Module_2_Industrial_Maintenance_Manageme.pptx

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1. ASMEN WIRE PROCESSING PLANT TECHNIQUE DEPARTMENT TRAINING ON INDUSTRIAL MAINTENANCE MANAGEMENT PRESENTED BY SOLOMON MINDA DATE 23/10/2024

2. Industrial Maintenance Management Industrial maintenance management is the systematic approach to ensuring the optimal performance, reliability, and safety of industrial assets.

3. Topic Outline PART ONE:-MAINTENANCE FOUNDAMENTAL AND MAINTENANCE MANAGEMENT OVERVIEW General Terminology What is maintenance Maintenance Functions Importance of maintenance Objectives of maintenance Area of maintenance Impact of poor maintenance Cost of maintenance Maintenance management PART TWO:-MAINTENANCE PLANNING AND SCHEDULING PART THREE:- CONTROL OF MAINTENANCE PART FOUR:-COMMON MAINTENANCE ACTIVITIES

4. Objectives for the discussions; By the end of the discussions; students should be able to; Know the basic types of maintenance activities Understand the concepts of Maintenance Planning and Scheduling Understand the controls of maintenance programs Learn some common maintenance activities

5. Maintenance Fundamental and Maintenance Management PART ONE

6. Maintenance Fundamental General terminology 1. Maintenance Combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it can perform the required function .(አንድን እቃ ተፈላጊውን ተግባር ሊያከናውን በሚችልበት ሁኔታ ውስጥ ለማቆየት ወይም ወደነበረበት ለመመለስ የሚደረግ ቴክኒካዊ እና አስተዳደራዊ እርምጃዎች ጥምረት 2 . Improvement Combination of all technical, administrative and managerial actions, intended to ameliorate the dependability of an item, without changing its required function( የሚፈለገውን ተግባር ሳይለውጥ የ አንድን እቃ አገልግሎት ለ ማሻሻል የ ሚደረግ/ የሚ ታቀዱ ቴክኒካዊ እና አስተዳደራዊ እርምጃዎች ጥምረት )

7. 3 . Modification Combination of all technical, administrative and managerial actions intended to change the function of an item . ( የእቃውን ተግባር ለመለወጥ የታቀዱ ሁሉንም ቴክኒካዊ, አስተዳደራዊ እና አስተዳደራዊ እርምጃዎች ጥምረት ) 4 . Preventive Maintenance Maintenance carried out at predetermined intervals It can be Condition based or Predetermined maintenance Condition based Maintenance :-based on performance and/or parameter monitoring and the subsequent actions Predetermined maintenance :-carried out in accordance with established intervals of time or number of units of use but without previous condition investigation Maintenance Fundamental

8. 5. Corrective maintenance :- carried out after fault recognition and intended to put an item into a state in which it can perform a required function can be performed as Deferred or Immediate maintenance Deferred Maintenance :-not immediately carried out after a fault detection but is delayed in accordance with given maintenance rules . Immediate Maintenance :- carried out without delay after a fault has been detected to avoid unacceptable consequences. 6 . Availability Performance Ability of an item to be in a state to perform a required function under given conditions at a given instant of time

9. 7. Reliability Ability of an item to perform a required function under given conditions for a given time interval .( አንድ እቃ ለተወሰነ የጊዜ ክፍተት በተሰጡ ሁኔታዎች ውስጥ አስፈላጊውን ተግባር ለማከናወን ያለው ችሎታ ) 8 . Maintainability Ability of an item under given conditions of use, to be retain in, or restored to, a state in which it can perform a required function, when maintenance is performed under given conditions and using stated procedures and resources( አንድ እቃ ከጥገና በሗላ የሚፈለገውን ተግባር ሊያከናውን በሚችልበት ሁኔታ ውስጥ የሚቆይበት ወይም ወደነበረበት ሁኔታ የሚመለስበት ጊዜ መለኪያ ነው

