maintenance or Operate to Failure or Unplanned Maintenance • Preventive or Scheduled Maintenance • Predictive or Condition Based Maintenance • Opportunity Maintenance • Design out Maintenance The equipment under breakdown maintenance...
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...MARKET SCOPE Asset performance management Addressing the root cause A properly and adequately designed asset performance management framework can bring a cohesive approach to manage assets, monitor equipment health, and ensure the compliance of critical operational & business processes. Such a framework has to leverage the established asset management capabilities provided by the best-in-class systems. Courtesy: PCM Ltd n the 1980s, the world was awakened by two major disasters that signified the vitality of engineering assets and the importance to manage their performance. The first event was a lethal methyl isocyanate (MIC) leak in Bhopal on December 2, 1984, and the second the catastrophic Chernobyl nuclear disaster on April 26, 1986. Over 20,000 were killed, and half a million victims maimed, disabled or otherwise affected in the Bhopal gas tragedy. Criminal cases were filed against the then corporate Chairman. In the Chernobyl reactor, the accident happened because of a combination of basic engineering deficiencies in the reactor and faulty actions of the operators (as per UN Chernobyl Forum report, the safety systems had been switched off, and the reactor was being operated under improper, unstable conditions, a situation which allowed an uncontrollable power surge to occur). More than 20 years have passed since the tragedy occurred, and it is difficult to tell precisely the number of deaths – past and future – attributable to the Chernobyl accident. Since the...
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...Coca-Cola has recently rolled out the Operational Excellent (OE) Site Lead within all of the facilities. This new position is in place to drive the OE culture, built OE capability, and to deliver the OE vision across the facility. The OE site lead is responsible to provide expertise, training and leadership on Lean Principles and Structured Problem Solving to all employees. Other programs that OE has led to are Total Productive Maintenance (TPM) and Total Quality Management (TQM) Recently Coca-Cola has been rolling out a new program called Total Productive Maintenance. This Total Productive Maintenance is a maintenance program that involves a newly defined concept for maintaining facility and equipment. The goal of the Total Productive Maintenance program is to noticeably increase production while at the same time, increasing employee morale and job satisfaction. Total Productive Maintenance was introduced to help the company to avoid waste, reduce cost and that the product sent to the customer had no defects. This program is set up at Coca-Cola to help the plant reduce unscheduled downtime on the machinery that...
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...“major failures causing significant undesired events are the result of a series of events, and compares it to the reaction of a domino line being tipped over by a single domino chip. And studying chain of event, or probable scenarios is at the heart of RFCA’s” (Perez) The author focuses on FTA (Fault tree analysis) as a tool to determine such root causes. And gives examples of cases where use of these tools could have OR have prevented multiple damages due to one component failure causing failure in surrounding components. RCFA – Root Cause Failure analysis “Root Cause Failure analysis is a structured process to identify any physical, human and latent causes of undesirable event(s).And how such a process can be used in achieving continuous plant reliability improvements by targeting mechanical and organizational deficiencies in a process facility” (Perez). A tool for “Identification and correction of the underlying problem”(Tronskar). “Simply stated, RCFA is a tool designed to help identify not only what and how an event occurred, but also why it happened. Only when investigators are able to determine why an event or failure occurred will they be able to specify workable corrective measures that prevent future events of the type observed.”(Rooney and Vanden Heuvel). The author, Perez,...
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...Spring 2010 School of Engineering Maintenance impact on Production Profitability - A Case Study Växjö, 2010 Thesis no:TEK 028/2010 Obamwonyi Martyn Enofe Gregory Aimienrovbiye Department of Terotechnology (Total Quality Maintenance) Linnaeus University School of Engineering Department of Terotechnology (Total Quality Maintenance) 4SE31E Degree Project Master Thesis Författare/ Authors Obamwonyi Martyn Enofe Gregory Aimienrovbiye Linnaeus University Institutionen / Institution School of Engineering Department of Terotechnology (Systemekonomi) Dokumenttyp/Type of document Examensarbete (Degree Project) Handledare/Tutors Matias Taye Examinator/ Examiner Basim Al-Najjar Title och undertitel/ Title and subtitle Maintenance impact on Production Profitability - A Case Study Sammanfattning/Abstract Maintenance has had a tremendous impact on company’s proficiency to optimize its production system in order to meet its long term objectives. Generally, a production system in which maintenance is not given attention may easily lead to the system producing defective product as a result of machine defect. The purpose of this thesis is to utilized tools and methods to analyze the impact of maintenance implementation in a production system. The analytical Hierarchy process was utilized to filter the defining factors and sub-factors considered to be related to the life length and performance of production equipment in the research which was carried out at SCA...
