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Maintenance Planning, Techniques & Cost Control: Snehal Pandya

This document discusses maintenance planning, techniques, and cost control. It defines maintenance as actions intended to retain equipment in working order or restore it to working order. The document outlines why maintenance is important for trouble-free operation, reliability, safety, and reducing costs. It describes different maintenance policies like breakdown, preventive, and predictive maintenance. It also discusses maintenance trends like total productive maintenance, automation, outsourcing, and inventory management techniques.

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Snehal Pandya
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79 views

Maintenance Planning, Techniques & Cost Control: Snehal Pandya

This document discusses maintenance planning, techniques, and cost control. It defines maintenance as actions intended to retain equipment in working order or restore it to working order. The document outlines why maintenance is important for trouble-free operation, reliability, safety, and reducing costs. It describes different maintenance policies like breakdown, preventive, and predictive maintenance. It also discusses maintenance trends like total productive maintenance, automation, outsourcing, and inventory management techniques.

Uploaded by

Snehal Pandya
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Maintenance Planning, Techniques & Cost Control  

                     
                   

Snehal Pandya
Why Maintenance

 Trouble free operation


 Reliability
 Quality Products
 Maximum return from asset
 To maximize the useful life
 Reduces the cost
 Increases the productivity
 Safety Integrity
 To give high confidence in future business
performance and profit
 Staff Motivation
 Environment Protection
What is Maintenance

 The combination of all technical and associated


administrative actions intended to retain an item in, or
restore it to, a state in which it can perform its required
function.
 To ensure that assets deliver the required function
and level of performance in terms of service or
production, in a sustainable manner, at an optimum
whole life cost without compromising health, safety,
environmental performance, or the organization's
reputation.
What is Maintenance

 Recording and maintenance of plant documentation


 Provision of information on present plant’s conditions
 Monitoring of defects, failures and their follow up
 Prepare, issue and expedite orders for spare parts,
material and services
 Cost control for spare parts, material and services
 Process Permit to Work system
 Control and follow up of de-energizing processes of
related systems
 Scheduling and Follow Up of plant outages
 Management of spare parts inventory
Maintenance Policies

 Breakdown / Corrective / Reactive


• Maintenance activities are limited to repairing the
equipment when a failure appears.
 Preventive
• Maintenance activities are developed with the
intention of reducing the probability of failure of
facilities or the degradation of a service.
 Predictive / Condition Monitoring
• Selected physical parameters associated with an
operating machine are sensed, measured and
recorded for the purpose of analyzing & comparing
the data and for making decisions related to the
operation and maintenance of the machine
Maintenance types

 Reliability Centered Maintenance


• RCM Method optimizes the number of scheduled
maintenance tasks
 Major
 Turnaround
 Long term asset replacement plan
Maintenance Methods

 Self
 Semi Outsource
 Outsource
 Specialized jobs
Maintenance Hurdles

 Schedule Conflicts
 Hiring
 Breakdowns
 Training
 Excessive Inventories
 Lack of Management Support
 Budget Control
Maintenance Trends - TPM

 Tries to maximize overall equipment effectiveness


and overall efficiency.
 Develops a preventive maintenance program for the
lifecycle of the equipment.
 Uses team-based concepts.
 Involves operators in maintaining the equipment.
 Uses motivational management (autonomous small
groups) to promote preventive maintenance
 Zero Maintenance
Maintenance Trends

 Doing more with less. Managers are charged with


the task of improving maintenance, accomplishing this
objective with reduced capital outlay, less time and
fewer people. As a result, managers are constantly
seeking ways to improve efficiency. For instance,
they're getting better at planning and scheduling.
Additionally, many are starting to use time-saving
products for maintenance tasks.
Maintenance Trends

 Automation. One big measure is the automation of


maintenance leading to changes in the way they're
planned, executed and tracked.
 the three significant automation developments
include: 1) increased reliance on handheld devices to
minimize paperwork and boost the accuracy of data
collection, 2) integration of management and
maintenance management functions and
departments, and 3) greater focus on integrating
control systems (hardware and software).
Maintenance Trends

 Outsourcing is on the rise as a growing number of


businesses are choosing to turn over their
maintenance functions to outside contractors. They
are outsourcing to better concentrate on core
competencies as well as to acquire expertise they
would not be able to develop on their own. For
example, service providers can teach a company's
maintenance staff how to perform tasks faster and
better. Additionally, managers often enjoy fixed costs
when they use outside contractors and can ultimately
cut overall maintenance expenses.
Maintenance Trends

 Increasing complexity. This trend is related to


outsourcing as companies often decide to outsource
because of the growing complexity of maintenance
management.
Maintenance Trends

 Value-driven design. Workspaces that are flexible,


able to accommodate multiple functions and capable
of supporting cutting edge technologies, such as
wireless LAN, are much coveted. In short, this value-
driven trend is characterized by a renewed emphasis
on maximizing usage and practicality.
Maintenance Trends

 Inventory Management keeping minimum inventory,


making inventory pools and JIT are the some of the
new techniques to have better inventory
management.
Maintenance Trends

 Short-term staffing. Managers are increasingly


relying on supplemental labor to help their in-house
staff to cope with unplanned work and to ensure that
their facility runs at full capacity, all the time.
Maintenance Mantras

 5P’s - Proper Planning prevents Poor Performance


 First Time Right – Every Time Right
 Prevent the wastage – As your Customer doesn't
pay for it
 Zero Leakage
Thanks.

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