10. Keeping equipment available , reliable and optimized Any activity carried out on an asset in order to ensure that the asset continue performing its intended functions, or to repair the equipment W hat is maintenance ? Asset ? Asset :- any item of physical plant or equipment It is the basic unit of maintenance

11. Maintenance Functions? Maintenance of existing equipment Equipment inspection and service Equipment installation Maintenance storekeeping Craft administration The maintenance department has a more involved list functions or responsibilities . The followings are the main categories

12. Maintenance Functions? 1 Maintenance of existing equipment's It is the basic reason for the department The department shall utilize cost effective maintenance program The maintenance department will make repair to the production equipment as quickly and economically as possible However , performing all the above tasks depends on one important item accurate record keeping . With out accurate record, it is impossible to complete the assigned task in timely and cost effectively manner

13. Maintenance Functions? 2 Equipment inspection and services This task requires determining the proper lubricant for the equipment . In addition to the types of the lubricant , the proper amount and time interval of application of the lubricant are necessary. The inspections are required to ensure that the equipment is in safe operation condition and is being serviced in timely manner Some installations will require the operation personnel some routine lubrication and servicing. Even where this is a common practice , the maintenance personnel should oversee the completion of the task

14. Maintenance Functions? 3 Equipment installation This responsibility varies from industry to industry and depends of the size of the installation and maintenance workforce Some industrial facilities that require constant changeover may have an installation department When large installation project occur in some industries with out the necessary workforce , outside contractors are used to supply the needed manpower

15. Maintenance Functions? 4. Maintenance storekeeping Receiving and distribution of the spares necessary for the repair and up keep of the plant equipment is one of the responsibility of the maintenance personnel's There are several important tasks involved in this responsibility. The first is recording the necessary spares for each piece of equipment . With all of the spares recorded , the maintenance department has the responsibility of setting the inventory level for each parts. As the spars are used, the replacement has to be ordered

16. Maintenance Functions? 5. Crafts administration Controlling the manpower used by the maintenance department Determining the size of the workforce also on eof the responsibility in this area The responsibility providing the required resources tools and supplies for the craft is also included in this area

17. Importance of Effective Maintenance Strategies Increased Efficiency Effective maintenance strategies reduce downtime and minimize interruptions in production, leading to higher output and improved overall efficiency. Reduced Costs Proactive maintenance helps prevent costly breakdowns and repairs, leading to lower operational expenses and improved cost control. Enhanced Safety Regular maintenance ensures equipment is functioning safely, reducing the risk of accidents, injuries, and workplace hazards. Increased Asset Lifespan Proper maintenance practices extend the useful life of industrial assets, delaying replacement and maximizing return on investment.

18. Minimizing lose of production time Minimizing the repair time and repair cost Minimizing the loss due to production stoppage Efficient use of maintenance personnel and equipment Prolonging the life of capital To keep all productive asset in good working To maximize efficiency and economy To improve the quality of product and productivity Maintenance Objectives

19. AREA OF MAINTENANCE Civil Maintenance- Building construction and maintenance, maintaining service facilities Mechanical Maintenance- Maintaining machines and equipment's, transport vehicles, compressors and furnaces. Electrical Maintenance- Maintaining electrical equipment's such as generators, transformer, motors, telephone systems, lighting, fans, etc.

20. IMPACT OF POOR MAINTENNACE Lower production capacity Higher production cost Poor product and service quality Lower employee and customer safety decreased customer satisfactio n

21. COST OF MAINTENNACE

22. What is Management ? Arts of doing what is possible out of what is available Sharing in overheads that leads to unity of goals Coordination of different tons in a harmony Guaranty of never being caught in surprise What is Maintenance Management ? It is the organization of maintenance with in an agreed policy Maintenance policy :- a statement of principle used to achieve maintenance objectives and guide Maintenance M anagement D ecision M aking

23. KEY STRATEGIES FOR EFFECTIVE MAINTENANCE MANAGEMENT Seven strategies for effective maintenance management Preventive Maintenance :-schedules regular upkeep to avert equipment failures Predictive Maintenance:- Forecasts potential equipment malfunctions before they occur Condition-Based Maintenance :-Conditions drive decisions – and data is empowering . Reliability-Centered Maintenance (RCM):- Prioritize what needs to be done and when. Utilizing RCM means basing maintenance decisions on the needs of an organization.

