The premise of a viable continuous improvement program must be that maximum plant performance depends on the integration of all critical functions within a plant. Redundancies studies, on-site spare management and models. The performance measurement elements are the productive time minus downtime expressed as a percentage of the scheduled time available. Availability refers to the duration of time that a plant or a particular equipment is able to perform its intended task. TS192 .D47 2002 658.2 ¢ 02—dc21 2001052634 ©2002 CRC Press LLC Preface Engineering maintenance is an important sector of the economy. It is verified by the Maintenance Superintendent. Safety, cost, schedule and quality objectives. Many systems are repairable; when the system fails — whether it is an automobile, a dishwasher, production equipment, etc. Scheduled Work is defined as: Any maintenance job or task that has a start date and time formally agreed to by both the Operations and Maintenance supervision, is placed on the Weekly Maintenance Schedule, and there are resources planned to address it. Literature. There was a plethora of job adverts, articles and presentations at conferences that included the term reliability. Definition: The “Equipment Down Time Delay” shows what percent each delay line item contributed to the total downtime. Advanced. Emergency availability 24/7. Procedure: Monthly and or as directed the Maintenance Planner will compile all necessary MIS data required to produce an accurate and timely report. The performance measurement is the productive time expressed as a percentage of the total time available. Spare parts management: risks and costs. Documentation: The Equipment down Time Delay data, calculations and routine monthly report will all be developed and contained on the sites MIS system. Maintenance audits. Using this important information, you can make more informed decisions when it comes to creating improvements in your maintenance management process. OH = Operating Hours It is verified by the Maintenance Superintendent. Copyright 2012-2021 911Metallurgist | All Rights Reserved, Maintenance Management Systems & Procedures. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. understand reliability analysis and improvement techniques. I. Overall equipment effectiveness is a maintenance KPI that measures an asset’s level of productivity. Standard KPI: Equipment Utilization will be calculated as follows: OH / OH + DH + I/SH X 100 = Equipment Utilization KPI Standard: Equipment Utilization will be calculated as follows: Operating Hours/Total Hours = Equipment Utilization. Outage due to equipment in hours per year = 1/rate = 1/MTTF = 0.01235 hours per year. It is the total maintenance work hours scheduled divided by the total scheduled and unscheduled hours worked for a given period of time. 1. This course aims to increase skills on how to implement a customized maintenance policy and to provide the practical tools to implement reliability improvement processes. Maintenance action plan and implementation. What Is Reliability Engineering?Learn about it here. Responsibility: The reporting of Equipment Utilization is the responsibility of the Production Controller. Turnaround justification: local regulation, maintenance, projects. This course is intended for engineers and maintenance managers in the process industries. We are then in a position to implement the maintenance strategy on the facility. Resource optimization. Definition: “Schedule Compliance” measures scheduled maintenance jobs against unscheduled jobs. Many workshops and case studies illustrating the techniques and topics studied. 1 844 858-2424 aidez-moi@locationloupak.ca. Cost-effective solutions. Inherent availability is determined purely by the design of the equipment. You must have JavaScript enabled in your browser to utilize the functionality of this website. LOCATION LOUPAK 2323, avenue des Érables Plessisville (Québec) G6L 2E9. IJSH = Idle/Standby Hours. The objective of this post is to bring clarity in understanding the two often confused terms viz, Availability and Reliability, by explaining in simple perspective for the purpose of understanding by a common maintenance man.. Let’s try to understand through this picture. set up conditions for the successful management of plant turnarounds. For more information and/or to organize a session: This course can be adapted to virtual classroom mode. Financial breakdown and cost estimate. Steering committee, organization and Key Performance Indicators. Maintenance Work will be defined “Scheduled”, when a specific job or task placed on the Joint Weekly Maintenance Schedule is addressed and completed on the date(s) that it had been planned. Procedure: Monthly and as directed the Maintenance Planner will compile all necessary This performance measurement applies to all Areas. Gestion des déchets Gestion du recyclage Service d’entretien Demande de soumission Contact. metric that measures the probability that a system is not failed or undergoing a repair action when it needs to be used Definition: The “Scheduled vs Unscheduled” Maintenance performance measure denotes what percent of controllable maintenance resources that were actually applied when scheduled. Periodic confirmation of schedule compliance