B.TANDARAYEN SENIOR ENGINEER

ktandarayen@yahoo.co.uk

TEL: 5753 0987

Ministry of Agro-Industry & FS

Outline of Presentation

Maintenance – overview

Sustainability Perspectives in

Maintenance

Link with Best Maintenance Practice

Situation in organisation

Discussion/Questions

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Discussion:

Maintenance practices and Operational

management with a focus on asset

(Vehicles/Plant/Equipment) life-cycle

with a sustainability perspective

Objective: Sustainability

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MAINTENANCE Maintenance is the most important

factor in improving the management of

ageing

The goal is to improve the ageing

management systems of infrastructure,

plants and equipment so that their

availability is maximised and their

management becomes more cost-

effective. 2/1/2017 Sustainability in Maintenance 5

Reason Maintenance is seen in

organisations as a mean to increase

productivity and profitability

Concern:

Finite raw materials

Growing population

Increasing consumption

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Graphical Representation

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Maintenance Link…… Maintenance and reliability is important

Maintenance and product quality

Maintenance and productivity

Maintenance and safety

Maintenance and supply chain, JIT

Failure cause disruption, waste,

accident, inconvenience and is

EXPENSIVE

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FAILURE Failure – inability to produce work in

appropriate manner

Equipment or machine failure on production floor may be due to: worn out bearing, pump, pressure leaks, broken shaft, overheated machine etc.

Equipment failure in office – failure of power supply, air-conditioning system, computer network, photocopy machine

Vehicle failure – brake, transmission, engine, cooling system

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Maintenance in Manufacturing

Companies Electronic

Automotive

Petrochemicals

Refinery

Furniture

Ceramics

Food and beverages

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Maintenance in Service

Industry Hospital

Restaurants

Transport companies

Banks

Hotels and resorts

Shopping malls / retail

Gas station

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MAINTENANCE

All actions necessary for retaining an item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification

Increase availability of a system

Keep system’s equipment in working order

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PERTINENT QUESTIONS

Why do we need maintenance?

What are the costs of doing maintenance?

What are the costs of not doing maintenance?

What are the benefits of maintenance?

How can maintenance increase profitability of a company?

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PURPOSE OF MAINTENANCE

Attempt to maximise performance of

production/service equipment efficiently

and regularly

Prevent breakdown or failures

Minimise production loss from failures

Increase reliability of the operating

systems

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Principle Objectives of Maintenance

To achieve product/service quality and customer satisfaction through adjusted and serviced equipment

Maximise useful life of equipment

Keep equipment safe and prevent safety hazards

Minimise frequency and severity of interruptions

Maximise production/service capacity – through high utilisation of facility

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Sustainability objectives

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Plant, Vehicles & equipment in good running condition

Minimum breakdown

Using minimum resources

No damage to the environment

Trained HR

Introducing the organisation

Ministry of Agro-Industry & FS

Engineering Workshop

Workforce: 125 workers

Engineering staff: 20 persons

Maintenance repairs of all vehicles,

plant and equipment of the Ministry

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Introduction of org, cont……

Range from: Vehicles (lorries, vans,

cars, tractors, agricultural implements),

Equipment (pumps, lab equipment, AC),

Plants (incinerators, refrigeration plant,

heat treatment plant) amongst others

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CHALLENGES WE FACED

Lack of Administration/Top

management support at the beginning

No participation of finance person in

analysing and reporting cost

Time and cost estimates for

maintenance works: non existent

No measure of performance

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Maintenance Management activities have to be designed, implemented and controlled through appropriate decision and management processes

Fields of action include: planning, accomplishment, control and improvement of all activities related to maintenance management, the activities are supported by information systems

Process

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I Review Maintenance practices - BMP

II Procurement

III Warehousing & Economic spare part

management

IV Considering and monitoring all costs

over the whole life-time of a plant

V Maintenance quality and quantity

Critical success factors for a

sustainable maintenance procedure

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VI Safety and Health at work

VII Environmental protection and waste

management

VIII Performance Appraisal - PMS

IX Training & Development

X Communication

XI Control

XII Feedback

Cont….

