equipment 2011 ioe me
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CONSTRUCTION EQUIPMENT
ANDTHEIR MAINTENANCE MANAGEMENT
.Shah
B.Sc. Mechanical Engineering (India) MS Manufacturing Engineering & Management (UK )
Institute of Engineering, Lalitpur
January, 2011
January 31, 2011 1
Equipment and their MaintenanceManagement
• Major construction Equipment used inConstruction Industries
• Equipment utilization in the Department ofoa s
• Fleet Management
• Maintenance & Operation System
• Source of Data
January 31, 2011 2Er. Satya Narayan Shah
Generally, we use the Equipmentwhen a job requires -
1. SPEED
2. QUALITY
3. ECONOMY
4. EMERGENCY/DISASTER
MANAGEMENTJanuary 31, 2011 3Er. Satya Narayan Shah
Pneumatic/Hydraulic Tools◦ Air Compressors
◦ Rock Drill/Jack Hammer/Other Drills
◦ Concrete Breaker
◦ Asphalt Cutter
◦ Impact Wrenches/Nail Driver
◦ Grinder
◦ Concrete Vibrator
◦ Back Fill Tamper
◦ Circular saw/ Chain Saw
◦ Road Broom
January 31, 2011 4Er. Satya Narayan Shah
Aggregate Producer Rock Crushers, Screen, and Conveyors Central Mix Plant, (Batch Plant/Continuous
Mix Plant)
Bitumen Decanter, Bitumen Heater Bitumen Distributor Portable Mix Plant Pavers Rotary Sweeper Aggregate Spreader Concrete Mixers/Concrete Batch Plant Concrete Vibrator
January 31, 2011 5Er. Satya Narayan Shah
Earth Moving Equipment◦ Dozers (Track/Wheel)
◦ Loader/Shovel (Track/Wheel)
◦ Excavators (Track/Wheel)/ )◦ Scrapers
◦ Grader
◦ Milling Machine
◦ Hauler (Off highway haulers, TippingTrucks, Mini Dumpers)
January 31, 2011 6Er. Satya Narayan Shah
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Compaction Equipment◦
Sheep Foot Rollers/TampingRollers
◦ Steel Wheel Static Rollerteel Wheel Static Roller
◦ Steel Wheel Vibrating Roller
◦ Pneumatic roller
◦ Plate Compactor/Rammer
January 31, 2011 7Er. Satya Narayan Shah
Ancillary Equipment Water Distributor
Rotary Tiller Mixer Portable Electric Generator
Welding Generator
Pile Driver
Water Pump
Boring Rig
Crane/ Fork Lift
Flat Bed Truck
Low Bed Transporter
January 31, 2011 8Er. Satya Narayan Shah
EQUIPMENT STATUS in DOR
ACTIVE EQUIPMENT: 487AVERAGE AGE (approx): 16.4 YRS.MORE THAN 25 YEARS OLD: 79 (16.22 %)21-25 YEARS OLD: 27(5.54%)16-20 YEARS OLD: 149(30.60%)
- .6-10 YEARS OLD: 82(16.84%)Up to 5 YEARS OLD: 40 (8.21%)MORE THAN 15 YEARS OLD: 255 (52.36%)Economic service life is taken as 15 yearsRAINY SEASON DEPLOYMENT: 100
(Equipment only)9January 31, 2011 Er. Satya Narayan Shah
LIST OF MAJOR EQUIPMENTType of Equipment Total No Average Age
Dozer Wheel 8 22
Dozer Track 21 15.3
Excavator 12 6.8
Motor Grader 21 19.2
.
