pm org

nawAS IS BUSINESS PROCESS

NEW ALLENBERRY WORKS

AS IS BUSINESS PROCESS STUDY

(NEW ALLENBERRY WORKS FARIDABAD)

DOCUMENT INFORMATIONSAP MODULE PLANT MAINTENANCEKEY USER BHAIRUN SINGHCREATION DATELAST UPDATE DATE 31-07-2006VERSION 1.1

REVIEW HISTORYREVIEWER DESIGNATION SIGNATURE

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Organization

Plant Maintenance

General Explanation

Maintenance Organization basically consists of Plant, Maintenance Planning Plant, Location, Planner Groups and Plant Section.

Maintenance Plant

The maintenance plant for a technical object is the plant at which it is installed.

NAW has got only one plant where maintenance activities are to be performed.

Maintenance Planning Plant

The Maintenance Planning Plant for a technical object is the plant in which the maintenance tasks for the object are planned and prepared. Maintenance Planner Groups work at the maintenance planning plant to plan and prepare the maintenance tasks for the plants that are assigned to the maintenance planning plant.

In NAW, Maintenance activities are planned centrally within the company.In that sense Maintenance Planning Plant at NAW will be one.

NAW has got only one plant so far as maintenance activities are concerned.

Location

The key in this field indicates a geographical location from the maintenance point of view.

NAW do not sub-divide the maintenance plant into sub locations.

Maintenance Planner Groups

There are Groups of employees responsible for the planning and processing of maintenance tasks in any plant.

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Maintenance work in NAW is divided into two groups i.e. Mechanical Maintenance and Electrical Maintenance and both the groups are headed by different officials. Both the groups have their own teams comprising of employees with several special fields to attend the maintenance jobs.

Maintenance Plant Section

It is a sub–division of maintenance plant into production areas. Machines or set of machines, which are represented in the system as pieces of equipment or functional location, are installed in the plant section.

NAW has got no plant sections defined as such but basically plant consists of Hobbing Section, Heat Treatment Section, Milling & Drilling Section, and Grinding Section.

Beside there are following areas which are managed and operated by Contractors but the maintenance activities are done by NAW.

Turning CNC TurningGrinding

Storage for Spares

NAW has got one central Stores for the storing the maintenance spares.The central store is called General Stores and is maintained by the Stores Dep’t itself.

Purpose

This contains the functions for Plant Maintenance.

Plant Maintenance comprises of the following activities:

Inspection

All measures which establish the actual condition of a technical object.

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Preventive maintenance

All measures which maintain the ideal condition of a technical object.

Repair

All measures which restore the ideal condition of a technical object

Other measures taken using the maintenance organization

Integration

In absence of any ERP System, no integration with other modules exists All activities are limited to interaction with Production and Materials Dep’t for attending the Preventive or Predictive Breakdowns, Repair complaints and getting spares (if required) to attend the complaint.

Technical Objects

NAW’s technical system should be sub divided in different function location followed by sub functional location, equipment and sub equipment.

NAW’s technical objects are those, which cannot be dismantled and used for different production stages.

The business object” Equipment” is an individual physical object that is to be maintained independently. Machines in the plant are described as equipments and the motors can be defined as the sub equipment.

All the objects are generally immovable and that usually have a long operational life.

Information about technical objects and equipments is stored in FoxPro database.

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Equipments Category

Different categories of equipments handled are

Production Equipments like Lathes, Hobbing, Shaving, CNC’s etc. PRT (Fork Lifts etc) Calibration and testing equipments

(Only Maintenance Dep’t equipments like multimeters etc).

Equipment Master Data No

Approximately 500 no equipment will be managed in the system.

Equipment Coding

NAW has its own coding system for various equipments but the sub equipments are not codified.

History is required to be tracked at the equipment level.

No cost analysis or damage analysis concept is followed.

Warranties

NAW track warranty from suppliers for original equipments (various machines, compressor, DG sets etc)

Usage History

Breakdown history is being maintained like time of breakdown, nature of breakdown, work done, M/c ok time, spares used.

Task List

Maintenance Task list describe a sequence of individual maintenance activities which must be performed within a company. Task lists are used to standardize these recurring work sequences and to plan them more effectively. Many manufacturers deliver their technical objects together with

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maintenance task lists; these task lists are, however, frequently created within the company itself.

