1. Welcome to ENGM03 Advanced Maintenance Practices ► Dr David Baglee ► david.baglee@sunderland.ac.uk david.baglee@sunderland.ac.uk ► Phone: 515 2869 AMAP The Industry Centre Wessington Way ► Wednesday 1pm-4pm ► Lectures and lab. ► One assignment and one exam?

2. Introduction to Maintenance Dr David Baglee School of Computing and Technology

3. Maintenance Spending ► Europe £100 Billion Annual Spend Employs 2 million people ► United Kingdom £14 Billion Annual Spend 5% of sales turnover 3 × Value of new plant investment 18% of book value

4. Trends ► Assets Assets must run longer (>3 years between turnarounds) Impact of asset failure can be very large ► Expertise Downsizing and aging workforce has caused ‘skill gap’ at plant sites Technology is evolving faster than it can be adopted ► Working Practices Asset management is moving from reactive to proactive Abnormal situation management procedures are improving operations effectiveness

5. Recent Events ► Tube Crash - Chancery Lane, London ► Electricity Supply Failure - USA, Italy, UK ► Rail Crash - Hatfield, UK ► Concorde Crash - CdG Airport, Paris ► BP Refinery Explosion, Texas

6. Example: Car Maintenance ► What must be done to maintain your car? Change the oil every 6,000 miles Check and/or change air filter Check and/or change hoses and belts Rotate tires every 12,000 miles Clean inside/wash outside Replace brake pads Regular inspection

7. Example: Car Maintenance ► Implications of poor car maintenance? Premature failures Increased running costs Unexpected breakdowns Poor operator morale Personal injury or death Government shuts you down

8. Barriers ► Limited staff ► Lack of training ► Inadequate diagnostic equipment ► Missing technical documentation ► Budget issues ► Inadequate monitoring of equipment ► Lack of management commitment ► Poor morale

9. Neglected Maintenance ► Operating equipment in manual override ► Incorrectly adjusted equipment ► Inefficient operations ► Inoperative equipment ► Steam, air, water leaks ► Faulty control systems ► Damaged HVAC equipment

10. Results of Poor Practices ► Short and Long term effects: Increased energy costs Increased major maintenance work Increased capital costs due to shortened equipment life Continued morale degradation

11. Costs Involved ► Equipment purchase ► Training ► Extra staff ► Costs can be insignificant when compared with cost of not improving maintenance methods ► Industry loses per year are huge due to inadequate maintenance activity

12. Benefits ► Improved equipment efficiency ► Increased product quality ► Identify equipment defects ► Reduced equipment failures ► Increased production ► Improved safety ► Minimize damage to equipment ► Provide guidelines for new equipment purchase ► Effectively prioritize decreasing resources ► Improve staff morale

13. Self Study ► Do the exercises on the self study sheet ► Take time to examine the Glossary of Terms provided on the following web site: www.skf.com/aptitudexchange/glossary.html