Managing Plant Maintenance

1. Plant Maintenance Managing Strategic Business Assets Anand Subramaniam

4. Maintenance – Objectives & Types

8. Strategy Alignment

9. Align Business & Maintenance Goals Business Goals Compliance, safety, risk management Automation, scheduling Training, support, parts management, predictive maintenance Plant & line efficiency Logistics simulation Drive Regulatory Compliance Reduce Time to Market Improve Uptime Optimise Operations Supply chain Visibility Traceability Fulfill, Flexible Accurate Improve Capacity, quality Improve Asset, Performance Improve Visibility. Inventory

10. Maintenance Challenges Lack of management attention to maintenance Standards not used Difficulties in measuring performance Lack off participation by accounting in analysing and reporting costs Difficulties in applying quantitative analysis Difficulties in obtaining time and cost estimates for maintenance works Maintenance Challenges Inadequate control procedures for work order, service requests etc. Inadequate budgetary control Failure to develop written objectives and policy Absence of cost reports to aid maintenance planning & control system Lack of consistent production goals (cost, quality, delivery, safety) Lack of specific responsibilities Lack understanding on maintenance costs types Lack Team Collaboration

11. Maintenance Strategies Maintenance Strategies Replacement Statistic / Reliability Condition Based Opportunity Maintenance Overhaul Preventative Maintenance Design Modification Breakdown / Correction Fault Finding Off Line On Line Time Based Use Based

13. Link Strategies to Maintenance Equipment MRO Process Management Condition Monitoring Network Services Spare Parts Agreements Scheduled & Emergency On-site Services Repair & Renewal Parts Services People Service Assessments Remote Monitoring & Diagnostics Instructor Led Training Self Paced Training Phone Support Predict Prevent React Eliminate Downtime Events Produce to Spec Stabilise Budget Reduce Downtime Duration Speed to Change

14. Maintenance Planning

15. Plant Lifecycle Customer Support Technology / Systems Design Install Operate Maintain Replace

17. Maintenance Load Forecasting Information on maintenance load demand/ backlog of maintenance work Maintenance Load Forecasting Control Maintenance System Maintenance Scheduling Maintenance Capacity Planning Output of Maintenance System

19. Maintenance Control

21. Cost Types & Control Direct Cost of Periodic Inspection Service Cost Repair Cost, Overhaul Cost Standby Cost of Operating and Maintaining a Standby Unit Lost Production Cost due to Equipment down time Degrade Cost occurring due to deterioration of the life span of equipment due to no maintenance or inadequate maintenance

24. Maintenance Terminology