JOB PLANNINGIMWT160

What is Maintenance

The activity carried out to prevent the occurrence of failure and activity carried out after failure to rectify the defect is called maintenance.

Maintenance Mission

To maximize and sustain the reliability of all manufacturing equipment and provide the capability to produce high quality products at the lowest possible cost over the life of the plant.

Objective of Maintenance

The primary objective of maintenance is to increase the operational reliability and personnel safety at minimum cost.

Failures are inevitable due to natural wear and tear.

Why Maintenance Required

Plant and machines in any organization is expected to run continuously without any interruption during the production period.Interruptions are frequently felt on account of machine break downs due to failures of machine parts / components.There is always some loss of production on account of machine failure.

Production Vs Maintenance

The total production that can be obtained from a plant depends upon its capacity and the number of working hours. Interruption on account of breakdown reduce the total time available for production. ThereforeProduction = Capacity x Availability.

Downtime

The duration by which any machine goes out of production due to break down is called downtime.The downtime is the total time taken on account of maintenance to rectify the fault.The total time taken on account of maintenance involves the time actually spent by the respective maintenance team to correct the fault and waiting time for want of spares required for rectify the defect.Downtime = Repair time + waiting time

Waiting Time

The waiting time is the most unproductive elements of total downtime . The reason for waiting time could be :-Want of sparesWant of crew membersLack of communication.Lack of proper supervision

Total DowntimeMAINTENANCE

Role of Maintenance

Maintenance play an important role in a manufacturing activity where plants and machineries are employed. No machine can work indefinitely and produce continuously . There is going to be some interruptions in production due to machine failures. At the same time higher the number of failures greater will be the loss of availability and production.

Role of Maintenance The frequent failures cause frequent interruption in the production and the plant and machines become unreliable. This degree of uncertainty in production due to machines failures is termed as reliability .Higher the reliability in operation lesser will be the failure or vice versa

Mean Time Between Failure ( MTBF)

This is the average time a machine can operate without the occurrence of any failure.MTBF indicates the operational reliability of the machine. Higher the value of MTBF, higher will be the operational reliability of the machine because of lesser number of failures.

Mean Time Between Failure ( MTBF)To improve the operational reliability , the number of failures should be reduced. Failures can be reduced if the machines are maintained properly with adequate care and attention.Failures can reduce by better maintenance.

Need For Maintenance

Need for maintenance arise for two reasons.To prevent the occurrence of any possible failures.To correct a failures in a shortest possible time.

EQUIPMENT MALFUNCTIONS

Equipment malfunctions have a direct impact on:Production capacityProduction costsProduct and service qualityEmployee or customer safetyCustomer satisfaction

PLANNED MAINTENANCE

The purpose of planned maintenance is to ensure the equipment conditions at their best with the minimum cost, enabling equipment to function at an optimal level whenever operation is required

There are typically four maintenance methods in Planned Maintenance:

Preventive Maintenance (PM) Breakdown Maintenance (BM)Corrective Maintenance (CM)Maintenance Prevention (MP)

Breakdown Maintenance No regular inspection and replacement are carried out. Equipment is restored after breakdown.

Corrective MaintenanceIt involves equipment improvements that result in maintainability and reliability improvements, prevention of breakdowns recurrence, maintenance time reduction, production time improvement, etc.

Maintenance PreventionIt involves feedback of information and new equipment development based on the feedback.

Preventive MaintenanceIt involves equipment health control and fixing before failure.

MAINTENANCE PLANNING AND SCHEDULINGEffective planning and scheduling contribute significantly to the following:

Reduced maintenance cost.Improved utilization of the maintenance workforce by reducing delays and interruptions.Improved quality of maintenance work by adopting the best methods and procedures and assigning the most qualified workers for the job.

Planning and Scheduling Objectives Minimizing the idle time of maintenance workers.

Maximizing the efficient use of work time, material, and equipment.

Maintaining the operating equipment at a responsive level to the need of production in terms of delivery schedule and quality.

Classification of Maintenance Work According to Planning and Scheduling Purposes Routine maintenance: are maintenance operations of a periodic nature. They are planned and scheduled and in advance. They are covered by blanket orders.

Emergency or breakdown maintenance: interrupt maintenance schedules in order to be performed. They are planned and scheduled as they happened.