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Originality

Many underlying issues regarding

sustainability performance in

maintenance of plant, equipment &

vehicles are discussed rarely and are

still undefined.

We will look at a generic framework to

explore and specify the integration of

sustainability aspects into maintenance

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Philosophy behind

Sustainability in Maintenance The organisation should focus:

Reduce the effects of their operations on

land, air, and water;

Programs should demonstrate sustainable

service delivery;

All employees apply Sustainable

Development in their jobs; and

Employ modern systems that support and

maintain Sustainable Development.

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TYPES OF MAINTENANCE

Maintenance may be classified into four

categories:

Reactive - Corrective or Breakdown

maintenance – Run To Failure

Scheduled or Preventive maintenance

Predictive maintenance

Reliability Centered Maintenance

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Reactive - Corrective or

Breakdown Maintenance

Reactive maintenance implies that repairs are

made after the equipment has failed and

cannot perform its normal function anymore

Quite justified in small factories where:

– Down times are non-critical and repair costs are

less than other type of maintenance

– Financial justification for scheduling are not felt

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Reliability Centered Maintenance

The approach use to determine the

maintenance requirements of any

physical asset in its operating context

Utilises predictive/preventive

maintenance techniques with root cause

failure analysis to detect and pinpoint

precise problems, combined with

advanced installation and repair

techniques 2/1/2017 Sustainability in Maintenance 27

Maintenance Costs

Maintenance

Commitment

Cost

PM Cost

Total Maintenance Cost

Breakdown Cost

Optimal

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Situation in organisation

Engineering Workshop

Maintenance approach

with Sustainable

Perspectives

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Maintenance

We lay emphasis on

preventive/schedule maintenance rather

than reactive/breakdown maintenance

for all plants, vehicles and equipment

Now, we are moving towards predictive

maintenance for some equipment;

stand-by Generator set..

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Scheduled/Preventive Maintenance

Preventive maintenance are actions

performed on time or schedule that

detect, preclude or mitigate degradation

of a component or system with the aim

of extending its useful life time

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Preventive Maintenance

involves:

Inspection

Lubrication

Repair and overhaul of equipment

If neglected can result in breakdown

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Predictive/Condition Based

Maintenance In predictive maintenance, machinery

conditions are periodically monitored and this enables the maintenance team to take timely actions, such as machine adjustment, repair or overhaul

It makes use of human sense and other sensitive instruments, such as

–audio gauge, vibration analyser, amplitude meter, pressure, temperature and resistance strain gauges etc.

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Cont….

Unusual sounds coming out of a rotating

equipment predicts a trouble

An excessively hot electric cable

predicts a trouble

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Technical Intervention Proper adjustment on engine and

calibration of FIP for proper combustion

Balancing wheel and complete wheel

alignment for longer life of tyres and

suspension system

Diagnosis and prompt intervention for

replacement of parts during PM/SM

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cont Submission of exact list of spare parts

as per engine code, make and model of

equipment/vehicle

Ensure availability at all times for:

lubricants – oil, grease, power steering

fluid, brake fluid and radiator coolant

Root cause analysis to prevent

recurrence

Recording of all work undertaken – Job

Card

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Shop Floor Level

Ensuring:

Supervision of all intervention

Proper guidance on the job

Use of proper tools – as far as possible

Manipulation of tools and equipment in

the workshop to be as per standards

Use of data book for proper adjustment

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Results

Less fuel consumption

Longer life of tyres & batteries

Fewer breakdown

Less equipment/vehicle awaiting for

spare parts

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Human Resource

Sustainable Human Resources

practices encourage working

arrangements that support sustainability

objectives, the provision of BMP

awareness into all training programs,

and the promotion of sustainable

practices.

