CONVENTIONAL MAINTENANCE

MANAGEMENT + CMMS+
e-Maintenance .
 Job Planning
• Planning of maintenance jobs basically deals with
answering two questions, “what ” and “How” of the job;
i.e., “what jobs/activities are to be done” and “how those
jobs and activities are to be done.

• The job planning forms the basic foundation, over which

the efficiency and cost of further actions (e.g.
scheduling, execution and control etc) will be decided.

• Person responsible for job planning should have

adequate qualities/capabilities, such as knowledge about
jobs and available techniques facilities and resources.
 Steps of Job Planning
1. Knowledge Base: It includes knowledge about
equipment, job, available techniques, material and
facilities etc.

2. Job Investigation at Site: It gives a clear perception

of the total job and also helps in ascertaining the
physical access and space limitation.

3. Identify and document the work: knowing earlier

two steps and knowing the needs of preventive,
predictive and other maintenance jobs, a complete
job/work list is made.
 Steps of Job Planning
4. Development of Repair Plan: Preparation of step-step
procedures which would accomplish the work with the
most economical use of time, manpower and
material.(see fig(a)).

5. Preparation of Tools, Tackles & Facilities Lists:

Job Plan sheet

6.Estimation of Time Required to do the Job: For

smaller jobs, it is easier, but for bigger jobs it may need
knowledge of “Work simplification”, “Work
measurement” and Critical Path analysis.
 Planning sheet for Changing V belt of Blower-X
Equipment Name: Blower X W.O Number Planner Date Seq
Equipment Code---- ---- Mr, --- ----- -----

Job Title- Change V belt (Cracked & worm)

Job scope Material, Tools & Equipments
Job Steps Crew Est. Description Qty Stock as on Co
hours st

1. Look out, disconnect & Tag 0.25

Motor starter,
2. Remove belt guard, loosen &
jack motor, remove bolts 0.75 Sheave guage(tool kit)
3. Check both sheaves for side
wall wear & radial run-out Mag. base dial Indicator 1set 4, SH-1
(should not be more the +1mm 1.0 •Big sheave (Part No.) 1 set 4 ,SH-1
for big & +0.25 for small end), •Bushing (Part No.) 1 set 3, SH-1
Replace Worn-out sheaves if •Small Sheave(Part No.) 1 set 3, SH-1
needed •Bushing (Part No.)

Drawing No:- Total time:- Total cost:-

 Planning Process
Open repair file
ok Check
waiting time planning spares
&matl
no
Postpone
repair
no
Discuss with
Plant Engineer
maintenance
I/c and others
for alternative Finalization of repair
plan

Print Repair plans/work-orders

 Job Manuals
• Job manuals includes methodologies, tools tackles
and facilities for all maintenance jobs which may
have to be done in future.

• This also involves saving the different plans and

modifying and expanding those plans for other
similar machines.
 Steps involved in preparing job manual
1. Make a list of all major and medium jobs of the plant
and codify for proper identification,

2. For each coded job, a separate job manual is to be

made in the form of job plan, indicating job steps,
tools, tackles, spares, consumables and facilities
needed and also indicating safety and statutory
clearance.

3. Each job manual, thus prepared, should and cross

checked and cleared by maintenance in-charge.
Steps involved in preparing job manual
4. Different job manuals should be bunched and sent to
respective potential users.

5. Necessary updating of job manuals, as needed, in

consultation with respective users.
 Uses of Job Manual
• For actual planning and scheduling of any job, the
job manuals provide ready information for use as it
is or for further micro-planning.

• The executing agencies refer to the job manual

before starting the job, to avoid frequent visits to
stores and thus save time.

• Material department may also use job manual for

better material procurement strategy.
 Cataloguing

 This mainly includes :

1) Defining each job as unique

2) Codifying each job numerically

 Unique definition of each job Is essential so that computer does

not make mistake and picks up correct jobs.