performance measures is the responsibility of the Maintenance Superintendent. DH = Down Hours. This paper covers the risk JavaScript seems to be disabled in your browser. Upon completion of the course, participants will be able to: implement and optimize maintenance policy. Title. Operation department contribution to maintenance optimization. Who can undertake maintenance of work equipment. Maintenance management is using intelligent computer software, such as MicroMain’s CMMS, to better track your business’s resources such as labor, materials, and equipment. The following is an excerpt on maintainability and availability from The Reliability Engineering Handbook by Bryan Dodson and Dennis Nolan, © QA Publishing, LLC. IMPROVING THE MAINTENANCE WORK MANAGEMENT. From failures management to equipment management. Work scheduling: task sequencing, procedures and work planning. Just call. This course is part of the advanced professional framework in industrial maintenance. This degradation is usually expressed as Remaining Useful Life (RUL), which is not affecting maintenance planning, but together with HI and IL, is key for financial planning of replacement or refurbishment. Preventive maintenance tools: vibration measurements, oil analysis, thermography, use of non-destructive testing. From failures management to equipment management. Responsibility: The monthly calculation and reporting of Physical Availability is the responsibility of the Maintenance Planner. It is verified by the Maintenance Superintendent. Common formula used for the Equipment Availability computation is. Standard KPI: Scheduled vs unscheduled maintenance work will be calculated as follows: SMH/(SMH ± Ulvill) x 100 = Percent of Maintenance work scheduled Routine maintenance: from the notification to the work acceptance. Definition: “Physical Availability” shows what percentage of the available time a piece of equipment or machine was operating based on its production schedule. equipment obsolescence, spare parts availability, maintenance costs as well as asset performance. Maintenance subcontracting: reasons, risks and control. set objectives in terms of the company's overall efficiency. implement an effective subcontracting policy. This performance measurement applies to all Maintenance Areas. TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production: No Breakdowns; No Small Stops or Slow Running; No Defects ; In addition it values a safe working environment: No Accidents; TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. Laboratory Testing Consulting & Engineering Process Equipment. FMECA, RCM, Fault Tree analysis: application, basic techniques, estimates and probabilities. SH = Scheduled Production Hours AVAILABILITY PERFORMANCE The ability of equipment to function properly, Despite occurrence of failures, disturbances and Limitations in the maintenance resources. Practical implications – Literature on classification of maintenance management has so far been very limited. Reliability Key Performance Indicators: MTBF, MTTR, availability. Definition: “Equipment Utilization” measures the percentage of time a piece of equipment is actually operationally in a 24 hour day, for a given period of time. KPI Standard: This standard will be written on ERP selection. For many years, maintenance was the term used for all stewardship of plant and equipment. Maintenance work should only be undertaken by those who are competent to do the work, who have been provided with sufficient information, instruction and training (PUWER regulations 8 and 9). The EMOP is the primary record and source of maintenance and operation information of each equipment item and includes the up-to-date maintenance and operating strategies. Conclusions Statistical analyses conducted by a number of industrial, trade and professional organizations conclusively point to the fact that maintenance is the primary source of less than 20 percent of availability losses. Maintenance Best Practices for Outstanding Equipment Reliability and Maintenance Results Maintenance Planning and Scheduling Day 1 Training Course Slides with Complete Explanations from the Maintenance Planning and Scheduling for World Class Reliability and Maintenance Performance 3-Day Training Course Phone: Fax: Email: Website: +61 (0) 402 731 563 +61 (8) 9457 8642 … An expertise confirmed in Maintenance Management & Equipment Availability . Regardless of the product or production type, all plants are integrated. Definition: The “Mechanical Availability” shows what percent of controllable time a piece of equipment or machine was mechanically and electrically ready to operate. Inspection plans: goals of an inspection department, links with maintenance work. This is expressed in percentage and calculated using the following methods To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). Routine maintenance: from the notification to the work acceptance. The performance measurement is the productive time expressed as a percentage of the time available. Application to investment choices. An international recognition of your competencies. The delivery method is interactive and based on participants’ own experience. Operation department contribution to maintenance optimization. The valuation of an equipment asset-dependent