Loader Backhoe 9 17.6
Roller 3 Wheel 52 19.9
Roller Pneumatic 14 18.2
Truck Tipper 95 20.2
10
2- equipment owned by Baitadi-Darchula Road Project, 26 - equipment
owned by Banepa-Sindhuli-Bardibas Project, 2 Tractors owned by Surkhet- Jumla-Road Project and 8 equipment owned by MTC which are not used by DOR’s day to day activities.January 31, 2011 Er. Satya Narayan Shah
% SHARE OF EQUIPMENT BYAGE
16.22
5.54
16.84
8.21
MORE THAN 25 YEARS OLD:
21‐25 YEARS OLD:
‐
11
30.60 22.59
11‐15YEARS OLD:
6‐15 YEARS OLD:
Up to 5 YEARS OLD:
January 31, 2011 Er. Satya Narayan Shah
EQUIPMENT AGEDISTRIBUTION
79
149
110
82
80
100
120
140
160
12
27
40
0
20
40
60
MORE THAN 25 YEARS
OLD:
21‐25 Y E AR S O LD : 1 6‐20 Y EA RS O L D: 1 1‐1 5Y EA RS O LD : 6‐15 Y EA RS O L D: U p to 5 YEARSOLD:
January 31, 2011 Er. Satya Narayan Shah
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DEPARTMENT OF ROADSOrganization
DIRECTOR
GENERAL
DDGPlanin &Desi n
DDG
Maintenance
DDGForeign
DDGMechanical
PDADB Directorate s
Cooperation
PMEU
RSSDU
GEU
BRIDGE
CENTRAL
L AB
GENERAL
DRU
Multi
Lateral
Bi-lateral Equipment
Maintenance
DEVELOPMENT
CONTRACT
MANAGEMENT
Administration
Procurement
and
Training
Accounts
January 31, 2011 13Er. Satya Narayan Shah
DoR Organization (Mechanical)
14
ORGANISATION MECHANICAL
Mechanical Branch:Equipment Maintenance and Management SectionEquipment Procurement and Training Section
Heavy Equipment Division (HED) : 6 Locations
Itahari, Hetauda, Kathmandu, Butwal, Nepalgunj, Godawari
Mechanical Office (MO) : 9 LocationsBirtamod, Lahan, Janakpur, Bharatpur, Kathmandu, Pokhara, Dang, Surkhet, Budar(2 MOs at Phidim and Butwal not opened)
Mechanical Training Centre (MTC), Lalitpur 15January 31, 2011 Er. Satya Narayan Shah 16Janu ar y 31, 2011 Er. Sat ya Nar ayan Shah
MANPOWER
Engineers (Diff. Level) 47
Mechanics (Diff. Level) 477
Operators (Diff. Level) 228
Sanctioned Posts: 1038 Posts
Drivers (Diff. Level) 89
Administrative Staff
(Diff Level)
90
Peon 50
Guard & Sweeper 57
Total 1038
January 31, 2011 17Er. Satya Narayan Shah
MECHANICAL BRANCH & ITS ANCILLARIES
To provide support services to the construction and maintenance of Highways and other constructions.
Other Government Agencies
Contractors
During Emergency Disaster Management
18Janu ar y 31, 2011 Er. Sat ya Nar ayan Shah
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MAIN RESPONSIBILITY
EQUIPMENT MANAGEMENT REPAIR & MAINTENANCE OF EQUIPMENT.
SUPPORT DIVISION
ROAD
OFFICES
AND
PROJECTS
FOR OPERATION OF EQUIPMENT
PROCUREMENT OF EQUIPMENT PROJECT REQUEST
SUPPORT DOR & OTHER CONSTRUCTION INDUSTRIES THROUGH PROVIDING TRAININGS TO THE MANPOWER
RENTING EQUIPMENT
19J anuar y 31, 2011 Er. Satya Nar ayan Shah
Activities of Mechanical BranchMajor activities of Mechanical Branch are as follows:
Monitoring of Heavy Equipment Divisions, Mechanical
Offices
and
Mechanical
Training
Centre.
Budgeting and Program formulation.
Equipment procurement.
Spare parts procurement from the manufacturer.
Monitoring of auction of equipment & vehicles.
Advise equipment and vehicle allocation.
Support DOR in policy formulation process.
January 31, 2011 20Er. Satya Narayan Shah
Activities of Heavy Equipment Divisions and
Mechanical Offices
Major activities of HEDs and MOs are as follows:
Repair and maintain equipment owned by the HEDs/MOs.
Repair and maintain vehicles owned by the Civil Divisions.
Avail equipment to the Civil Divisions as per the directions of the Regional Directorate.
Support and monitor Mechanical Offices (not applicable to MO)
Support DoR projects.
Give equipment on hire without affecting the departmental work and administer Revolving Fund from the hire revenue. Keep store inventory record of asset owned by the HEDs/MOs
January 31, 2011 21Er. Satya Narayan Shah
Activities of Heavy Equipment Divisions and
Mechanical Offices‐ contd…….
Maintain and report necessary records of financial expenditure as per the financial regulation.
Maintain and report repair, maintenance and operation records of equipments and vehicles as per the directives of the Mechanical Branch.
Advise Re ional Directorate Division Road Offices and Road , Projects related to equipment and vehicles.
Plan necessary spare parts requirements and send requisition to department for procurement of spare parts from the manufacturer, if necessary.
Auction economically not repairable, obsolete and scrap asset.
January 31, 2011 22Er. Satya Narayan Shah
Activities of Mechanical Training Centre Develop and provide trainings in operation of the
construction equipment to DoR employees.
Develop and provide trainings in repair and maintenance of the construction equipment to DoR employees.
Develop and provide modular trainings and custom made trainings to other agencies and individuals and administer Revolving Fund from the training fees.
