ASSET MANAGEMENT

A Maintenance perspective…..

CHALLENGES –Maintenance Industry

To select the most appropriate techniques to deal with each type of failure process in order to fulfill all the expectations of the owners & users of the assets

Cost-effective and enduring Solutions Ensure Zero Surprises Organization Culture Understanding Change Increasing Production Demands

Maintenance Management• Maintenance, as apart of the wider scope

asset management, is of central importance for an efficient operation of Industry.

• Modern organizations must move toward improving the maintenance process.

• Preserving assets while fulfilling the overall mission of the company is key to any maintenance effort.

• Development of new applicable maintenance techniques is the need of the Hour

Symptoms to Recognize Too many emergencies.

Everything is Priority One. High Inventory Costs Fixing the same thing over and

over Frequent Downtime Late product or service delivery

due to equipment problems

Growing expectations of Maintenance

Changing Maintenance Techniques

Asset Management-Presume Machinery and Equipments must be

preserved and Productive Life must be Extended

Maintenance & OE Norms must be challenged

The original composition & performance of machinery and its components change due to a multitude of factors that include age, temperature, vibration, duration of operation, corrosion and other environmental factors

Concept of Making Maintenance a Profit Centre

Use of Specialty Consumables with a view to Extend Useful Life of Productive Assets

Productive Assets must be monitored in Real Time

Methodology

Benchmarking Survey Assessment of maintenance practices and

production processes Evaluation of Machinery and Parts Identification of Critical Machineries Assessment of Spare part Inventories & Costs Collection and collation of DATA BEFORE

application Predictive Maintenance Techniques

Methodology

Discover and Identify Application Introduction of Specialty Products & Solutions Continuous monitoring wherever product is

supplied. Use of Ultrasound, Vibration, Leak and

Diagnostic tools ‘before’ and ‘post’ application

Submit Reports that CONFIRM cost effectiveness as a result of Specialty Product usage as per recommendations

Case study-A Reputed Cigarette maf., Co.,

Audit and Survey of Critical Plant Machinery in Primary & Secondary Manufacturing

Ultrasound Diagnosis of critical parts and components before Application

Evaluation of Maintenance Downtime and Spare part costs

Consumables replaced with Specialty equivalents Extension of maintenance intervals Reduction in Downtime and Spare Part costs Post Application Audit of selected Applications Leak & Energy Audits using Ultrasound Tools Savings in Energy,Downtime & Production costs Long Term Condition Monitoring, Maintenance & Leak

Detection Contract

Case study-A Reputed Cigarette maf., Co

CASE STUDY-A Reputed Automotive giant

Audit and Survey of Entire Plant Study of Processes Identification of Specific Departments & Key

Applications Cause and effect Study of Specific Applications Use of Ultrasound and Vibration Tools for Diagnosis

and Quantification Introduction of a suite of Solutions across all the

Applications covering Lubricants, Alloys ,Chemicals, Coatings

Introduction of Energy Audits and Leak detection services

Continuous Monitoring & Evaluation of selected Applications

Maintenance Intervals extended & Better Productivity Quantified

Case Study-A reputed Paper and Pulp IndustryCUSTOMER : TNPL STUDY OF VACCUN PUMPS & AIR SEPERATORS IN P . M . II WITH CTRL UL 101 DETECTOR

AIR SEPERATORS / VACCUM PUMPS

368

369

370

367

366

365

364

363

FEEDER GEAR BOX406

407

405

404

403

402

401

Position no 366 Gear Box Metallic Sound heard.

Abnormal sound heard from Air Seperator no 404.

Position no 364 was found to be having more Vibration & severe metallic noise heard.

369

368

367

366

365

364

363

PUMPS

Pump no 364 found to be in excellent working condition.

CONTACT US:P E R M A W E L D , #148, 1st Floor, Subbaiah Circle, Lalbagh Road, Bangalore-560027, Ph. 2277067 / Fax: 080- 2277650, E-mail: permaweld@vsnl.com

MINIMISE TROUBLESHOOTING TIME WITH CTRL UL101 DETECTOR

The Way Forward

Use of Specialty Products to Extend Maintenance Intervals & Reduce Downtime

Condition Based Monitoring & Scheduling Predictive maintenance Techniques Information based Management Reliability Centered Maintenance Change from ‘Reactive’ to ‘Proactive’

Maintenance Real time Non Invasive Diagnosis Change the Organization Culture Ensure Zero Surprises

Sunil V Rao, Director,Strategic AccountsTCS,Bangalore,Indiasuneilrao@gmail.com