 “carry out bolt tightening ” & “tightening of bolts” may mean the
same to human but computer will take the two different
statements as two different jobs
 In an industry, generally three digit job code can accommodate all
jobs. Depending on the type of maintenance system adopted, the
jobs can be classified in the following categories;

Frequency Based (001 to 500 Condition Based (501 to 999

Nos) Nos)

Checking, adjustment & minor repairs Replacements (501 to 650)

(001 to 200)

Lubrication (201 to 350) Repair and reconditioning (651 to

850)

Replacements (351 to 500) Overhauling (851 to 999)

 History Cards/Sheet

 After codification and cataloguing next important thing is to

prepare History Card/Sheet for each system, equipment or
subassemblies.

 These give few essential information about acquisition of

assets/material, which are permanent records and few essential
information about maintenance and upkeep of assets.

 This can be in the form of manual records like cards, sheets or

registers or in computer memory.
 History Cards Uses

 It keeps permanent record of the machine , major jobs done &

constraints faced if any.

 It provides ready information and guide for planning repair jobs,

shut downs and oil changing etc.

 It serves as a guide for spares planning and inventory control of

consumables like lubricating oils.
 What is work order?
• It is simply define as “format used for detailed
information about work to be carried out.”
• All maintenance job initiated by written work order
(in the form of card or sheet or computer print out)
monitories till completion & finally documentation
into history.
 Design of W.O.
1.Wide lines so mechanic can write in easily.
2.Size it to fit on clipboard if you expect the
mechanic to write on it (or buy special
clipboards).
3.Put your organization name on top to be more
professional.
4.Use check-off boxes where possible to reduce
writing and improve completeness.
5.Use of bar codes to speed data entry.
 Contt..
• 6.consider a paperless work order system
where everything is typed or scanned into
terminal around the organization.
• 7.Bar code increases accuracy.
 Computer –Generated WO
 Advantage-
1.data entry is more accurate since comp. will not
generated bad codes.
2.Each file attached to the WO based on each file
setup.
3.Differential diagnosis items can be added. This
could transfer useful information to less experienced
repair mechanics.
4.WO’s that lost in the shop are still on the system
and easily reprint.

 Data entry strategies-
The most continuous problem with maintenance is the
accurate & timely gathering/entry of data. and sub problems
of this are-
1.Incomplete W.O.
2.Inaccurate information ,inconsistent coding of the same
activity .
3.Missng transactions.
4.Inaccurate reporting of part no.
5.unreleable / incomplete log sheets.
6.Problem caused by broken meters/cycle counter
,odometer & hour meter.
 Strategies

1.Time-Keeping & card-type systems.

2.Laser scanning data entry.
3.Software used with page scanners.
4.Laser scanning of part labels.
 Maintenance write –up form
1.This form would be filled by PM inspector or
sophisticated user.
2.This is common type of W.O.
3.During the emergency ,the documentation
would be completed when the job is
completed.
4.Maintenance dept. needed periodic training
sessions in correctly feeling out this document.
 2.Maintenance log sheet
1.This form could carried out by craftsperson for
all the short repairs that do in the course of
their day.
2.Intermiitent work stoppages are usually
corrected by short , unrecorded adjustments
& repairs
3.Sometime major repairs are done by
numerous short repairs or adjustments.
 Work Permit
• This is component of work order
• Maintenance dep't. Issues work permits to
different executing agencies (mostly outside
agencies) permitted them to start their work.
• Work permit mentions work permit no. work
order no.( on basis of which this work permit
is issued).
 Maintenance records & documentation

• Record and documentation are

information's/data pertaining to an
installation & subsequent maintenance done,
condition/ defect observed & rectified various
plans& also various plans made for future
implementation.
 Types of maintenance records

1.Ratio of planned to unplanned work.

