Maintenance Planning Systems
Maintenance Planning Systems
A.K.Mohindru
Ex-General Manager
NTPC Ltd.
Presentation Overview
Machinery Failure
Maintenance Objectives
Maintenance Types
Maintenance Cost
Availability
Integration of Maintenance
Maintenance Department
Engineers Duties
Efficient Maintenance Service
Maintenance Records
Overhaul Management
Machinery Failure
Total damage
Loss of asset
Loss of
production
Loss of life
Machinery failure
Production capacity
Production costs
Product and service quality
Employee or customer safety
Customer satisfaction
Problems in Maintenance
Lack of management attention to maintenance
1. Increased Availability
2. Maximize useful life of equipment
3. Reducing Cost of production
4. Safety Requirements
5. Customer Satisfaction
Breakdown Maintenance
Planned Maintenance
Preventive Maintenance
Predictive Maintenance
Maintenance Types
Breakdown Maintenance
Run the equipment till breakdowns No organized efforts to find out
reasons
No services except occasional
lubrication unless failure occurs •No stock of spares
•
No maintenance men on regular •No budget
basis
•No records and No Safety
Maintenance done by sub-
contractors
* Initially it looks economical
Putting the machine in good condition timely e.g replacement of filter/oil, plant
overhaul based on manufacturer recommendation
Maintenance Types
Planned Maintenance advantages
PM increases reliability
PM reduces work-load
1. Temperature
2. Vibration
3. Cracks
4. Deterioration
5. Voltage/current
6. Performance evaluation
Maintenance Types
Predictive Maintenance
Condition Monitoring
Condition Monitoring
Maintenance Cost
1. Overhead Expanses
2. Labour Cost
3. Spares and Consumables
4. Loss due to down time
Maintenance Cost
Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Cost
Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Cost
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Maintenance
Commitment
Maintenance Cost
Cost
Total Maintenance Cost
PM Cost
Breakdown Cost
Optimal Maintenance
Commitment
Maintenance Cost
Availability
Mean-Time-between-Failures MTBF
Mean-Time-to-Repair, MTTR
Resource Availability
Keep spares well in advance
Mobilize work force quickly
Keep job area ready to work : lighting, scaffolding, power
supply etc
Integration of Maintenance
Company
Production
Administration
Dep't
Availability Spares
Procurement
Equipment
Maintenance Departments
Maintenance Work Force
Engineer
Boiler Maintenance
Supervisor
Foreman Foreman
Pressure Parts Rotating Machines
Fitters/Technicians Fitters/Technicians
Riggers Riggers
Helpers Helpers
Maintenance Departments
Repair Crews and Standby Machines
Repairs often performed on an emergency basis to:
Minimize interruptions to production
In emergency situations:
Specialists may work overtime
the system should be easy to use and provide the engineer with all of
the information that is required to make better decisions.
The purpose of the asset register is to centralise this data for use in
planning
maintenance work.
History Record:
When job is done?
When completed?
Planning Sheet:
When next to be done?
Equipment Identification
Equipment Identification
ID Fan1A
ID Fan 1B
FD Fan 1A
FD Fan 1B
PA Fan 1A
PA Fan 1B
Boiler Feed Pump 1A
Maintenance Records
Work Instruction
Singrauli Super Thermal Power Station
Equipment: Boiler Feed Pump RPM: 3600 KW 1500 Kw
00
0.5D
Maintenance Records
Operation Guidance Note
Preparation of resources:
Engineering Declaration: 12 months advance
Contract: 3 months in advance
Spares procurement; 12 months advance
Shut down planning ; rolling plan
Mobilization
Pert Chart activitiy listing
Allocation of executive team to monitor
Daily work progress meeting
Overhaul Execution
PERT & CPM
CPM
What is CPM?
Critical Path Method
• The estimate of time (duration) that each activity will take to completion.