Keep store inventory record of asset owned by the MTC. Maintain and report necessary records of financial
expenditure as per the financial regulation.
January 31, 2011 23Er. Satya Narayan Shah
FLEET MANAGEMENTFleet management is the function that oversees, coordinates and facilitates various Equipment related activities • TOTAL FLEET REQUIREMENT- COMPOSITION
• TOTAL FLEET AVAILABLE
• ASSET MANAGEMENT• REPORTS/INFORMATION GENERATION
• EQUIPMENT DEPLOYMENT
• EQUIPMENT RENTING
• EQUIPMENT MAINTENANCE
• DISPOSAL
• REPLACEMENT
• INSURANCE
• HEALTH, SAFETY & SECURITY 24Er. Satya Narayan Shah
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BENEFITS OF FLEETMANAGEMENT
Optimize the Fleet Operations
•Improve equipment efficiency•Fact-based decision making
January 31, 2011 Er. Satya Narayan Shah 25
•Improve return on your assets•Secure extra revenue by billing correctlyand preventing under billing
BENEFITS OF FLEETMANAGEMENT
Optimize the Use, Size & Maintenance
of Fleet•Reduce capital expenditures
January 31, 2011 Er. Satya Narayan Shah 26
• e uce cos s or ma n enance, repa r an
operations•Lower total cost of ownership•Extend asset life cycles and warranties•Proof adherence to agreed Service Level
Agreements
BENEFITS OF FLEETMANAGEMENT
Increase Safety & Security•Provide access control to the fleet•Detect safety violations
January 31, 2011 Er. Satya Narayan Shah 27
practices•Formulate safety norms/standards andguidelines•Insurance policy
EQUIPMENT OPERATIONAL & MAINTENANCE
SYSTEM
• TO ENSURE THAT THE OPERATIONAL FLEET
REQUIREMENT IS OPERABLE AND MAINTAINABLE
WITHIN THE ALLOCATED BUDGET
IDENTIFICATION OF EQUIPMENT
EQUIPMENT MOVEMENT MONITORING
January 31, 2011Er. Satya Narayan Shah
EQUIPMENT MOVEMENT MONITORING
OPERATION RECORD KEEPING
MONITOR STATUS OF EQUIPMENT
• TO PROVIDE ALL INFORMATION AND ADVICE TO TOP
MANAGEMENT FOR THE PROCESS OF DECISION
MAKING
28
CLASSIFYING EQUIPMENT
Similar Design
Heavy Equipment – Graders, Trucks, Loaders
Light Equipment – Vans, Sedans, Pickups
Similar Use
12000 K i 20000
January 31, 2011Er. Satya Narayan Shah
12000 Kg operating wt excavator vs. 20000
Kg operating wt excavator
Single cab pickup vs. Double cab pickup
Regular vs. Limited Use
Pile driver, mini duper, tipper trucks, inspection
vehicles
29
Life of Equipment• Service Life; which indicates the amount of time a
unit is capable of operating and rendering service.The service life often permits the use of equipmentwell beyond its economic life
• Technological Life; which represents the relative
newer models. The difference is represented byobsolesce factor in hire rate calculation.
• Economic Life; which is critical as it refers to bothtime and costs and generally refers to the timewhen maintenance costs exceed the units ability togenerate revenue, i.e. the unit is no longer costeffective to operate. 30
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Departmental EquipmentIdentification
• It is necessary to have a system to identifyeach equipment as the Department
operates the largest fleet of equipment inthe country.
• The DoR has developed and introduced asystem to allot RD No to all theConstruction Equipment and InspectionVehicles.
• RD No. consists of Departmental Code (foreach type of equipment) and Equipment No.(allotted to every individual equipment) e.g..001-017January 31, 2011 31Er. Satya Narayan Shah
Coding System Of Construction EquipmentASPHALT PLANT 001
ASPHALT PLANT 001
ASPHALT PAVER 002
ASPHALT, MIXER 003
BROOM ROAD, TOWED 009
BORING RIG 011
CRANE MOBILE 021
CRANE MOBILE 021
CRUSHER STONE 022
CUTTER CONCRETE 024
DOZER WHEEL 030
DOZER, TRACK 031
January 31, 2011 32Er. Satya Narayan Shah
Maintenance of EquipmentObjectives of MaintenanceEffective fleet management aims at reducing
and minimizing overall costs through maximumcost effective utilization of resources such asvehicles, fuel, spare parts, etc.
• To reduce down time
• To lower overall maintenance costs
• To improve plant efficiency and performance
• To assure residual value
• To improve safety levels
• To reduce the demand for skilled maintenance staff.January 31, 2011 33Er. Satya Narayan Shah
Maintenance is: -• Replacing oils, which become contaminated with
particles and break down into constituents, one of whichis acid.