2.Production delay & downtimes.
3.Planned work &percentage to planned work
achieved.
4.Ratio of preventive work to corrective work.
5.equipment failure pattern & repetitive
breakdowns.
6.Perment records like-
1.Instruction manual.
2.Operating Manual.
3.Maintenance Manual.
4.Job Manual.
5.Important Drawing.
7.Spare cards & trends in spare part
consumptions.
8.Records which are regularly updated-
1.History card.
2.Periodical schedules.
3.Networks
• 9.Cost report/Information .
• 10.Indicator on possible standardization
policies.
• 11.Condition monitoring report.
 CMMS
•Definition of Computerized Maintenance
Management System (CMMS)
−CMMS is a software package that maintains a
computer database of information about
maintenance operations
−the CMMS is used by clinical engineers to collect,
store and analyze data on the inventory, corrective
and preventive maintenance in addition to other
activities related to medical devices
 Acronyms, Acronyms, Acronyms
• CMMS
• MMS
• AMS
• EAMS

They all mean the same thing!

• CMMS - What is it? What does it do? How does it
help?
• CMMS
• Multi-Systems Integration
• Challenges
 What is a CMMS?

• Software Application

• Centralized Database

• Business Paradigm
– Integrates strategic planning with
operations, maintenance and capital
investment decision-making.
 What does a CMMS do?

• Maintains information about an

organization’s maintenance operations.
– Problem Tracking (Call Center)
– Work Orders (Reactive/Corrective & PM)
– Inspections
– Asset Inventory & Management
– Inventory Control (Parts / Materials)
– Permits
• Basic elements of the inventory module
– Equipment inventory number
– Equipment description (type) and class code
– Manufacturer's name and code to identify manufacturer
– Model and serial numbers
– Manufacturer & vendor details (name, code, …)
– Purchase price & installation date & location
– Warranty expiration date as indicated by the purchase
order
– PPM procedure reference
– Maintenance responsibility
– Status flag to indicate the current status of the equipment
– Other customizable fields
 Equipment model table

Equipment type table Entered values Equipment location

Manufacturer name and table
Entered values code Entered values
Equipment model number
Equipment code and Facility name and code
name Stored values Building code
Department name and
Safety responsibility code
Stored values Parts list Stored values
IPM procedures
Trained staff names
IPM frequency and codes Building default values
Risk level Trained operator
Staff responsible Peripheral store code

Entered values

Inventory number (auto- generated)

Installation date
Seller code and name
Accessories and software
Purchase order number (purchase price)
 Migrating your

Conventional Maintenance
to
eMaintenance

using technology
 Conventional maintenance

In conventional maintenance, managers make

decisions based on information (reports) from
people lower down the organization.

People on the ground (technicians &

contractors) rely on periodic / routine manual
inspections to detect failures or depend on
complaints from clients / users.

Limitations of Conventional Maintenance

Lack Transparency (reports are manually generated)
Low efficiency (labor intensive)
Low availability (slow response to failures)
Low client satisfaction (complaint before service)
 eMaintenance

With eMainenance, managers make decisions

based on real time information (from machine
generated KPIs, and reports) via the Internet.
Decision makers at any level may access up to
date information from their desktops instead of
relying on human-generated reports.
Contractors receive failure alerts through SMS
& email rather than through client complaints.
Advantages of eMaintenance
Unprecedented Transparency (no human inputs)
High efficiency (data at finger tips, fully automated)
High availability (Fast response, Low Downtime)
Satisfied Clients (less complaints)
 Beyond CMMS

Organizations managing large assets often rely on a

Computerized Maintenance Management System (CMMS).
CMMS keeps track of work orders, inventories, etc. It records
downtime manually, & generates maintenance KPIs from
these manual inputs.
The “Missing Link” of conventional CMMS is the Real-Time link
between the CMMS software and the assets being maintained.

