To get a smooth, reliable and cost
effective maintenance in a company,
different functions in the company
has to be coordinated and not only
the maintenance department alone.
1. Replace
2. Repair
3. Overhaul
4. Rebuild
5. Service / Lubricate
6. Inspect
7. Test
8. Adjust
9. Align
10. Calibrate
11. Install
12. Record Keeping
Equipment's and Machines used to
support manufacturing units /
services
i.e. Industries, Offices, Hospitals,
Hotel
1. Electricity
2. Water
3. Air Electricity :
From Electricity BoardFrom Captive Poser Plant through proper Distribution Panels
Through : High Voltage Supply SystemTo SubstationTo Step-down TransformerTo Distribution PanelTo Manufacturing Plants
Water : Hot – SteamNormalCold
Air : FansAir-conditioningHeaters
Compressed Air : AirOxygenVacuum
Gas Plants : OxygenNitrogenHydrogen
Fuel Gases : LPGCNG
Liquid : DieselPetrolFurnace oil
Solid : CokeCoal
Streaming Production
To Accommodate New Machine
Line Balancing
INSTALLATION – COMMISSIONING
Make Suitable Place, Location in Production line
Following Points to be Considered
1.Foundation
2.Electric Supply
3.Compressed Air
4.Air Conditioning
5.Sound Proof Enclosure
6.Material Handlinga) Raw Materialb) Finish Goodsc) Scrap Handling
1. Temparary Shed2. R. C. C. Structiure3. M. S. Structure
Check Following a) Foundation – Load Bearing Capacity of Soilb) Walls – Load Bearing Walls
Partition Walls Brick Walls, A. C. Sheets, M. S. Sheets
c) Top – R.C.C. Slab, A.C. Sheets, Galvanism Sheet
d) Lighting - Ventilation
1. Very High Skills, Expertise Services
2. Huge Man Power for Short duration
3. Low Skill Jobs
4. Hazardus Jobs
5. Small Jobs, Variety Job on regular basis
1. Check for water leakages
a) Rain Water
b) Toilet Leakages
2. Structural Audit
R.C.C. Beams & Columns, Slabs, Walls
3. Structure Repairs
Plastering
Painting
Type of Fire Extinguisher1.Water2.Sand3.Soda Acid4.Dry Chemical Powder5.Foam6.Co2 Carbon-di-Oxide gas
How to take care1.No Smoking, No Welding2.Fire Extinguishers in near vicinity3.Water hydrants around factory4.Escape routs, ladder in case of fire5.Well designed Electrification6.Automatic Sprinklers.
Type of Fire Extingusher
TYPE OF FIREPaper Wood Cloth
Paint Varnish
PetrolumThinner
Electric
WATER
SODA ACID
DRY CHEMICAL POWDER
FOAM
CO2
SAND
GAS WATER SOLID
1. Waste gases from furnace, boiler, contains corbon-di-oxied (Co2), Carbon Monoxide. Supper di Oxide (So2), and ash & many gases. This should be passed through water sprinkler to tall mast Chimani to atmosphere. This reduces air Pollution.
2. Waste water contains oil, chemicals, pestisdes. This water should pass through effluent treatment plant and then to municipal drain
3. Solid waste – Hazardous solid waste should be collected and hand over to compitent waste processing units.
Most important function of every body
1. Cleanliness
2. Safety Guards
3. Safety equipment's, Uniform, ShoesHelmets, goggles, hand gloves, aprons safety belt
4. Safety awarenessa) Safety Postersb) Training Programsc) Safety Drills
5. Safety ApparatusSafety ShowerBreathing ApparatusStrecher, AmbulanceMedical FacilityDoctor, Hospital
Type of energies used
1. Electrical Power
2. Fuel Oil, Gas, Solid Fuels
3. Water
4. Compressed Air, Gas
5. Light
Check how efficiently we are using energy check energy Bills
Collect data of individual plants, machines use ABC Analysis. Weighted average, Importation creat awareness among employees
Quality Base indices Performance Base indices Compare with standards
AUDIT PROCESS
Audit process is required to measure / review performance and effectiveness of each individual departments.
Following are some of the measuring parameters
1.Overall Equipment Effectiveness (OEE)
2.Availability of Equipment
3.Meantime between FailureMeantime to Repair
1. Overtime worked against plan
2. PM schedule compliance
3. Time taken to answer maintenance call
4. Budget Compliance
5. PM Backlog man hrs.
6. Critical equipment availability
7. Number of breakdowns unplanned maintenance
8. Production equipment performance (output)
9. Equipment performance (Quality)
10. Availability & Reliability
11. Mean Time Between Failure (MTBF)
1. Develop a corrective plan for improving personnel compliance
2. Enhance your decision makinga) prioritizing b) Justifying decision
3. Give tool to negotiate at higher managerial level
4. Provide input for future budgeting 5. Motivate maintenance personnel’s6. Show chances of increase in resources
Utilisation7. Audit report allows you to target areas
of opportunity without re engineering.
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