24. 5. Total Productive Maintenance (TPM):- utilizes and engages the entire workforce in maintenance activities – from the shop floor to management. The goal here is to foster a shared responsibility for equipment care through active involvement and preventative maintenance from all different parties. 6 Root Cause Analysis (RCA):- When failures occur, use an RCA to dig deep to uncover the underlying causes rather than addressing the symptoms . 7 Computerized Maintenance Management Systems (CMMS):- sophisticated software that centralizes maintenance data, automates maintenance scheduling, and tracks performance metrics

25. Maintenance Planning and scheduling PART TWO

26. Planning Planning of maintenance jobs basically deals with answering two questions, ‘ what ’ and ‘ h ow ’ of the job; ‘ what activities are to be done ?’ and ‘ how those jobs and activities are to be done ?’ Maintenance Planning & Scheduling

27. The Role of Planner

28. Maintenance Planning and Scheduling Planning Management survey shows that the average productivity of maintenance employee is between 25 to 35% This mean that a craft man has less than 4 hours of productive time per 8 –hours day due to poor maintenance management

29. Maintenance Planning and Scheduling The followings are some of the cause of west of productive time Weighting for instruction Looking for supervisors Checking out the job Multiple trips to the store and No special tools Weighting for approval Too money craft workers per job Insufficient worker schedule for the jobs Incomplete planning and communication Weighting for equipment to be shutdown Weighting for drawing from engineers

30. Maintenance Planning and Scheduling On the average, 2 hours are lost every time worker is pulled off a job for any reason To prevent this major loss of productivity , it is necessary to implement some form of job planning function The concept of job planning is what to be done and how is to be don e Job planning consists of two main areas ; crafts skill material require for the job

31. Maintenance Planning and Scheduling Planning Can be accomplished by the supervisor if there are relatively few maintenance personnel If there are more than 20 crafts man , the planning is better to be done by a separate maintenance planner personnel

32. Maintenance Planning and Scheduling Types of work to be planed Emergency Maintenance and critical Maintenance (work needed immediately or within 24 hours) is seldom planed This request are of sort duration and performed so quickly that there is no time to plan them This types of work orders should not be considered in planning function

33. Maintenance Planning and Scheduling Types of work to be planed Normal corrective or routine work orders should be the primary consideration of the planning function This work orders are received and placed in work backlog As the workforce and material become available , then it is scheduled Included in this types of work are predictive and preventive maintenance work order

34. Maintenance Planning and Scheduling Types of work to be planed The other group of request that can be planned are the shutdown , turn around or the outage work order For this types of work order , it is important that the equipment be shutdown and overhauled with in the shortest possible time

35. Maintenance Planning and Scheduling How to plan maintenance work Effective planning require the planner to be skilled and knowledgeable in the craft area they are planning The planning begins once the work order is approved by the management It is then assigned to the planner The planner must decide the following The craft required The time required ‘ The material required and Whether outside help in the form of specialist, contractor and special rental equipment re required

36. Steps of Job Planning

37. Maintenance Planning and Scheduling Benefits of planning maintenance Long-term plans insight Decision making support Figuring out area of cost reduction Training areas and needs Optimizing connectivity among operation and maintenance department

38. Scheduling Scheduling Scheduling is the function of coordinating all of the logistical issue around the issues regarding the execution phase of the work. Scheduled of maintenance jobs basically deals with answering two questions— ‘ Who ’ and ‘ When ’ of job, i.e ., “ who would do the job ” and “ when the job would be started and done ”.