• Replacing filters, which become blocked with particlesreducing flow or allowing fluids directly into precisioncomponents by being by-passed.
• ,lubricating properties resulting in abnormal componentwear.
• Adjusting for normal wears in order to ensure maintainstandard performance.
• Adjusting, calibrating and setting in order to ensureeconomic operation.
• Enabling worn or damaged components to be replacedbefore serious and costly breakdown occur.
34
MAINTENANCE PLANNING
Manufacturer’s maintenance schedules
Staff and skill level
Spare parts stock level and lead times
Consumable stock level and local sources
January 31, 2011Er. Satya Narayan Shah
Status and level of workshop tools/ capacity
Work priority
Field maintenance capability
Availability of fund/budget
35
MAINTENANCE SCHEDULING
Cycle scheduling- which is the
determination of work required on
equipment through unit inspections. This
method is used to identify work tasks
January 31, 2011Er. Satya Narayan Shah
method is used to identify work taskswhich might be necessary in addition to
the standard periodic servicing tasks.
Calendar scheduling- which is the logging
of required activities on a calendar or
planning chart.36
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MAINTENANCE CATEGORIES
Unscheduled maintenance- resulting fromaccidents, breakdown caused by unforeseencomponent or component failure, abuse of
equipment, operator negligence etc. Planned maintenance- refers to all the
planning of all maintenance works; reduces
January 31, 2011Er. Satya Narayan Shah
p gthe need of unscheduled maintenance.
Preventive Maintenance/ MinorMaintenance
Major Repair
Overhaul
Reconditioning/Rehabilitation
37
Preventive Maintenance/ Minor Maintenance
Replacement of oils, filters, greases etc.
Specified intervals
Prevents the need of repairs – reduces
b kd
January 31, 2011Er. Satya Narayan Shah
breakdowns.
Activities are-
Walk around check, operator’s report
Scheduled periodic servicing
Scheduled periodic inspection
38
Major Repair
Defects identified before complete failure of
the equipment
Repair against failure of a component/unit
Only the broken down parts are replaced
January 31, 2011Er. Satya Narayan Shah
39
ver au•Returning a unit to an economic operational
condition
• Limited to broken-down component only
Reconditioning/Rehabilitation
Total overhauling of the equipment
Rebuilding to economic operational condition.
Returning the equipment as good as new
equipment.
It d t k ll th t f th
January 31, 2011Er. Satya Narayan Shah
It undertakes all the components of the
equipment
Proper testing and calibration is required after
rehabilitation.
Special tools and workshop facilities are
required.40
LIFE EXTENSION THROUGH
OVERHAUL/RECONDITION
This option can be applied to two
situations when the economic life span
has been exceeded;
January 31, 2011Er. Satya Narayan Shah
the equipment is required due to lack of
fund for replacement.
the equipment has specialized function
and low utilization.
41
FACTORS TO BE EVALUATED FOR OVERHAUL
CONSIDERATION
Replacement cost of comparable unit
Availability of spare parts
Workshop facilities
January 31, 2011Er. Satya Narayan Shah
pThe Benefits- Reliability, Maintenance
Cost, Performance against Replacement.
Cost Estimation Vs. Budget
42
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WORKSHOP DOCUMENTATION
Repair Requisition form
Job Record Card
Cost estimate form
January 31, 2011Er. Satya Narayan Shah
Spare parts stock situation
Spare part order form
External repair form
43
REPORTS/INFORMATION
Inventory of Spare Parts
Annual Report on Equipment Utilization
Annual Equipment Status
January 31, 2011Er. Satya Narayan Shah
q p
Annual Report on Activities of HEDs &
MOs
Recovery on Equipment
Profit Loss Analysis
44
EQUIPMENT OPERATIONSYSTEM
• Operational Control System
– Monthly Status Report
– Annual equipment Inventory
– ovemen on ro
– Equipment Operation Log Sheet
– Monthly Utilization Report
– Monthly Hire Report
– Theoretical Hire Report
– Vehicle log SheetJanuary 31, 2011 45Er. Satya Narayan Shah
SOURCE OF DATA
• Goods Requisition Forms
• Contract Document/Purchase Order• Invoice• Letter of Credit
• Store Entry Voucher• Repair Order• Job Card• Operation Logbook
• Equipment Hire BillJanuary 31, 2011 46Er. Satya Narayan Shah
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QuestionsPlease
??
?? ??
January 31, 2011 59Er. Satya Narayan Shah
THANK YOU ALL
January 31, 2011 60Er. Satya Narayan Shah
Contact: [email protected]@dor.gov.np