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...Recommend and Implement a New Maintenance Ticketing Process Comcast South Florida has recently launched its new Customer Guarantee program that guarantees the work and services performed for 30 days or the consumer is able to receive several different packages as compensation. Recently the organization has changed its ticketing process when referring jobs to the Maintenance / Engineering Department and has asked my local leadership team to review and revamp the new process. This proposal provides a brief overview of the current process including its intricacies and outlines how we will perform our research and testing in preparation for our full report. Problem The newly revised Maintenance / Engineering ticketing system (also known as the - refer to maintenance) was intended to streamline the process and reduce downtime. Unfortunately, this revised ticketing process resides within its own system (TTS and Watchtower) and does not communicate with the current billing system (CSG), work order system or the call center. This has caused unnecessary additional down time for customers if their issues were not resolved the 1st time, financial loss from the company’s perspective and an inconvenienced customer. We need to identify a methodology that will allow the new ticketing system to communicate to the traditional billing system and all cross-functional areas. Justification/Feasibility With the new addition of Watchtower and TTS maintaining and issuing maintenance ticket numbers, the communication...
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...The ABC’s of Failure – Getting Rid of the Noise in Your System For the past 40 years, I have observed many companies, including DuPont (where I spent 27 years) pursuing planned maintenance with the standard tools of planned maintenance: inspections, planning, scheduling, materials procurement, CMMS systems, etc. with the same results. They succeed for a while and get their percent planned and scheduled maintenance up to the 80+ only to see that drop back later to 60 I am amazed how many of the companies we work with have had this experience. This pattern of behavior has led us to conclude that the reason for this experience is that only 60% of the normal work of maintenance is inherently plannable. The rest of the work is created by random acts of what we are now calling care-lessness. The sites where we see people break this pattern and achieve 92% to 96% planned maintenance for the long term without regressing, are the ones who eliminate the inherently unplannable work. Of course, this cannot be done by maintenance alone. Everyone who does work at a site contributes to the defects that create the unplannable work, and therefore everyone must participate in eliminating the defects that create the 40% of the work that is unplannable. In the diagram below we attempt to more clearly articulate the true significance of Defect Elimination by outlining the ABC’s of failure. Fundamentally, failures happen because things that exist are not perfect. To reduce failures we must eliminate...
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.... Chapter Failure prevention and recovery 19 Eurotunnel response team during one of their regular patrols in the tunnel Source: Eurotunnel Introduction One obvious way of improving operations performance is by preventing failure. Failure is rarely unimportant, but in some operations it is vital that processes do not fail. Failure in aircraft in flight, for example, or electricity supplies to hospitals, or car seat belts, or the emergency services can be literally fatal. For these operations dependability is not just desirable, it is essential. Even in less critical situations, having dependable processes can give a competitive advantage. But no process is perfect and failures will occur. So it is important that we learn from all failures and have plans in place which help them recover and minimize their effects. Figure 19.1 shows how this chapter fits into the operation’s improvement activities. Operations strategy Failure prevention and recovery Operations process improvement makes processes better Design Operations management Improvement Total quality management organizes process improvement Planning and control Failure prevention and recovery stops processes becoming worse Topic covered in this chapter Figure 19.1 This chapter covers failure prevention and recovery . 618 Part Four Improvement Key questions I I I I I ??? Why do operations fail? How is failure measured? How can failure and potential failure be...
