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Set up any preventative maintenance system takes considerable Time, Effort and Investment.
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PT. MAINTEK TECHNICAL PT. MAINTEK TECHNICAL SERVICESSERVICES
PT. MAINTEK TECHNICAL PT. MAINTEK TECHNICAL SERVICESSERVICES
MAINTENANCE SERVICES
(021) 781 4915, 7883 4282E-mail: maintek@cbn.net.id
Maintenance Systems
Prepared for
Maintek
ClientsJune 2007
Maintenance Systems
To set up any preventativemaintenance system takesconsiderable
Time, Effort and Investment.
Why Bother ?
Not all company management consider a complete and proper maintenance is necessary.
I mean why bother, the plant is still running, sure there are some problems with breakdowns, but they’re eventually fixed anyway.
A spread of heavy duty mining equipment operating with proper maintenance will after two years of operation provide generally around 90% availability.
The same spread of equipment without a proper maintenance system will provide after 2 years of operation from 60% to 40% availability.
Well Consider This
These are true figures based on many observations made over the years in Southeast Asia.Though the figures are for heavy duty mobile plant a similar story would be told for fixed production facilities although probably a lot less dramatic.
True Figures
Let us use a very simple imagined scenario.A mining company needs 100 trucks to produce 10 million tons of coal for one year.
Mining Company
The mining company can receive $40 per ton of coal, which would mean that with proper maintenance (90% Availability) they can expect to receive (9 million x $40) $360 million) gross.
$ 360,000,000 Revenue
Without proper maintenance and let us say 50% availability the company can expect to receive (5 million x $40)$200 million gross.Big difference, $160 million is being lost per year because of decreased production.
$ 160,000,000 Lost
So the company decides to have a proper preventive maintenance system implemented.
Decision
The problem is deciding which preventative
maintenance system to use as companymanagement are unlikely to keep
investingin different maintenance systems that
returnless than required results.
Maintenance management personnel havethe responsibility of ensuring themaintenance team have the tools andequipment required to perform their dutiesefficiently so the company assets cancontinue production at the desired levelsplus the added responsibility of ensuringsafety and budgetary targets are met.
This is where conflicts can commence.
Maintenance teams need time, tools andmaterials to complete their job properly
butproduction targets don’t allow for lengthydowntime.
Any extended downtime equals reducedincome for the business.
How do the maintenancemanagement team balance the
conflicts of their role?
InternetFirstly MaintenanceManagement look foranswers from outside the business.
In today’s modernage of communicationthe internet is normallythe first place they look.
The internet carries a vast amount of dataon the subject of preventative maintenancebut because of the huge volumes ofinformation confusion sets in.
There are literally hundreds of maintenance
systems available and thousands ofconsultants telling you “Their system isbest”.
What is Best?
What system is best?
Is it Condition Based Maintenance (CBM), Reliability Centred Maintenance (RCM), Risk Based Maintenance (RBM), Planned Maintenance Optimisation (PMO) or one of the many other maintenance systems?
In reality, any step forward towards
better maintenance, no matter how small, is a step in the right
direction.
What Happens Next
At this point the Maintenance Manager is
overwhelmed from the vast amounts of
internet information.
The Maintenance Manager has twochoices……………
1.
Try to keep the maintenance
division going without any
real change.
DO NOTHING
2.
Contact consultants
for moreinformation.
ACTION
Consultants
All maintenanceconsultants will
havespecialistmaintenanceskills and providetheir skills to
clientsfor one reason………
To earn income.
Most maintenance consultantswill work in one of two ways:
Method 1.
Do all the workfor you and tellyourmaintenancepersonnel whatto do.
Method 2.
Provide trainingclasses to teach your
maintenancepersonnel thetheory of theirMaintenancesystem.
Both of these methods have merit but both have
shortcomingsand the Return On Investment
(ROI) for the client has not been
maximised.
How is Maintek Different?Maintek takes a totally different approach.
Maintek does not believe the client should betotally reliant on a consulting company for theirmaintenance needs.
Maintek believes the best results are achievedby up-skilling the client’s own personnel so theycan produce the best results independently.
To Maintek it is simple, the foundation of all efficient Maintenance Systems is a properly functioning CMMS (Computer Maintenance Management System).