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Human Resources Promote diversity and non-

discriminatory practices

Develop human capital

Continue to promote and safeguard

health and safety

Promote work-life balance and

employee well-being – Welfare

association

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1. Managers/Senior Staff

Managers need to be knowledgeable of

Sustainability in Maintenance and the

action plan commitments that

encompass their role in the org

As a manager, we have the

responsibility to enable employees to

engage in BMP by providing them with

information and other resource

information available

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2. Employees

The contribution of every employee in

the organisation is important

They are the one who gets the work

done, it is only through them that we

have been able to inculcate that

sustainability concept – but in simple

term - good maintenance practices

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Culturisation

Encouraging a cooperative attitude that

strengthens group action – team spirit

Encouraging individuals in a group to

assimilate common concepts and

principles of good maintenance

practices

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3. Training, awareness and

competence It is vital that all personnel, whose work

may create a significant impact upon

sustainability, have appropriate training.

The need to establish and maintain

procedures to make employees and

members at each relevant function and

level aware of sustainability perspective

through best maintenance practices

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Application A Training Need Analysis among all

employees of the Division was

conducted

We set up a Training Unit in 2012

Training has started in January 2013 at

the frequency of one session per month

We are in second year now

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Actions/Results

Technical Training in respective trades

based on requirements of workers:

mechanics, hydraulics, maintenance

Behavioural Training: improve attitude

at work- supervisory, concepts, etc

Inculcating the sense of responsibility

and accountability in the maintenance

process (together with

traceability/proper reporting) 2/1/2017 Sustainability in Maintenance 46

4. Occupational Safety & Health

Strict adherence to the OSHA of

Mauritius

Service of a PT Safety & Health Officer

Provision of appropriate PPE to all the

workers according to their respective

trade

Training: First AID, Workshop safety,

Manual handling, electrical hazards

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OSH cont..

Medical surveillance to all workers and

staff (Technical & Admin) together with

proper records and follow up

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5. Performance

Performance Management System –

started in 2008, sensitisation, training,

pilot trial etc, at full go now

Identifying the Key Task, Key

Performance Indicators and

Performance Standards for all

employees

Appraisal on individual basis and on 6

monthly basis

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Results

Main activities, objectives and target

identified in relation to the Program

Based Budgeting (PBB)

Key responsibilities and duties identified

Shared responsibilities

Employees and management

cooperation

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6. Procurement

Public Procurement Act

Depending on the monetary

value/amount of the purchase:

At least three quotations

Formal tendering process

Bid Evaluation Committee

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7. Warehousing/Spare

Parts/Stock

Formal written policies and guidelines

through the Financial Management

Manual

Provision of minimum replacement

stock

Use of additional warehouse for the

stock of current spares – tyres etc

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8. Control

For People and all Asset

Equipment – office

Equipment – Workshop

Stock – Spare Parts

CCTV Surveillance – Future project

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Recording & Reporting

Work Order System : Detailed work to

be effected

Daily work distribution book

Job card for each and every piece of

work

Cost Centre

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9. Disposals

Old Vehicle, Plant & Equipment & Spare

Parts (old) by auction sale

IT Equipment – sorted and sold as lot

Used lubricant oil, grease, brake fluid,

power steering fluid, coolant – collected

by private company for recycle/reuse

Used Oil Filters, Air Filters & Fuel Filter

Battery, Tyres & Belts – sold as lot

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10.Drivers/Operators Training/Sensitisation on:

Basic Verification/Maintenance of

vehicle/equipmnet

Identification of abnormal noise,

overheating, vibrations

Tyre safety & defensive driving

Very important role is prompt reporting

to the Engineering Workshop

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Results

With this approach we have been able to:

Reduce Energy consumption

Reduce consumption of materials/spare

parts/lubricant

Reduce impact on environment

Improvement in the work environment

Educated and Trained personel/HR

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Difficulty/Reality Too much time in handling task

Procedures for purchase lengthy

Recording not full go

Distribution of work – Not equitable

Behaviour of Workers in workshop and

on site – Arguable!

Presence of Engineer in workshop:

More time to be spent

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Cont…. Limited Resources:

Budget control PBB

No Recruitment with retirement, more

that 50% of workers above 55 years of

age……………..

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Conclusion

To achieve the objectives, there is the

need to have all the above components

working together – adopting the holistic

approach

However, reality is quite a different thing

The biggest challenge is dealing with

people in organisation

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End word

Implementation should be done on an

organisational perspective:

Work as a team to pilot changes

Evaluate results

Determine effectiveness

Revise measure to best suit the needs

of the organisation

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