39. Scheduling Maintenance Schedule Technique: . 1. Weekly general schedule is made to provide weeks’ worth of work for each employee in an area. 2. Daily schedule is developed to provide a day’s work for each maintenance employee of the area . 3. Gantt charts are used to represent the timings of tasks required to complete a project. 4. Bar charts used for technical analysis which represents the relative magnitude of the values . 5. PERT/CPM (Program Evaluation and Review Technique/Critical Path Method) are used to find the time required for completion of the job and helps in the allocation of resources .

40. Planning and Scheduling Contributes Effective Planning and Scheduling contribute significantly to the following ; Reduced maintenance cost Improve utilization of the maintenance workforce by reducing delays and interruptions. Improved quality of maintenance work by adopting the best methods and procedures and assigning the most qualified workers for the job.

41. Planning VS. Scheduling

42. Planning VS. Scheduling

43. How Maintenance Activities are Managed? Maintenance activities can be managed by; Organizing Team Programming Activities Planning Activities Establishing Work Flow Creating Procedures Controlling Costs/Finance

44. Basic Types of Maintenance Activities These are some of the Basic Types of Maintenance; Preventive Maintenance (PM) Predictive Maintenance or Condition Based Maintenance ( PdM ) Corrective Maintenance (CM) Reactive Maintenance (RM) Redesign and Modification Reliability Centered Maintenance (RCM)

45. Control Of Maintenance PART THREE

46. Control of Maintenance By requirements : How are maintenance activities being controlled at a desired output? Authorization (Authorized by and official) Maintenance Plan and Schedule Issue of Materials against proper authorization Maintenance Budgets Equipment Records

47. Control of Maintenance By critical questions: Along maintenance activities, here are some issues that can be met How much maintenance is needed? What size of maintenance crews must be used? Can maintenance be sub-contracted? Should maintenance staff be covered by wage incentives schemes? Can effective used be made of computers for analyzing and scheduling activities?

48. Common Maintenance Activities PART FOUR

49. Common Maintenance Activities Repair Activities To fix or to mend (a thing that is suffering from damage or fault ) Examples: Equipment Overhaul Car Repair Rectification of damaged components Tapping/Welding of holes Alignment of pumps Hot bolting Pipe/Spool Replacement

50. Common Maintenance Activities 2. Lubrication Process of adding lubricant (grease or oil) to a solid-solid contact . The reduced friction leads to less wear, heat generation and energy loss – all of which reduce operation costs and downtime . Cooling and debris removal are the other important benefits provided by a fluid lubricant .

51. Common Maintenance Activities 2. Lubrication Important things to consider;

52. Common Maintenance Activities 3. Calibration Comparison between two measurements one of known magnitude or correctness made or set with one device and another measurement made in as similar a way as possible with a second device . The device with the known or assigned correctness is called the standard. The second device is the unit under test, test instrument , or any of several other names for the device being calibrated.

53. Common Maintenance Activities 3. Calibration Calibration Record

54. References

55. References Roy Zapata (2015). Basic Concepts of Maintenance 1 and 2. Education and Training Technology Unit, Center for Industrial Technology and Enterprise (CITE) Cebu City. B.S Dhillon (2002). Engineering Maintenance: A Modern Approach. CRC Press LLC S. Kumar & N.Suresh (2008, 2nd Ed.). Production and Operations Management, Chapter 8: Maintenance Management. New Age International Publishers . Online References: http://maintenanceworld.com http://www.engineeredsoftware.com http://www.plantservices.com http://www.lifetime-reliability.com http://reliabilityweb.com http:// www.maintenanceonline.co.uk

56. Questions???

57. Assignment No. 1 Essay: Discuss your perspective of Maintenance Management. (20 pts) Explain how Maintenance Planning and Scheduling will influence your management style? (20pts) Share your thoughts on the ways of controlling maintenance. (20 pts) Aside from the common maintenance activities shared from this discussions, discuss an another one maintenance activities you may know. (20 pts)

58. Thank You!