Activities for a technical object include for example Inspections Maintenance Repairs

Task lists help to reduce the maintenance effort.

Using maintenance task lists, you can reduce the time required to create maintenance orders and maintenance items as you can refer back to the operations and sequences already entered in the maintenance task list.

NAW uses maintenance task lists in the following areas of Plant Maintenance:

Preventive maintenance Predictive maintenance

Maintenance task lists contain important information such as general checklist, spares and tools required for the work steps or the time required to perform the work

Machine History, Running Breakdown points and Health Report generated by Production user is also considered during maintenance.

Maintenance Planning

Purpose

Ensuring a high availability of objects in the long term is an important part of Plant Maintenance. Planned maintenance is used to avoid system breakdowns or the breakdown of other objects, which - in addition to the repair costs - often result in much higher costs subsequently owing to production breakdown.

There are many benefits in using planned maintenance within any company. It is the generic term for inspections, preventive maintenance and planned repairs, for which the time and scope of the work can be planned in advance.

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Another reason for planned maintenance is the need for quality assurance, since, for example, the quality of products manufactured at a technical system is substantially affected by the operating condition of the production plant.

It is also often more cost-effective to maintain objects regularly, and therefore prevent a much more expensive breakdown. You can determine the data required for this using past data supplied by the system.

Maintenance planning is done for each and every equipment in NAW.

NAW has different frequencies of preventive maintenance, predictive maintenance, strategy based e.g. daily, weekly, monthly, quarterly and so on.

At NAW Preventive maintenance is planned for each and every maintenance equipment and not for a group of maintenance objects. (E.g. one plan for a production line consisting of several pieces of equipments)

At times external services are also availed for specific jobs.

There are various machines under Annual Maintenance Contract. NAW would like to capture all data pertaining to these machines. These could be contract details, next due date of maintenance / Service Engineer’s visit, problem attended and other details giving total history of the particular machine.

Business Process

Breakdown notification

Breakdown complaint is entered by the concerned Production Dep’t in “Breakdown Reporting Register” kept at Electrical and Mechanical Maintenance Department. Both the Maintenance Departments have separate registers for recording such complaints.

Details such as Dept, Machine no., nature of problem, date and time are entered while registering the complaint in the register by the production user.

On the basis of complaint, the machine is attended by either Electrical or Mechanical Maintenance personals.

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Sometimes Production Department, not sure of nature of problem, register the breakdown complaint with both Mechanical and Electrical Departments.

At times a complaint registered with Mechanical Maintenance, is found to be of electrical nature by the attending Mechanical person. In such case the attending person from Mechanical Maintenance goes to Electrical Department and registers or refers the complaint to them. Or it can be vice versa.

How is System going to help to create situations where time required for managing the technical object is reduced and where time wasted in referring the complaint by one department to another is avoided. Prompt attention to the complaint and resolving it timely would help reduce loss of production.

In case in-house repair of the machine is not possible Maintenance Dep’t takes up with Purchase Dep’t for arrangement of Work order for getting the machine or equipment repaired from outside agencies.

Similarly in case of non-availability of spares required to repair the machine it is the Purchase Dep’t, which would make the Purchase order for the spares. Initial activities such as locating the vendor, price negotiation or delivery terms may be done either by maintenance or Purchase dep’t separately or jointly.

As soon as the machine or equipment is repaired, the Maintenance Dep’t hands over the machine to the Production Dep’t and asks for First Piece Approval. If the First piece approval is positive the machine is handed over to the user and the complaint Register is updated by entering the time of handing over the machine and also details like the type of problem, spares used and other relevant details.

Based on various entries in Breakdown Reporting Register, Daily log Book is updated as a final record of breakdown activities carried out on a particular machine or equipment.

All this data are entered into the system to generate a Breakdown Analysis Report.

These reports besides enabling the Maintenance Dep’t to make a analysis of the problem also serves as a Management Information Report.

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Maintenance Engineer is responsible for processing of the identified work.

Identified work is prioritized according to the condition of the machine and as per the requirement of the Production Dep’t.

Maintenance work is performed without entering cost.

NAW record technical information (for example which part of the equipment was broken, damage or cause of damage etc) about a maintenance problem in order to create a service history or to enable further evaluations e.g. the machine history record.

Technical data entered are damages occurred, work carried out, time taken, spare parts used and who performed the task. This is recorded by the Maintenance Engineer in the Breakdown register who is responsible for maintaining all such records.