organization is significantly affected by the effectiveness with which that equipment is managed. A new shift in maintenance paradigm is also highlighted. Your leadership must understand that reliability management is not just doing maintenance better. Reliability methods: criticality Analysis, TPM, RCM. It is also suitable for managers directly concerned with operating costs and equipment management. Scheduled vs Unscheduled Maintenance Work. Some of the most efficient methods are ABC and PIEU. Work scheduling: task sequencing, procedures and work planning. It is verified by the Technical Services Superintendent. Responsibility: The monthly calculation and reporting of Equipment Utilization is the responsibility of the Maintenance Planner. Integration of the maintenance policy within the company. KPI Standard: Physical Availability will be calculated as follows: SH – DFI I SH X 100 = Physical Availability Availability is well established in the literature of stochastic modeling and optimal maintenance. Detailed preparation and works management. This performance measurement applies to all Maintenance Areas. Preventive maintenance, therefore, loses its urgency and breakdown maintenance becomes the order of the day. The more details you give on your situation, the better we can help you. Availability, also known as operational availability, is expressed as the percentage of time that an asset is operating compared to its total scheduled operation time. Procedure: Monthly and/or as directed the Maintenance Planner will compile all necessary MIS data required to produce an accurate and timely report. Maintenance is another important aspect of system performance after reliability. Documentation: The Utilization Availability data, calculations and routine monthly report will all be developed and contained on the sites MIS system. This performance measurement applies to all Maintenance Areas. Level : Access all documents (photos, videos, etc.) Maintenance levels in regulations. Without an integrated, coordinated effort by all functional groups, reasonable levels of performance are not achievable. Overall cost of failure: non-efficiency costs. It provides the baseline information including equipment maintenance and operating parameters. Then reliability centered maintenance (RCM) started to take off and this saw the advent of reliability, or to be more correct, the term reliability. Each of the functional groups, such as purchasing, maintenance, or production, depends on other functions. In his book Introduction to TPM published in 1988, he notes that prize-winning companies have OEE scores of 85% or more—known as the world class rating. It can be certified, under the conditions set out in "prerequisites". Maintenance Management Systems & Procedures The Availability & MTTR, MTBR . Documentation: The Physical Availability data, calculations and routine monthly report will all be developed and contained on the sites MIS system. Implement a model to manage detached pieces inventory . Inherent availability (Ai) = 713940 / (713940+1) = 713940 / 713941 = 99.999860% Inherent unavailability = 1 / 713940 = 0.000140%. Different types of maintenance contracts. Basic Maintenance Management KPI’s: Equipment Mechanical & Physical Availability, Down Time Delays, Utilization & Schedule Compliance VS Unscheduled Work. For equipment that is expected to be op… Documentation: The Scheduled Compliance work data, calculations and routine monthly reports will be developed and contained in the Smelter’s MIS system. This course is available in In-house and is customizable. Responsibility: The monthly calculation and reporting of Mechanical Availability is the responsibility of the Maintenance Planner. Waste management Recycling management Maintenance … It is most often expressed as a percentage, using the following calculation: Availability = 100 x (Available Time (hours) / Total Time (hours)) For equipment and/or systems that are expected to be able to be operated 24 hours per day, 7 days per week, Total Time is usually defined as being 24 hours/day, 7 days/week (in other words 8,760 hours per year). 4. âBad actorsâ detection and classification. An average company, on the other hand, might have an OEE score of around 40%. Evaluating the criticality of assets will guarantee the availability of spare parts for high-priority equipment. A scheduled, documented cleaning and maintenance program can go a long way and benefit your processing in a number of ways, such as: Minimizing wear and tear on machines; Saving you money on repair and replacement parts; Extending the overall life of your equipment Try our Maintenance Software For Free. UMH = Unscheduled Maintenance Work Hours Definition: The “Equipment Utilization” shows what percentage of the available time a piece of equipment or machine was actually operating. Maintainability and Availability. It is verified by the Maintenance Superintendent. Rental of sturdy and safe equipment that is new or refurbished. Standard data used for a turnaround. In addition, maintenance management must ensure that all maintenance employees follow standard practices and fully support continuous improvement. It is verified by the Maintenance Superintendent. Plant maintenance—Management. MH + UMH = Total