To get a smooth, reliable and cost

effective maintenance in a company,

different functions in the company

has to be coordinated and not only

the maintenance department alone.

1. Replace

2. Repair

3. Overhaul

4. Rebuild

5. Service / Lubricate

6. Inspect

7. Test

8. Adjust

9. Align

10. Calibrate

11. Install

12. Record Keeping

Equipment's and Machines used to

support manufacturing units /

services

i.e. Industries, Offices, Hospitals,

Hotel

1. Electricity

2. Water

3. Air Electricity :

From Electricity BoardFrom Captive Poser Plant through proper Distribution Panels

Through : High Voltage Supply SystemTo SubstationTo Step-down TransformerTo Distribution PanelTo Manufacturing Plants

Water : Hot – SteamNormalCold

Air : FansAir-conditioningHeaters

Compressed Air : AirOxygenVacuum

Gas Plants : OxygenNitrogenHydrogen

Fuel Gases : LPGCNG

Liquid : DieselPetrolFurnace oil

Solid : CokeCoal

Streaming Production

To Accommodate New Machine

Line Balancing

INSTALLATION – COMMISSIONING

Make Suitable Place, Location in Production line

Following Points to be Considered

1.Foundation

2.Electric Supply

3.Compressed Air

4.Air Conditioning

5.Sound Proof Enclosure

6.Material Handlinga) Raw Materialb) Finish Goodsc) Scrap Handling

1. Temparary Shed2. R. C. C. Structiure3. M. S. Structure

Check Following a) Foundation – Load Bearing Capacity of Soilb) Walls – Load Bearing Walls

Partition Walls Brick Walls, A. C. Sheets, M. S. Sheets

c) Top – R.C.C. Slab, A.C. Sheets, Galvanism Sheet

d) Lighting - Ventilation

1. Very High Skills, Expertise Services

2. Huge Man Power for Short duration

3. Low Skill Jobs

4. Hazardus Jobs

5. Small Jobs, Variety Job on regular basis

1. Check for water leakages

a) Rain Water

b) Toilet Leakages

2. Structural Audit

R.C.C. Beams & Columns, Slabs, Walls

3. Structure Repairs

Plastering

Painting

Type of Fire Extinguisher1.Water2.Sand3.Soda Acid4.Dry Chemical Powder5.Foam6.Co2 Carbon-di-Oxide gas

How to take care1.No Smoking, No Welding2.Fire Extinguishers in near vicinity3.Water hydrants around factory4.Escape routs, ladder in case of fire5.Well designed Electrification6.Automatic Sprinklers.

Type of Fire Extingusher

TYPE OF FIREPaper Wood Cloth

Paint Varnish

PetrolumThinner

Electric

WATER

SODA ACID

DRY CHEMICAL POWDER

FOAM

CO2

SAND

GAS WATER SOLID

1. Waste gases from furnace, boiler, contains corbon-di-oxied (Co2), Carbon Monoxide. Supper di Oxide (So2), and ash & many gases. This should be passed through water sprinkler to tall mast Chimani to atmosphere. This reduces air Pollution.

2. Waste water contains oil, chemicals, pestisdes. This water should pass through effluent treatment plant and then to municipal drain

3. Solid waste – Hazardous solid waste should be collected and hand over to compitent waste processing units.

Most important function of every body

1. Cleanliness

2. Safety Guards

3. Safety equipment's, Uniform, ShoesHelmets, goggles, hand gloves, aprons safety belt

4. Safety awarenessa) Safety Postersb) Training Programsc) Safety Drills

5. Safety ApparatusSafety ShowerBreathing ApparatusStrecher, AmbulanceMedical FacilityDoctor, Hospital

Type of energies used

1. Electrical Power

2. Fuel Oil, Gas, Solid Fuels

3. Water

4. Compressed Air, Gas

5. Light

Check how efficiently we are using energy check energy Bills

Collect data of individual plants, machines use ABC Analysis. Weighted average, Importation creat awareness among employees

Quality Base indices Performance Base indices Compare with standards

AUDIT PROCESS

Audit process is required to measure / review performance and effectiveness of each individual departments.

Following are some of the measuring parameters

1.Overall Equipment Effectiveness (OEE)

2.Availability of Equipment

3.Meantime between FailureMeantime to Repair

1. Overtime worked against plan

2. PM schedule compliance

3. Time taken to answer maintenance call

4. Budget Compliance

5. PM Backlog man hrs.

6. Critical equipment availability

7. Number of breakdowns unplanned maintenance

8. Production equipment performance (output)

9. Equipment performance (Quality)

10. Availability & Reliability

11. Mean Time Between Failure (MTBF)

1. Develop a corrective plan for improving personnel compliance

2. Enhance your decision makinga) prioritizing b) Justifying decision

3. Give tool to negotiate at higher managerial level

4. Provide input for future budgeting 5. Motivate maintenance personnel’s6. Show chances of increase in resources

Utilisation7. Audit report allows you to target areas

of opportunity without re engineering.