NAW would like to capture value of spare parts used for any breakdown along with the manpower cost.

Technical findings are recorded after completion of the work so as create a Machine History Record.

There is no coding system which allows standardized entry of technical information.

Preventive Maintenance

Preventive Maintenance is according to a predefined schedule as daily, weekly, monthly or quarterly.

Mechanical Maintenance Dept plans the Preventive Maintenance schedules and Electrical Dept follows the schedule and both the departments attend the machine simultaneously.

Task lists are common for same machines of same models. Mechanical and Electrical Dept have common task list

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Preventive Maintenance is planned for period April to March. The planning is generally done in the last week of March for the coming financial year.

Preventive Maintenance if not attended due to any reason is carried forward to next month whereas Predictive Maintenance is not.

NAW would like to get a report of postponed PM Schedule with reasons thereof.

Predictive maintenance

Predictive maintenance is a type of preventive maintenance where in which the machine is not stopped for the checking. It is otherwise can be termed as conditional monitoring.

Predictive maintenance is also performed as per predefined schedule and checklist for each and every equipment in every production line. In case any abnormality is observed during predictive maintenance, the machine is undertaken for maintenance in consultation with PPC and Production Dep’t. Mechanical Maintenance Dept and electrical department plans the Predictive Maintenance schedules separately.

Predictive Maintenance is planned for period April to March. The planning is generally done in the last week of March for the coming financial year.

NAW would like to get a report of postponed Predictive Maintenance Schedule. Reminders need to be given if the predictive maintenance has not been done. Reasons for postponing need to be given.

Indent Process

When any spare is to be purchased for the maintenance activity, the maintenance person logs the requirement in the indent register. Once the HOD signs the indent register, the indent file goes back to the purchase department for purchasing activities.Once the material has come from the vendor, the MRIR is created and the material is inspected. The report is sent to the head of the department for approval and the MRIR register is updated.

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Machine health report

The machine health report is the one, which has the problems corresponding to a particular machine. At the beginning of every month the production supervisor enters the problems corresponding to the machines. The NC points from the predictive maintenance will also be taken to the machine health report. This machine health report will be used during the corrective maintenance process.

Diesel issue

The diesel issue happens with the HOD signature and similar to the material issue pass. The diesel is moved from the general store to the service tank in the generator room. The meter reading and running hours are also noted down.

Installation of machines is also done by the Maintenance Dep’t.

Information System

Information System is the node where all the standard reports are available.

Damage AnalysisBreakdown AnalysisCost Analysis

Analysis at NAW

Machine Breakdown Reporting RegisterMachine ListMachine History RecordPreventive Maintenance SchedulePredictive Maintenance ScheduleDaily Maintenance ChecklistGeneral Checklist for Preventive Maintenance Checklist of Preventive MaintenanceList of ManualsList of critical spares

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Power consumptionDiesel consumptionOil consumptionLubrication Chart Machine wisePurchase IndentIssue PassDaily Log BookMachine Health ReportSummary of Machine wise Breakdown.MTBF : Mean Time between Failure Report Formula : Available Hour minus B/D Hours divided by no of B/Ds

(Example : Available Hours = No of MachinesX HoursXNo of days)

MTTR : Mean Time Repair Breakdown Hours divided by No of B/Ds

FORMAT / REPORT NAME ANNEXUREo Checklist Predictive Maintenance Motorso ,, ,, ,, Panelo ,, ,, ,, Main Switch o ,, ,, ,, Lubricationo ,, ,, ,, Filtero ,, ,, ,, Oil Filtrationo ,, ,, ,, Generalo Indento Issue Passo Register Oil Consumptiono Summary Oil Consumptiono Health Reporto Machine Health Reporto Register Meter Readingo Diesel Consumption Registero Diesel Consumption Analysis o Annual Maintenance Schedule

12345678910111212a131415161718

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o Monthly Maintenance Scheduleo Machine Historyo Check Points Machine Checkingo Health Report OK Pointso Indent Registero Breakdown Reporting Registero Breakdown Log Booko Machine OK Slipo Break down Summaryo Predictive Maintenance Analysis Reporto Pending Break down Reporto Check Point Not Ok Report o Machine Utilization V/S Breakdown Reporto PIV chain check listo Checklist for coupling

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