Sustainability in Maintenance - Seminar 2014
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Transcript of Sustainability in Maintenance - Seminar 2014
B.TANDARAYEN SENIOR ENGINEER
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
2/1/2017 Sustainability in Maintenance 3
Discussion:
Maintenance practices and Operational
management with a focus on asset
(Vehicles/Plant/Equipment) life-cycle
with a sustainability perspective
Objective: Sustainability
2/1/2017 Sustainability in Maintenance 4
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
2/1/2017 Sustainability in Maintenance 6
Graphical Representation
2/1/2017 Sustainability in Maintenance 7
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
2/1/2017 Sustainability in Maintenance 8
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
2/1/2017 Sustainability in Maintenance 9
Maintenance in Manufacturing
Companies Electronic
Automotive
Petrochemicals
Refinery
Furniture
Ceramics
Food and beverages
2/1/2017 Sustainability in Maintenance 10
Maintenance in Service
Industry Hospital
Restaurants
Transport companies
Banks
Hotels and resorts
Shopping malls / retail
Gas station
2/1/2017 Sustainability in Maintenance 11
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
2/1/2017 Sustainability in Maintenance 12
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?
2/1/2017 Sustainability in Maintenance 13
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
2/1/2017 Sustainability in Maintenance 14
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
2/1/2017 Sustainability in Maintenance 15
Sustainability objectives
2/1/2017 Sustainability in Maintenance 16
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
2/1/2017 Sustainability in Maintenance 17
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
2/1/2017 Sustainability in Maintenance 18
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
2/1/2017 Sustainability in Maintenance 19
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
2/1/2017 Sustainability in Maintenance 20
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
2/1/2017 Sustainability in Maintenance 21
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….
2/1/2017 Sustainability in Maintenance 22
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
2/1/2017 Sustainability in Maintenance 23
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.
2/1/2017 Sustainability in Maintenance 24
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
2/1/2017 Sustainability in Maintenance 25
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
2/1/2017 Sustainability in Maintenance 26
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
2/1/2017 Sustainability in Maintenance 28
Situation in organisation
Engineering Workshop
Maintenance approach
with Sustainable
Perspectives
2/1/2017 Sustainability in Maintenance 29
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..
2/1/2017 Sustainability in Maintenance 30
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
2/1/2017 Sustainability in Maintenance 31
Preventive Maintenance
involves:
Inspection
Lubrication
Repair and overhaul of equipment
If neglected can result in breakdown
2/1/2017 Sustainability in Maintenance 32
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.
2/1/2017 Sustainability in Maintenance 33
Cont….
Unusual sounds coming out of a rotating
equipment predicts a trouble
An excessively hot electric cable
predicts a trouble
2/1/2017 Sustainability in Maintenance 34
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
2/1/2017 Sustainability in Maintenance 35
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
2/1/2017 Sustainability in Maintenance 36
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
2/1/2017 Sustainability in Maintenance 37
Results
Less fuel consumption
Longer life of tyres & batteries
Fewer breakdown
Less equipment/vehicle awaiting for
spare parts
2/1/2017 Sustainability in Maintenance 38
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.
2/1/2017 Sustainability in Maintenance 39
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
2/1/2017 Sustainability in Maintenance 40
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
2/1/2017 Sustainability in Maintenance 41
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
2/1/2017 Sustainability in Maintenance 42
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
2/1/2017 Sustainability in Maintenance 43
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
2/1/2017 Sustainability in Maintenance 44
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
2/1/2017 Sustainability in Maintenance 45
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
2/1/2017 Sustainability in Maintenance 47
OSH cont..
Medical surveillance to all workers and
staff (Technical & Admin) together with
proper records and follow up
2/1/2017 Sustainability in Maintenance 48
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
2/1/2017 Sustainability in Maintenance 49
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
2/1/2017 Sustainability in Maintenance 50
6. Procurement
Public Procurement Act
Depending on the monetary
value/amount of the purchase:
At least three quotations
Formal tendering process
Bid Evaluation Committee
2/1/2017 Sustainability in Maintenance 51
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
2/1/2017 Sustainability in Maintenance 52
8. Control
For People and all Asset
Equipment – office
Equipment – Workshop
Stock – Spare Parts
CCTV Surveillance – Future project
2/1/2017 Sustainability in Maintenance 53
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
2/1/2017 Sustainability in Maintenance 54
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
2/1/2017 Sustainability in Maintenance 55
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
2/1/2017 Sustainability in Maintenance 56
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
2/1/2017 Sustainability in Maintenance 57
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
2/1/2017 Sustainability in Maintenance 58
Cont…. Limited Resources:
Budget control PBB
No Recruitment with retirement, more
that 50% of workers above 55 years of
age……………..
2/1/2017 Sustainability in Maintenance 59
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
2/1/2017 Sustainability in Maintenance 60
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
2/1/2017 Sustainability in Maintenance 61
2/1/2017 Sustainability in Maintenance 62
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