Design modifications: are planned and scheduled and they depend on eliminating the cause of repeated breakdowns.

Scheduled overhaul and shutdowns of the plant: planned and scheduled in advanced.

Overhaul, general repairs, and replacement: planned and scheduled in advanced.

Preventive maintenance: planned and scheduled in advanced.

An essential part of planning and scheduling is to forecast future work and to balance the workload between these categories.

The maintenance management system should aim to have over 90% of the maintenance work planned and scheduled.

MAINTENANCE ORGANIZATIONS

CHIEFENGINEERASSISTANTCHIEFENGINEER

ELECTRICALLEAD PERSONMECHANICALLEAD PERSONWELDINGLEAD PERSON

INSTRUMENTATIONTECHNICIANELECTRICIANMILLWRIGHTMULTISKILLEDMULTISKILLEDMULTISKILLEDWELDEROPERATING ENGINEEROFFICE SUPPORT PERSONINSTRUMENTAION LEAD PERSON

STEAM PLANTLEAD PERSON

OFFICE SUPPORT LEAD PERSON

Planning

Planning is the process by which the elements required to perform a task are determined in advance of the job start.

Planning It comprises all the functions related to the preparation of:

The work orderBill of materialPurchase requisitionNecessary drawingsLabor planning sheet including standard timesAll data needed prior to scheduling and releasing the work order.

Important General Scheduling NotesNot all breakdowns are emergencies.Utilize natural windows of opportunity, before requesting plant downtime.Do not schedule task unless all resources are available.On maintenance days schedule jobs with highest priority first.At weekly planning meeting plan by job, identify those that require production involvement and coordinate.Daily scheduling is by resource. Target 100% resource utilization.Dont allow slack at beginning of day just in case of breakdown

Work Planning StepsA plan is not just a list of tasks, the basics of any plan is as follows:Who will perform?What needs to be done?How should the job be done?Why should it be done this way?Which tools, spare parts, materials and equipment are required?Is there are existing plans available in the maintenance program?

Work Planning StepsWork planning and control had a 5 Vital aspect of maintenance management and concerns:Request work.Planning and estimating of work.Effective scheduling of work.Quality feedback of work done and other information into equipment history.Managing and controlling the workload.

Work Planning Steps((FAILING TO PLAN. IS PLANNING TO FAIL))Dont forget the (4) Rules of P. D. C. A

1- P - PLAN2- D - DO4- A - ACT3- C - CHECK

Planning Procedures Determine the job content.Develop work plan. This entails the sequence of the activities in the job and establishing the best methods and procedures to accomplish the job.Establish crew size for the job.Plan and order parts and material.Check if special tools and equipment are needed and obtain them.Assign workers with appropriate skills.

Planning Procedures Review safety procedures.Set priorities for all maintenance work.Assign cost accounts.Complete the work order.Review the backlog and develop plans for controlling it.Predict the maintenance load using effective forecasting technique.

Basic Levels of Planning Process (Depend on The Planning Horizon) Long-rang planning: it covers a period of 3 to 5 years and sets plans for future activities and long-range improvement.Medium-range planning: it covers a period of 1 month to 1 year.Short-rang planning: it covers a period of 1 day to 1 week. It focuses on the determination of all the elements required to perform maintenance tasks in advance.

Long-Range Planning

sets plans for future activities and long-range improvement.

Medium-Range PlanningSpecify how the maintenance workers will operate.Provide details of major overhauls, construction jobs, preventive maintenance plans, and plant shutdowns.Balances the need for staffing over the period covered.Estimates required spare parts and material acquisition.

Short-Range Planning

It focuses on the determination of all the elements required to perform maintenance tasks in advance.

Scheduling

Is the process by which jobs are matched with resources and sequenced to be executed at a certain points in time.

Scheduling Scheduling deals with the specific time and phasing of planned jobs together with the orders to perform the work, monitoring the work, controlling it, and reporting on job progress.

Successful planning needs a feedback from scheduling.

Maintenance Job Priority System Priorities are established to ensure that the most critical work is scheduled first.It is developed under coordination with operations staff.It should be dynamic.It must be updated periodically to reflect changes in operation and maintenance strategies.It typically includes three to ten levels of priority.

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