Maintenance Work Hours. MIS data required to produce an accurate and timely report. Each one can tell you something different about how an asset operates. Maintenance Management Responsibilities Risks Based Inspection and basics in Safety Instrumented Systems (SIS). Analytical techniques for evaluation of a mine's maintenance performance using equipment fdure and repair time data are presented. It assumes that spare parts and manpower are 100 percent Responsibility: The weekly calculation and reporting of Schedule Compliance is the responsibility of the Maintenance Planner. DH = Down Hours and checklists from the equipment sheet in your Mobility Work application. Leave your phone number if you would like us to call you. By continuing with the above example of the AHU, its availability is: 300 divided by 360. Plant engineering, purchasing and other plant fu… Task planning and project manager tools: coordination ranges, execution ranges, margins, critical path. Conduct consistent cleaning and maintenance. At the same time, you have direct access to all the data you need regarding equipment, resources, and logistics. Availability is, in essence, the amount of time that an item of equipment or system is able to be operated when desired. Different types of maintenance: preventive (systematic, conditional, predictive) and corrective. The performance measurement is the total amount of scheduled maintenance resources directed towards maintenance tasks expressed as a percentage of total maintenance hours. Life Cycle Cost (LCC). Procedure: Monthly or as directed the Production Senior will compile all necessary data required to produce an accurate and timely report. Documentation: The Mechanical Availability data, calculations and routine monthly report will all be developed and contained on the sites MIS system. SMH = Scheduled Maintenance Work Hours The performance measurement is the line item summary of the total amount of equipment or machinery downage expressed as a percentage of total delay hours. The efficacy of these techniques is illustrated through a case study of the mobile equipment in an underground mine operating at high altitude. Standard KPI: Mechanical Availability will be calculated as follows: OH / OH + DU X 100 = Mechanical Availability DH = Down Hours. “The term ‘equipment management’ implies a cohesive effort on the part of the entire organization—not just those routine activities performed by the maintenance department.” Beyond having predictive, cohesive maintenance practices, the focus of the Caterpillar® document is on one key factor: Measurement. opted for Total Productive Maintenance (TPM) usually rank their equipment according to maintenance standards Basic Elements of Maintenance Management. Documentation: Equipment Utilization data, calculations and routine monthly reports will be developed and contained in the sites MIS system. The performance measurement is an equipment’s or machine’s time expressed as a percentage of controllable time. The Availability of an Equipment is known by different names such as – Equipment Availability – Operational Availability etc. Responsibility: The monthly calculation and reporting of Equipment Down Time Delays is the responsibility of the Maintenance Planner. Predictive maintenance contributes to the availability of equipment because, on the basis of data analytics coming from the equipment and benches coupled to Thales engineering expertise, it can detect the need for maintenance service before failure. KPI Standard: The “Equipment Down Time Delays” report is a line item summary of individual delay groups that contribute to the total downage time for the reported period. It is defined as the expected level of availability for the performance of corrective maintenance only. Responsibility: The monthly calculation and reporting of Scheduled vs Unscheduled Maintenance work is the responsibility of the Maintenance Planner. Dynamics Maintenance Management supports your organization by optimizing your plant’s preventative periodic maintenance and internal maintenance requests as well as repairs. In U.S. manufacturing, equipment availability is generally ensured by the existence of standby equipment, i.e., buying two machines when one will produce the desired throughput. OEE is a combination of three factors that tell you how efficient an asset is during the manufacturing process: asset availability, asset performance, and production quality. Overall Equipment Effectiveness (OEE) was conceptualized and introduced by the father of Total Productive Maintenance (TPM), Seiichi Nakajima. Documentation: The Scheduled vs Unscheduled Work data, calculations and routine monthly report will all be developed and contained on the sites MIS system. This is a key success factor in contributing to missions success. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. The main objectives of maintenance management are as follows: (1) Minimizing the loss of productive time because of equipment failure to maximize the availability of plant, equipment and machinery for productive utilization through planned maintenance. Inherent availability is the steady state availability when considering only the corrective downtime of the system.
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