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SEMINAR ONMAINTENANCE STRATEGIES FOR
IMPROVEMENT OF PRODUCTIVITY AT INDUSTRY
By
GREEJESH PRAKASH
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Key Phrases
■ Maintenance, Maintenance Strategy, Types of Maintenance, Maintenance System,
Productivity, Maintenance Engineering, Maintenance Cost
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Objectives
■ To highlight the benefits of maintenance strategy
■ To study the new strategy of maintenance for better productivity
■ Approaches for the better maintenance strategy leading in to better profitability
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What is Maintenance Strategy?
“Management method used in order to achieve the maintenance
objectives.”
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Maintenance Objectives?
■ The targets assigned to or accepted by the management and maintenance
department.
■ Targets may include availability, cost reduction, product quality, environment
preservation, safety
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Introduction
■ Maintenance is an activity carried out for any equipment to ensure its reliability to
perform its functions
■ It is any activity carried out on an asset in order to ensure that the asset continues
to perform its intended functions
■ To repair any equipment that has failed
■ To keep the equipment running, or to restore to its favorable operating condition
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Another Perspective
■ Maintenance function is not only to maintain
■ Its also to enhance the process or the plant operation system
■ With the turnaround planning.
■ Most management now saw maintenance efficiency as
■ A factor that can affect the all business effectiveness and risk-safety,
■ Environmental integrity
■ Energy efficiency
■ Product quality and customer service and not contained only to plant availability and cost.
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Another Perspective
Maintenance
Environmental integrity
Energy efficiency
Product quality
customer service
Plant
Availability
and
Cost
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Methodologies
Direct Participation
Technical Experience
Primary Sources
Internet Studies
Books
Interviews
Secondary Sources
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Literature Review
FIRST GENERATION SECOND GENERATION THIRD GENERATION
Fix it when it broke Scheduled overhauls
Systems for planning and controlling work
Low-tech computerization
Condition monitoring
Design for reliability and maintainability
Hazard studies
High-tech computers
Failure Modes & effect analysis
Expert Systems
Multi-tasking and team work
1930 1940 1950 1960 1970 1980 1990 2000 NOW
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Literature Review
Fourth Generation of Maintenance
Definite negotiation of risk
Coherence between functional demand, equipment design and maintenance
Development in information
technology to detect, predict, diagnose and
prevent
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Literature Review
Fourth
Generation
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Different Strategies
Maintenance Strategy Maintenance Approach Signification
Breakdown Maintenance Fix-it when broke Large maintenance budget
Preventive MaintenanceScheduled Maintenance
Periodic component
replacement
Predictive Maintenance Condition-based MonitoringMaintenance decision based on
equipment condition
Proactive Maintenance Detection of Sources of Failures Monitoring and correcting failing
root causes
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Different Strategies
■ Reliability Centered maintenance
■ Root Cause Failure Analysis
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Discussion
■ In the maintenance enterprise state, presentation assurances and constant
upgrading goals deliver better switch over maintenance outcomes
■ Guarantee manufacture goals which are actuality stretched
■ The assortment of a precise equipment of low installed budget helps to decrease
budget
■ Driving up maintenance budget and downtime which is not promising to the vender
maintenance team
■ Therefore an enhanced solution should be a combined and aligned method
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Finding
■ Maintenance should be initiated when the facility or system is just a proposal, which
is even earlier the preparation stage
■ And lasts up until it is time to for the facility to de-commissioning
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Finding
Proposal Construction Commissioning
Operation Decommissioning
Integrated and aligned approach of maintenance program
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Findings
■ By dropping the direct and indirect cost of system failure, the perception of
productive, effective and cost-effective can be attained
■ Return of Assets = Revenue -------------------------------- (1)
(Asset Value)
■ Revenue = Price x Volume -------------------------------- (2)
■ Volume = Max. Capacity x Overall Equipment Effectiveness ------------- (3)
Effective maintenance has a constructive result on calculation (1), (2) and (3).
Enhanced maintenance assistances to improve efficiency by dropping the need for
costly capital advancements to upturn output.
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Effective Maintenance Vs Non Effective Maintenance
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Conclusion
■ fix-it-when-it-broke to a more complex approach
■ adopted maintenance strategy of a more integrated approach and alignment
■ maintenance will also be part of the investment decision-making
Improved Maintenance
Effectiveness
Productivity
Profitability
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Recommendation
■ Any industry should use effective strategy in order to improve efficiency
■ Reducing the direct and indirect cost of maintenance using preventive and
predictive maintenance will remarkably reduce the maintenance cost
■ Maintenance actions could be started when the facility or system is just a proposal.
Proposal Construction Commissioning Operation
Decommissioning
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References
■ HISHAM BIN JABAR, Segi Perkasa Sdn Bhd, PLANT MAINTENANCE STRATEGY: KEY
FOR ENHANCING PROFITABILITY
■ General Electric (www.ge.com)
■ Dhillon, S. B. (2006). (2006) Maintainability, Maintenance, and Reliability for
Engineers
■ Mobley, K. (2004). Maintenance Fundamentals (2nd edition). Elsevier Inc.
■ Moubray JM. (2000). Maintenance Management – A New Paradigm. Retrieved from
Maintenance Resources.Com