solutions for industrial services maintenance is a topic for the top management: from reactive fault...
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Solutions for Industrial Services
Maintenance is a topic for the top management: from reactive fault repair to a value adding factor
Tobias Zaers
Maintenance is a topic for the top management
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Costs:• Personnel• Depreciation• Operation supply material• Maintenance (DIN 31051:2003)
• Maintenance• Inspection• Repair• Improvement
Effizienz einer Anlage
CostsReliabilityAvailability
Reactive fault repair
Efficiency
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Impacts of reactive fault repair to efficiency
Efficiency ist the top target for the operation of production equipment. This means to guarantee high reliability and availability for lowest cost.
Within DIN 31051 reactive failure repair is defined as apart of the whole maintenance subject. Repair in this context is defined as „the measures that are leading a specific element back to the operational condition, except improvement measures.“
Reactive fault repair is not leading to an increase of reliablity and availability and therefore can not contribute to an increase of efficiency.
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Increase of reliability and availability
ReliabilityAvailability
WorkOptmisation
Reduction of down times
Reduction of reaktive work
Tools, Methods & Techniques
Tools, Methods & Techniques
Tools, Methods & Tecniques Tools, Methods &
Techniques
Execution Efficiency
Improvemnt of planning
Plannable efforts
Improvement
Reduction of reactive work
Quality improvement in execution
Reduction ofimmediate
assignments
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Increase of reliability and availability
A reduction of downtimes is only available by preventive maintenance or improvement of the equipment. Repairs are only leading back to the operational condition, causes of failure howevere are not eliminated.
An improvement of the equipment will allow to reduce future reactive assignments.
An improvement of the planning allows efficient maintenance execution as efforts can be optimised and cost could be saved.
To be able to realise these measures tools, methods and techniques are necessary. To using these, specific training or consultancy is required.
The use of sophisticated technologies for condition monitoring can further increase reliability and availability as imminent failures can be predicted with higher accuracy. Wearing parts can be used to their maximum lifetime. Unusual equipment conditions can quickly be recognised.
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Maintenance potentials
1.500
7.500
Direct
Indirect
Maintenance cost in Europe (in Mrd. €)
Personnel, operating supplies, spare partsmaintenance systems
DowntimesQuality failuresLegal consequencesLoss of imageStorage costInvestment for replacement
Estimated potential 5-25%
Source: Trends, Potenziale und Handlungsfelder Nachhaltiger Instandhaltung Ergebnisbericht der vom BMBF geförderten Untersuchung „Nachhaltige Instandhaltung“; FVI – Forum Vision Instandhaltung e.V.
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Requirements for maintenance management
Exploitation ofMaintenanceOpportunities
Economy
Information Technology
Technology
OrganisationLegal Requirements
Produktion PlanningPurchasing
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Requirements to the Maintenance Management
To exploit maintenance opportunities diverse areas have to be oncorporated Economics (e.g. for investments) Technology developments Organisation Production Planning (Integration of maintenance planning) Purchasing and materials management (optmised storage and procurement
prcesses) Legal requirements …
The common competence of maintenance managers is not allowing to deal with the requirements in a comprehensive way. The realisation of successful concepts requires strategic decisions and support by the top level.
Therefore it is of utmost importance for the top management to know the potentials to be able to make successful implementation maintenance concepts a part of the company strategy and to initiate the work on those concepts.
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Lifecycle
Further optimisation of maintenance can be supported by specialised service
partners or groups whose core competency is the develoment and realisation of maintenance strategies.
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Maintain 2007
The Maintain 2007 offers top managers a forum to broadly inform themselves on the topic maintenance.
Big companies as well as small and medium sized companies are offered the opportunity to collect information and share experience.
Solutions for Industrial Services
Thanks for your attention!