Professional Documents
Culture Documents
INTRODUCTION
and the implementation strategies in a process industry. Maintenance is one of the most
critical areas governing any process industry. Maintenance, when neglected leads to
equipment effectiveness through the people that operate and maintain the equipment. The
various scientific approaches were adopted to improve maintenance and support logistics.
The maintenance concept and culture went through a radical change during the last
decade in India. In the process industry, where production was given prime importance,
maintenance was regarded as a liability. With the onset of various new concepts like
Management, World - Class Manufacturing etc., the maintenance discipline got its due
functions which need to be carried out to achieve a total quality production system of
world-class stature through the use of scientific methods, effective equipment and highly
dedicated workforce.
Maintenance Organization
Autonomous Maintenance
A. Maintenance Organization:
number of levels with clearly defined duties and responsibilities. This would result in
more accountability and empowerment to take decisions at the lowest level. Table I
shows the responsibility matrix level – wise in terms of execution, planning and control.
Services Department should mainly consist of two sections namely Engineering and
Services. The Engineering Section should be responsible for Planning, Control, Expert
Cell, Inspection Cell for Material Quality Control and Industrial Engineering activities.
The Services section should consist of sub-sections like Safety, Fire-Fighting and
Industrial Transport.
Sr.No Responsibility 1 2 3
1. Equipment Maintenance
A Work Distribution
B Repair
C Replacement
D Maintainability
2. BUILDING MAINTENANCE
A Roofs, Floors, Partitions
B Building Services Equipment
C Minor Construction & Rearrangement
3. ROUTINE & PREVENTIVE MAINTENANCE
A Inspection
B Lubrication
C Minor Construction & Rearrangement
4 MATERIAL MANAGEMENT
A Indent Preparation
B Inventory Control
C Spares Availability
D Stores Expenses
5 VENDOR DEVELOPMENT
A Monitoring Jobs
B Contractor’s Expenses
6 BUDGETARY CONTROL
A Budget Preparation
B Budget Monitoring
7 EMERGENCY PLANNING
8 PERSONNEL MANAGEMENT
A Labour Relations
B Overtime & Absenteeism Monitoring
9 TRAINING & DEVELOPMENT
A Training of workers
B Training of staff
C Autonomous Maintenance
10 RECRUITMENT & PLACEMENT
A Selection of staff
B Internal Mobility
11 PERFORMANCE APPRAISAL
A Staff
B Workers
12 WCM & ISO CONCEPT
13 MIS
A Report Generation
B Analysis
C Action Plan
14 COMMUNICATION
that right information reaches the right person at the right time, such that decisions are
taken promptly. The nature of information required at each level varies, so proper formats
contain all important information with deviations from the norms and corresponding
action plans. The executive summary format for top - level management should contain
inventory, pending orders), contractor's norms and expenses, labor overtime due to
absenteeism / others, accidents (severity index and frequency index), new schemes
deviation).
The various formats required for middle and lower level management are listed below:
Downtime Records
Stores Expenses
Contractor's Expenses
Overtime Analysis
Accident Analysis
lives and work through "On the Job Training" and Self-development.
the workers training should lay more emphasis on skills, craftsmanship and behavioral,
the management training should focus on new technology and emerging new
23 Advancements in Maintenance
24 World Class Maintenance
material, machines and money effectively and efficiently. This requires proper
defined as the optimum utilization of all resources to keep delays and non-productive
proficiency to anticipate and correct problems before they call for major repairs.
maintenance crew has full day's work and the job is completed in time. Critical Path
Method (CPM) and Programme Evaluation & Review Techniques (PERT) are useful
pollution free environment. Safety policies and principles should be designed to avoid
mis-operations and near miss accident chances. Safety Audit would provide a high level
of surveillance of unsafe places of work and action. The scientific techniques like
HAZOP (Hazard Operability Studies) and HAZAN (Hazard Analysis) should be used to
Occupational Health & Safety (OH&S) and Environmental Management Systems (EMS)
availability, performance rate, and quality rate. It is necessary to calculate O.E.E. of all
equipment from time to time and proper actions should be taken to improve upon it.
Mean Time Between Maintenance (MTBM) and Mean Time To Repair (MTTR) should
Benchmarking of these parameters within the departments / sister concerns will help in
The severity index is the ratio of total productive hours lost due to
stoppages to the total machine running hours. The frequency index, is the ratio of total
Availability: Availability is the probability that the equipment is available for production.
The machine stoppages affect availability. The stoppages of spinning machine may be
Downtime in hours
Availability = 1 -
Total running hours
due to component failures, administrative and supply downtime. This can be best
Performance :
Standard Production: It is defined as the rated capacity of the machine to produce a
Target Production : It is the production figure to be met during a day as decided by the
Actual Production : It is the quantity of fiber produced during a day under actual ideal
Actual Production
Performance Rate = × 100
TargetProduction
Hence, the performance may be more than 100% as the actual production
Quality Rate
Deem Quality: It is the ratio of actual quality achieved during production to the
Actual Quality: It is the actual quality produced by the machine taking into
Table 3 shows the O.E.E. calculation of Spinning Machine for the period October 1997
to October 1998. Similar calculations were performed for critical equipment like Slurry
Press, Multi-Stage Flash Evaporators, Acid Plant, Boiler, Turbines. The Best in Class
values of various system parameters of this critical equipment are shown in Table 4.
and standard deviation of maintenance parameters. The goal should be to improve upon
G. Autonomous Maintenance
by changing the way people think about and work with equipment through out the
company. It helps in shaping right attitudes among the employees by creating proper
systems and procedures of doing right things, every time and on time.
production department that has a maintenance function and is intended to keep the plant
operating efficiency and stable in order to meet production targets and plans. The goals
operation and daily checks, to bring equipment to its ideal state through restoration and
proper management and to establish the basic conditions needed to keep equipment well-
maintained.(5)
Maintenance. The major expenses incurred include material cost, manpower cost and
rework. Hence, it is mandatory that spare parts management and manpower utilization
should be given utmost attention. The maintenance cost analysis and the deviations
should be properly analyzed. The budgeting should be done on an yearly basis and
replacement activity requires lot of investment and kills the skill of maintenance
personnel. The replacement of equipment is often done before achieving its useful life.
according to the guidelines provided and proper analysis should be done regarding the
failures and its frequency. This helps in prolonging the life of equipment, upgrading
CONCLUSION
application of above systems and procedures. The top – level management should render
full support. The middle level management should render full support. The middle level
management should analyze all maintenance parameters and should make all efforts to
improve maintainability, reliability and overall equipment effectiveness. The lower level
management should be able to implement the new concepts in a scientific manner and
make every effort to improve their department working by adopting best maintenance
practices and upgrading skills and knowledge. The operators and maintenance workers
should understand and adopt autonomous maintenance concepts, safety practices and
implemented the concept of World – Class Manufacturing and achieved excellent results
in all its pillars. The implementation of World-Class Maintenance would definitely strive
all process industries to achieve better results in equipment maintenance, enhancing plant
REFERENCES
2. Bernard T Lewis, “Management Handbook for Plant Engineers” Mc Graw Hill Book
Company, 1976
3. Gopalakrishnan & Banerji A.K., “Maintenance & Spare Parts Management”, Prentice