Adopting eMaintenance adds a Real Time dimension to CMMS

Human inputs, Client
Conventional CMMS Work Orders, Reports, KPIs
Complaints

Human inputs, Client

Complaints
CMMS + Automatic Work Orders, Online
Reports, Real-Time KPIs
iSCADA
eMaintenance Real-Time Machine Inputs
 eMaintenance
Automatic Failure Detection,
Automatic Analysis, Automatic Reporting

CMMS
Computerized Maintenance Management System

Manual Failure Detection,

Automatic Analysis, Manual Reporting

Conventional Maintenance
Manual Failure Detection,
Manual Analysis, Manual Reporting
Implementing eMaintenance
using

an Internet-based
Data Acquisition Tool
for
Managing Remote Assets
 Data Integration, Consolidation & Online Collaboration

Universal Access
Online Collaboration

Alarm Monitoring
iSCADA
 Reactive Maintenance
Condition Monitoring
Server

 Proactive Maintenance
Architecture
Remote Metering Event Alerts
 Utilities Management

Globally Any Site via Internet: LAN, WAN, PSTN, GSM, GPRS, ACeS, or VSAT

Slave
Gateway Gateway

Power Fire
Meter Panel

Site 1: Alarms Site 2: Sensors Site 3: Meters

Any Site, Any System Site N: Tanks
 How to connect FAP to Internet
Typical
Step 1: Application
Prepare Dry Contacts
at all control panels
Step 2:
Retrofit iSCADA
Gateway to control
panels & connect to Step 3:
telephone line Log on to website
View status, reports, KPIs.
Receive Alerts

Fire Alarm Panels

HR Pump Panels
Sprinkler Pump Panels
Water Tank Level
Generator Sets

10 points per gateway Unlimited Users

expandable to 160
using Slave devices
Screen
Shots
Alarm Monitoring

 Monitor by Location
 Monitor by System
 Online Report, Real Time Statistics
Screen
Shots
Condition Monitoring

 Proactive Maintenance
 Power Quality Management
Screen
Shots
Hosted Data Acquisition
Combination of Alarm Monitoring,
Conditioning Monitoring & Metering
Screen
Shots
Machine Generated KPIs

 Key Performance Indicators (KPIs)

 Maintenance Benchmarking
 Benefits of eMaintenance

Transparency
Everything was recorded automatically without human
intervention. Reports & statistics are available online to
top management in real time.

Efficiency
Reduces manpower for fault detection and paper work

Availability
Automatic detection and SMS enables quick actions to be
taken. This improves the overall availability of our
systems.
 Benefits of iSCADA
Low cost of data transmission
Since all communications between devices, server and users are Internet
based, this translates into the lowest cost compared to all other systems.
Devices can be placed anywhere in the world, and users can seamlessly
communicate with their devices from any Internet connection.

Consolidation & Integration of information

Since all data is stored in a central database in the Internet, users have
global access to consolidated data from many systems or locations. In point-
to-point systems, data resides in a particular physical location (typically a
control room), and access is restricted. Data from any Vendor systems can
be integrated into a single iSCADA application.

Fast & Easy Deployment

User friendly hardware interfaces with a wide range of legacy appliances
and transducers. Managed services eliminate cost and complexities of
owning and maintaining server and software.

Universally accepted User Interface

Web-based solutions like iSCADA have a universally accepted, familiar and
user-friendly Graphical User Interface (GUI). This takes the complexities out
of sophisticated engineering solutions, and places information in the hands
of managers and other decision makers. It also flattens the learning curve for
engineers.
 Demo Demo Setup DW
You are Office
Here
iSCADA Server
NTT Data Centre
Cyberjaya

Mobile Alerts

Broadband, Auto & Dedicated Dialup

Manual Sampling Digital inputs only
Shared Dialup
Sampling, 30 min.

Puchong New Zealand Cyberjaya

Gateway Gateway
2000 1000
series series

Room Temperature Indoor / Outdoor Temp Security Alarm

Room Humidity Indoor / Outdoor RH
Heater / RTD Sensor Light Sensor
KW Transducer,
KWH Meter