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...River Arch User Fee 451000 - Interest & Dividend Inc 470000 - Rental Income 496000 - Boat Ramp Income 499000 - Miscellaneous Income Total Other Income Total River Walk Income General & Administrative 504000 - Accounting/Audit 506500 - Committees 506600 - Swim Team 508000 - Corporate Fees 511000 - Dues/Subscriptions 524000 - Insurance 528000 - Legal 532000 - Postage/Distribution 534000 - Printing 542000 - Uncollectable Accounts 549900 - Administrative/Salaries Total General & Administrative Common Utilities 551000 - Electricity 552000 - Gas 555000 - Telephone 557000 - Water Total Common Utilities Service & Contracts 566000 - Grounds Maintenance 568000 - Management 570000 - Pool Management 573000 - Security 576000 - Trash Removal Total Service & Contracts Building Maintenance Exp 587000 - General Bldg Maint & Rep 589000 - Lights Total Building Maintenance Exp Page 1 of 2 2012 Budget 371,640.00 371,640.00 2,000.00 3,864.00 6,426.00 4,750.00 5,000.00 11,000.00 100.00 300.00 33,440.00 405,080.00 4,000.00 2,000.00 3,200.00 250.00 279.00 12,000.00 2,000.00 4,700.00 12,000.00 1,000.00 11,000.00 52,429.00 22,000.00 3,000.00 1,950.00 6,000.00 32,950.00 83,000.00 49,279.00 52,000.00 11,000.00 5,000.00 200,279.00 24,000.00 8,000.00 32,000.00 2012 Monthly Budget 30,970.00 30,970.00 166.67 322.00 535.50 395.83 416.67 916.67 8.33 25.00 2,786.67 33,756.67 333.33 166.67 266.67 20.83 23.25 1,000.00 166.67 391.67 1,000.00 83.33 916.67 4,369.09 1,833.33 250.00 162.50 500.00 2,745.83 6,916.67...
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...completed much faster by technicians that perform it regularly and have all of the special equipment necessary. Taking everything into consideration I recommend that we outsource the inspection. Should Pacific Jet outsource the 72 month inspection? This is the first 72 month inspection that our 135 charter company (Pacific Jet) has coming due. Since we are a small operation with only 3 aircraft and 4 maintenance technicians performing a 72 month inspection in-house will be a huge undertaking. The main items to consider are costs, aircraft downtime, and quality control issues. We have to decide if we want to perform this inspection in-house our outsource it. The airlines have been outsourcing maintenance for decades and have accelerated this outsourcing rapidly since 2001. In 2005, some airlines outsourced as much as 62 percent of their maintenance and that number continues to grow. While they have increased their outsourcing of maintenance their accident rates have declined, statistically proving that outsourced maintenance is safe (Armstrong, 2007). There are many companies that could perform this inspection for us if we decide to outsource...
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...performance. Resources include manpower, materials, tools and special equipment. Access refers to when the equipment will be prepared and accessible so that it can be worked on in safe (locked out/tagged out) condition, with necessary precautions taken, permits obtained, and any specialized documentation, drawings, or information in hand. Proper time relates to job start, duration of execution, and completion within the time frame agreed upon with the internal customer during the weekly coordination meeting. The Weekly Expectation Scheduling is the locus from which all maintenance activity is executed. Scheduling should be viewed as the “point” function and “marketing arm” of the system because it yields the earliest tangible results (often within weeks of start up). All individuals and groups perform better and accomplish more with clearly established, communicated and published expectations. When the maintenance function is managed without a weekly schedule, there are no specific expectations as to what is to be accomplished with the resources for which payroll checks will be drawn. Instead, whatever reactive demands are made is what will be done. The fundamental requirement target (the schedule) against which to control, followed by action (execution of the schedule) to achieve the target. The results, measured against the original intention (called schedule compliance), provide feedback for correcting deviations (improving future schedule compliance). Managers...
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...our spirit all aided us to surmount difficulties during doing the research and show our ability confidently as well. We are also indebted to HUCFL Second - year English students for their cooperation to complete our questionnaires and their active contributions to suggest feasible solutions for our research topic. Last but not least, we can’t help mentioning the remarkable efforts of our group members. They conducted the research to the best of their ability and worked very hard to perfect the research as well as possible. Their merits are thankworthy. ABSTRACT Our research was carried out to investigate the attitude of HUCFL Second- year English students toward the school facility protection and some solutions for school facility maintenance. Due to the important of school facilities in the cause of HUCFL’s education- training and its status quo, we carried out the small- scale research to examine main causes of HUCFL’s facility damage. We delivered 20 questionnaires randomly to the Second – year English students and we thereafter analyzed the data collected from those questionnaires. Based on the research findings, we had the clear understanding about the concerned reality of HUCFL’s school facilities and the close relationship between the lack of students’ awareness and the degraded quality of the facilities. What is more, we realized that the students’ responsibility for protecting the school facilities is the main...
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