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Transcript of Dubrovnik Airport Galiot Conference, Split 8/9. MAY 2014. Author: Tomislav Macan, DBV Airport Chief...
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GALIOT – MAINTENANCE
Dubrovnik Airport
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance function
All actions necessary for retaining an item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification
Increase availability of a system Keep system’s equipment in working
order
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Question? Why do we need maintenance? What are the costs of doing
maintenance? What are the costs of not doing
maintenance? What are the benefits of maintenance? How can maintenance increase
profitability of company?
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Purpose of Maintenance
Attempt to maximize performance of production equipment efficiently and regularly
Prevent breakdown or failures Minimize production loss from failures Increase reliability of the operating
systems
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Principle Objectives in Maintenance To achieve product quality and
customer satisfaction through adjusted and serviced equipment
Maximize useful life of equipment Keep equipment safe and prevent
safety hazards Minimize frequency and severity of
interruptions Maximize production capacity –
through high utilization of facilityGaliot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance Objectives
Must be consistent with the goals of production (cost, quality, delivery, safety)
Must be comprehensive and include specific responsibilities
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance Costs
Cost to replace or repair Losses of output Delayed shipment Scrap and rework
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance types
Three types of maintenance
Breakdown maintenance – emergency or priority repairs on failed equipment
Preventive (scheduled) maintenance – routine inspection and servicing to keep facilities in good repair
Predictive (Condition-based) maintenance
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Corrective or Breakdown Maintenance
Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed and can not perform its normal function anymore
Quite justified in small factories where: Down times are non-critical and repair costs are
less than other type of maintenanceFinancial justification for scheduling are not felt
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Disadvantages of Corrective Maintenance Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance Excessive delay in production & reduces output Faster plant deterioration Increases chances of accidents and less safety
for both workers and machines More spoilt materials Direct loss of profit Can not be employed for equipments regulated
by statutory provisions e.g. cranes, lift and hoists etc
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Preventive Maintenance (PM) Principle – “Prevention is better than cure” Procedure - Stitch-in-time It
locates weak spots of machinery and equipments
provides them periodic/scheduled inspections and minor repairs to reduce the danger of unanticipated breakdowns
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Implementing Preventive Maintenance Need to know when a system requires
service or is likely to fail High initial failure rates are known as
infant mortality Once a product settles in, MTBF
generally follows a normal distribution Good reporting and record keeping can
aid the decision on when preventive maintenance should be performed
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Candidates for Preventive Maintenance
Mean Time Between Failure (MTBF)
Frequency of FailureGood candidates have more normal distribution with low variability
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Advantages of PM Advantages:
Reduces break down and thereby down time Lass odd-time repair and reduces over time of crews
Greater safety of workersLower maintenance and repair costsLess stand-by equipments and spare partsBetter product quality and fewer reworks and scraps
Increases plant lifeIncreases chances to get production incentive bonus
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Predictive (Condition-based) Maintenance In predictive maintenance, machinery
conditions are periodically monitored and this enables the maintenance crews to take timely actions, such as machine adjustment, repair or overhaul
It makes use of human sense and other sensitive instruments, such asaudio gauge, vibration analyzer, amplitude meter, pressure, temperature and resistance strain gauges etc.
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Predictive Maintenance (Contd.)
Unusual sounds coming out of a rotating equipment predicts a trouble
An excessively hot electric cable predicts a trouble
Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Computerized Maintenance System
Output Reports
Inventory and purchasing reports
Equipment parts list
Equipment history reports
Cost analysis (Actual vs. standard)
Work orders– Preventive
maintenance– Scheduled
downtime– Emergency
maintenance
Data entry– Work requests– Purchase
requests– Time reporting– Contract work
Data Files
Personnel data with skills,
wages, etc.
