Maintenance Planning, Techniques & Cost Control
Snehal Pandya
Why Maintenance
Trouble free operation
Reliability
Quality Products
Maximum return from asset
To maximize the useful life
Reduces the cost
Increases the productivity
Safety Integrity
To give high confidence in future business
performance and profit
Staff Motivation
Environment Protection
What is Maintenance
The combination of all technical and associated
administrative actions intended to retain an item in, or
restore it to, a state in which it can perform its required
function.
To ensure that assets deliver the required function
and level of performance in terms of service or
production, in a sustainable manner, at an optimum
whole life cost without compromising health, safety,
environmental performance, or the organization's
reputation.
What is Maintenance
Recording and maintenance of plant documentation
Provision of information on present plant’s conditions
Monitoring of defects, failures and their follow up
Prepare, issue and expedite orders for spare parts,
material and services
Cost control for spare parts, material and services
Process Permit to Work system
Control and follow up of de-energizing processes of
related systems
Scheduling and Follow Up of plant outages
Management of spare parts inventory
Maintenance Policies
Breakdown / Corrective / Reactive
• Maintenance activities are limited to repairing the
equipment when a failure appears.
Preventive
• Maintenance activities are developed with the
intention of reducing the probability of failure of
facilities or the degradation of a service.
Predictive / Condition Monitoring
• Selected physical parameters associated with an
operating machine are sensed, measured and
recorded for the purpose of analyzing & comparing
the data and for making decisions related to the
operation and maintenance of the machine
Maintenance types
Reliability Centered Maintenance
• RCM Method optimizes the number of scheduled
maintenance tasks
Major
Turnaround
Long term asset replacement plan
Maintenance Methods
Self
Semi Outsource
Outsource
Specialized jobs
Maintenance Hurdles
Schedule Conflicts
Hiring
Breakdowns
Training
Excessive Inventories
Lack of Management Support
Budget Control
Maintenance Trends - TPM
Tries to maximize overall equipment effectiveness
and overall efficiency.
Develops a preventive maintenance program for the
lifecycle of the equipment.
Uses team-based concepts.
Involves operators in maintaining the equipment.
Uses motivational management (autonomous small
groups) to promote preventive maintenance
Zero Maintenance
Maintenance Trends
Doing more with less. Managers are charged with
the task of improving maintenance, accomplishing this
objective with reduced capital outlay, less time and
fewer people. As a result, managers are constantly
seeking ways to improve efficiency. For instance,
they're getting better at planning and scheduling.
Additionally, many are starting to use time-saving
products for maintenance tasks.
Maintenance Trends
Automation. One big measure is the automation of
maintenance leading to changes in the way they're
planned, executed and tracked.
the three significant automation developments
include: 1) increased reliance on handheld devices to
minimize paperwork and boost the accuracy of data
collection, 2) integration of management and
maintenance management functions and
departments, and 3) greater focus on integrating
control systems (hardware and software).
Maintenance Trends
Outsourcing is on the rise as a growing number of
businesses are choosing to turn over their
maintenance functions to outside contractors. They
are outsourcing to better concentrate on core
competencies as well as to acquire expertise they
would not be able to develop on their own. For
example, service providers can teach a company's
maintenance staff how to perform tasks faster and
better. Additionally, managers often enjoy fixed costs
when they use outside contractors and can ultimately
cut overall maintenance expenses.
Maintenance Trends
Increasing complexity. This trend is related to
outsourcing as companies often decide to outsource
because of the growing complexity of maintenance
management.
Maintenance Trends
Value-driven design. Workspaces that are flexible,
able to accommodate multiple functions and capable
of supporting cutting edge technologies, such as
wireless LAN, are much coveted. In short, this value-
driven trend is characterized by a renewed emphasis
on maximizing usage and practicality.
Maintenance Trends
Inventory Management keeping minimum inventory,
making inventory pools and JIT are the some of the
new techniques to have better inventory
management.
Maintenance Trends
Short-term staffing. Managers are increasingly
relying on supplemental labor to help their in-house
staff to cope with unplanned work and to ensure that
their facility runs at full capacity, all the time.
Maintenance Mantras
5P’s - Proper Planning prevents Poor Performance
First Time Right – Every Time Right
Prevent the wastage – As your Customer doesn't
pay for it
Zero Leakage
Thanks.