(There are simply too many maintenance tasks to be remembered by one person or even several persons)
Maintek would join with your company’s maintenance team and implement (Install) a CMMS Program.
Foundation
Maintek would use the existing maintenance strategies (tasks) already being used by the company maintenance team.
Working together will mean the need to have lengthy training sessions is eliminated as training takes place during working hours over a period of time.
Usually the greatest downfall of most maintenance programs is when Preventive Maintenance (PM) tasks are forgotten, ignored and or are not completed fully.
This leads to a cycle:The more PM tasks which are not completed leads to more breakdowns.
The more breakdowns that occur leads to more PM tasks which are not completed.
Why? Because the maintenance staff are too busy fixing breakdowns.
This is known in the maintenance fraternity as the:
“Vicious Cycle of Reactive Maintenance”
One of the most common reason as to why the Vicious Cycle starts is because.Management will not allow the maintenance crew enough time or resources to complete preventive maintenance tasks.
Vicious Cycle
This is a common mistake made by many managers, the thinking goes that by not stopping the production facilities for maintenance will allow for increased production.Well the reverse is true, less maintenance leads to more breakdowns and less production.
Less Maintenance. More Breakdowns. Less Production.
All items of equipment which do not receive the required preventive maintenance will for sure breakdown, and most likely at the most inconvenient time.
There is one fact which can not be ignored.
An unplanned repair cost is many times greater than a planned repair.
In fact Caterpillar have estimated that an unplanned repair can be 2 thirds more expensive to complete than a planned repair.
Unplanned Repairs
Safety
So far we have only talked about production.Safety has not been mentioned.An item of equipment that receives regular maintenance will be less likely to fail and cause a fire or injure the operator.
In fact in this current period of time where legal action is far more common than it used to be. It could be considered to be criminally negligent in some law courts for a company to operate facilities that are not fully protected by a properly operating preventive maintenance system.
Litigation
Work Smarter not Harder
Some companies will buy a CMMS program on a CD and give this to the maintenance people and expect this to be the end of their maintenance problems.This approach will not work, in fact the money paid for the CD will be wasted.
WHY because there are simply too many tasks that need to be completed before a CMMS will become functional.
The existing maintenance people will already have a full workload and to expect that there will be enough time to start up a new CMMS is unreasonable.
Too Many Tasks.
A complete CMMS program consists of many parts.Asset Register (Equipment)Preventive Maintenance (PM) Tasks.Scheduling of PM’sOperation of a Hardcopy Work-order System.
Why ?
Collection of the maintenance data. (Historical)Input of the historical data into the CMMS.And so on.In fact think of the CMMS CD as only one part of the maintenance tool kit.
Work Orders Produced
Maintenance Supervisors Plan Work
Historical Data Input to CMMS
Maintenance Crews Alerted
Maintenance Historical
Data is Collected
Maintenance Work
Completed
Spare Parts
Collected.
Computerised
Maintenance
Management
Systems.
CMMS
Maintek unifies the maintenance personnel
into one dynamic team with one goal……….
Maintenance Excellence
Each maintenance task is closely examined
with the client’s maintenance team in aworkshop situation and collectively theclient’s maintenance team determine if
eachtask is adding to the reliability ofthe asset.
As each task is analysed the client’sMaintenance team are gaining practicalexperience in the formal theories ofmaintenance excellence and continualimprovement.
The coaching is practical experience using
The maintenance teams own data so eachmember of the team retains the
knowledgetransferred from Maintek.
All the work is performed by the client’smaintenance team under the direction ofMaintek’s senior facilitators and reliabilityengineers so the client’s maintenance teamimmediately take ownership of the processbecause it is their work and they have madethe decisions.
The change process is adopted smoothly asall stakeholders know why change wasneeded and the can see the benefits.
Maintek ensures the client’s own maintenancepersonnel are proficient in their newly gainedknowledge and the system continues withoutthe need of additional and ongoing consultingservices thus saving the client two fold,increased production with lower maintenanceexpenditure.
Maintek is always available for ongoingsupport, if required.
Implementation
Maintek’s method is a “Top Down – BottomUp” approach, meaning support is
requiredfrom top company management so themaintenance personnel can work from thebottom up to implement maintenanceexcellence and achieve the business’sgoals.
“Top Down – Bottom Up”
Support from Management
Support from Maintenance Team
RESULTS
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