Equipment file with parts list
Maintenanceand work order
schedule
Inventory of spare parts
Repair history file
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance Costs The traditional view attempted to
balance preventive and breakdown maintenance costs
Typically this approach failed to consider the true total cost of breakdowns Inventory Employee morale Schedule unreliability
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance Costs – traditional view
Total costs
Breakdown maintenance costs
Cos
ts
Maintenance commitment
Preventive maintenance costs
Optimal point (lowestcost maintenance policy)
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Maintenance Costs – Full cost view
Cos
ts
Maintenance commitmentOptimal point (lowest
cost maintenance policy)
Total costs
Full cost of breakdowns
Preventive maintenance costs
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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How Maintenance is Performed
Operator Maintenance department
Manufacturer’s field service
Depot service(return equipment)
Preventive maintenance costs less and is faster the more we move to the left
Competence is higher as we move to the right
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Total Productive Maintenance (TPM) Designing machines that are reliable, easy
to operate, and easy to maintain Emphasizing total cost of ownership when
purchasing machines, so that service and maintenance are included in the cost
Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot service
Training workers to operate and maintain their own machines
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Categorization of facilities, equipment and systems
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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DUBROVNIK AIRPORT MAINTENANCE CONCEPT
Documents : Zakon o zračnom prometu 69/09 (čl. 79) Pravilnik o aerodromima NN 64/12 Pravilnik o održavanju i pregledanju aerodroma te mjerama potrebnim
za njegovu sigurnu uporabu, NN 65/05 ICAO Annexes and Airport service manuals (Annex 9)
Brochures and practices: Strategic Approach to Facilities Life Cycle Management Product technical sheets “Best practice”
• the result is
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Aerodromski priručnik poglavlje 4.7.
INTERNI PRIRUČNIK ZA ODRŽAVANJE
1. OPREMA ZA PRIHVAT I OTPREMU ZRAKOPLOVA I PUTNIKA
2. VOZILA IZVAN PLATFORME
3. ELEKTRO OPREMA
4. ELEKTRONIČKA OPREMA
5. STROJARSKA OPREMA
6. OBJEKTI I INFRASTRUKTURA
7. RTG UREĐAJI
8. INFORMATIKAGaliot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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GALIOT Device structure
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Galiot Device structure layers
Categories: 96 (GSE 19)
Devices: 600 (GSE 300)
Procedures: 400
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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GALIOT Departments
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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ImplementationYear of admin. % of admin. in 2013.
GSE equipment 2003. 100
Public vehicles 2003. 100
Electro eq. 2005. 100
Electronics 2009. 50
Mechanic eq. 2009. 50
Infrastructure 2005. 90
Security eq. 2006. 100
IT 2010. 50
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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GALIOT History at DBV Airport 2003. - Maintenance of GSE equipment 2004. – UKMP, Accident report, NOTAM, RIFF,
Update with lighting equip. 2005. – update with electrical equip. and infrastrucutre 2006. – reporting, messaging, alarm, scheduling,
update with security equip. 2008. – Emergency module 2009. – update with Airport manual (incl. electronic
and mechanic equip.). Iphone application for Emergency module
2010.-2013. full integration of Galiot based at Airport Manual including new module structure.
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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GALIOT Maintenance 2014.
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Izbornik 1
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Izbornik 2
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Report – GSE Maintenance
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Report – Lighting Maintenance
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Report – GSE repair
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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Statistics and Audits2013.
Preventive maintenance
Repairs Upgrade and new
Outsourcing
GSE equipment (aprox. 120 selfpropelled + 200 towed units)
517 (without weekly overhaul by operators)
580 18 8
AUDITS by Airlines, Agency and others Authorities: Total 15-20 yearly checking procedured and SLA of which 3-5 checking in detail GSE maintenance and 2-3 checking in detail operational surfaces, pavements,
strips, lighting, signage and markings.
Galiot Conference, Split 8/9. MAY 2014.
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GALIOT – Maintenance conclusion
easy planning and control automatic counting and scheduling self-made procedures easy administration useful reports and notifications important warnings by levels history
Galiot Conference, Split 8/9. MAY 2014.
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GALIOT – Maintenance module
THANKS TO MER SYSTEMS
for development of the module according to best practice and
custom made by DBV Airport inside National and EU regulatory frame
&
keep it up to date.
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer