Maintenance Equipment Frequency

Hello AUREL MARES

If a proper answer is given to you, it's going to be a Post of several hundred pages, to cover most options.

I'm sorry that my auto-poster is otherwise presently occupied.

Kind Regards....

Hi AUREL MARES,

It seems you know what is maintenance. You define it quite well in your post, however you forget the more recent maintenance type: Predictive, which is been used to reduce preventive and corrective.

There's no unique answer to your question. It depends on the type of equipment, its cost, the cost of different options for maintenance, the criticality of equipment in the plant, the criticality of the plant, etc.

For example, in some big power plants, many small valves have a maintenance limited to check for leaks and lubrication of stem and upon valve seat leakage, the valve is replaced by a new one. On some other more expensive and important to plant availability equipment if cost analysis allows, a predictive maintenance with continuous or discontinuous monitoring of some parameters is made, allowing thus to make a trending of the behaviour and servicing it just when needed.

Maybe you could take a look on some last trending in maintenance, RCM, etc.

Kind regards

As "Sparkstation" said it varies from organization to organization and also type of the equipment/ building/ etc. See my Bio-data as a Maintenance Person: Started as Small-time technician with electrical contractor with a big Ship-yard, 3yrs with SPM manufacturer, 6 yrs with Civil contractor (Dam-works) maintaining construction equipment, cranes, pumps, DG sets, compressors, etc; 5 yrs with FMCG (Gillette) maintaining facilities and many very sensitive process equipments; 3 semiconductor diode plant Plant facilities & equipment, 2 yrs Metal film Resistor mfg P&E, 2 yrs same company Discrete components mfg like transistors/ Ics etc P&E, 4 yrs Wafer foundry, 3 yrs Big glass plant mfg Bulbs, Florescent lamps and all components, FMCG plastic components mfg tooth-brushes etc; Now with VRLA & various other battery manufacturing. Though I have hands-on Electrical, Electronics & mechanical experience on various equipments, now my organization treats me as an Electronics specialist. I have won a good name in all the companies I have worked! I just first understand actual requirements of the management and deliver goods by best utilizing resources.

i really get impressed that you first understand actual management requirement and deliver goods by best utilizing resourses.

i think that best utilizing resorses means maintenance. in my soap department i am facing lot of problem management which is production oriented, unskilled manpower because low paid low educated manpower, resorses availability because its a kenya, handling of corrosive material, less co-operation because of uneven salary structure. i think all the problem i am facing as a maintenance incharge. i am solving one problem till that time two more problems will stand in front of me.

can anybody suggest me something how can i overcome on this problem?

any system or any maintenance ideas or tips

Maintenance!

Very Vaaast subject. I tried to quantify many times and gaveup. first i tried to prepare a maintenance calender for my plant. Overall plan was OK. When i went into details it started expanding -Daily, weekly, monthly, annual... recording activities to create data base to arrive at cost of maintenance in terms of labor, power, time, cost..... motivation of maintenance personnel..... teaching maintenance personnel the operation principles of each and every component... buffer stock of spares for maintenance... tools required for easy and efficient maintenance.... convincing management regarding the necessity of inventory.... raising the image of maintenance department to enable co-operation from production, quality departments...

Try it!!

Ragotham

Ok, I understand your situation. I too passed such a situation. My team used to steel all tools used for maintenance, but I could solve the problem. Here is some guidance. I see your case is managing people, not just equipments.

1. Be always positive, while talking, in all your actions and what ever you do.
2. Learning is most powerful cheap and best motivator. You have to motivate your team by teaching some thing new and different. Highly motivated people deliver goods.
3. Teach your people having the pleasure of achieving zero breakdowns.
4. Teach them how preventive and corrective maintenance reduce their work burden and the same time they can enjoy a sense of belonging.
5. Generate positive competition among them.

For this read some good management books. visit: http://www.immeindia.org/contact.htm you get good literature from them.

start with small and simple things for improvement. You can more easily tune youngsters than most experienced.

Best of luck!

I used to be the maintenance engineer at an aquaculture facility. I was in the same situation, by the time you've fixed one problem another two have developed.

I found it was because there was no real maintenance structure in place. As others have described I sat down and wrote up maintenance schedules for each and every bit of plant. Then I stuck to the schedule and logged everything I did.

This way I was able to account for my actions when questioned and even though I was still very busy I felt in control of the situation.

By the way it is not easy to do and it took me about 6 months to get everything into place and this is a relatively small operation.

Books could be written (and likely have been) on the topic(s) of maintenance. It is a production/quality/sales/housekeeping effort, and to be effective it requires buy-in, supportive buy-in, not just lip service, from both top management and the plant floor grassroots. And as previously noted, it will vary in it's requirements from place to place and time to time; it is not a static topic.

please anybody can tell me any specific book for the same

thanks in advance.

Hello sandeep lokhande

There is no single book or manual to cover all possibilities.

There are books written which cover a narrow range of maintenance.

Try Google Results 1 - 10 of about 402,000 for maintenance manual plant equipment. (0.28 seconds)

As you should see there on Google, you need to narrow the scope of what you need.

Of course you could always purchase all the books offered, and then after understanding all the multiple informations contained therein, sit down and spend the rest of your life composing and writing "The Complete Maintenance Manual For Almost Every Eventuality Or Situation".

The book would, of course, be too great a job for any printer or publisher, and as an electronic file, the book would be thousands of GB of data, need to be word-searchable, complete with diagrams and pictures.....think about what you ask, please.

Narrow the scope of your Maintenance enquiry, and perhaps you may be better assisted.

It is neither practical nor possible to write a Maintenance Manual to cover all eventualities and situations.

Kind Regards....

Dear Mr. Sandeep,

S Chand & company, New Delhi published few books on equipment maintenance. Annamalai University conduct correspondence course on "Maintenance Management".

Hello all! Coincidentally, I am preparing a report for the US Coast Guard regarding maintenance. I currently have open on my desk three books that may or may not help you in your quest for knowledge... They deal specifically with Reliability Centered Maintenance, which might be too narrow a field for you, but here they are anyway:

1. Moubray, John, "Reliability-Centered Maintenance," Industrial Press, New York City, NY, 1997.

2. Smith, Anthony M., "Reliability-Centered Maintenance," McGraw-Hill, New York City, NY, 1993.

3. Bloom, Neil, "Reliability Centered Maintenance (RCM) Implementation Made Simple," McGraw-Hill, New York City, NY, 2006.

I should probably warn you that they are extremely hard to come by, even in the region of the country that they were published! I had to order them through the inter-library loan system, and they took nearly a month to arrive. I'm not familiar with how libraries work (in any nation), but it may be possible for you to get a hold of these same titles where you are. I hope this helps some. If not, I looked through a bunch of databases to find just enough info to scrape together to create what my boss called a "cocktail discussion." I hope you have better luck than I did!