1. CHALLENGES IN MAINTENANCE FUNCTIONS
MECH. JOBS RELATING TO MACHINERY AND EQUIPMENT, AND SYSTEMS TOWARDS BETTER PRODUCTIVITY, HIGHER PRODUCTION LEVELS, CAPACITY UTILIZATION, EFFICIENT CAPITAL EMPLOYMENT AND REDUCED LOSSES
ELECTRICAL JOBS RELATING TO ALL ELECTRIC PRIME MOVERS, POWER CONTROL, PLANNING LOAD DISTRIBUTION
CIVIL AND ENVIRONMENTAL JOBS RELATING TO MAINTENANCE
ELECTRONIC JOBS RELATED TO SOLID STATE DEVICES AND MICROPROCESSOR CONTROL

2. EXPECTATIONS REDUCTION IN UNSCHEDULED BREAKDOWNS
ELIMINATION OF TIME SCHEDULED OVERHAULS
INCREASE IN OPERATING LIFE OF THE ASSETS
REDUCTION IN DOWNTIME
REDUCTION IN MAINTENANCE MANPOWER
REDUCTION OF SPARES INVENTORY
MAXIMIZING EQUIPMENT EFFECTIVENESS

3. TOTAL PREVENTIVE MAINTENANCE
FAILURE MODE AND EFFECT ANALYSIS
CRITICALITY ANALYSIS
PRELIMINARY HAZARD ANALYSIS
FAULT TREE ANALYSIS
HAZOP STUDIES
CAUSE-CONSEQUENCE-COST ANALYSIS
INTEGRATING VARIOUS MAINTENANCE SYSTEMS
DETEREMINING AREAS OF CONDITION MONITORING
DOCUMENTATION PROCEDURES AND SYSTEMS

4. IDENTIFYING LOSSES DUE TO FAILURES AND ADJUSTMENT OF SPEEDS AND MINOR STOPPAGES
LOCATING DEFECT LOSSES
HAVING PROPER LUBRICATION SYSTEM FOR ENERGY SAVINGS

5. EFFECTIVE MAINTENANCE
RESTORE SYSTEM PRODUCTIVITY
IMPROVES EQUIPMENT RELIABILITY
AVOID UNNECESSARY SHUTDOWNS
INCREASE OF EQUIPMENT EFFICIENCY
PROLONG SYSTEM LIFE
IMPROVE OVERALL PLANT EFFECTIVENESS
MAINTAIN PRODUCT QUALITY
INCREASE PLANT PROFIT

6. NON-EFFECTIVE MAINTENANCE
INCREASED MAINTENANCE COST
REDUCED SYSTEM / EQUIPMENT LIFE
INDUCED / CREATED UNWANTED WASTE
ADDITIONAL COST TO CLEAN THE EQUIPMENT
CAN AFFECT PRODUCT QUALITY
REDUCED PLANT PRODUCTIVITY
DOWNGRADED SYSTEM EFFECTIVENESS
DECREASED PLANT PROFIT
POOR SKILL LEVEL
REPITITIVE FAILURE

7. OVERALL EQUIPMENT EFFECTIVESSS
AVAILABILITY
PERFORMANCE RATE
QUALITY RATE
MTBF , MTTR, MUT, MDT, MCT, MLDT
INHERENT AVAILABILITY
STEADY-STATE AVAILABILITY
OPERATIONAL AVAILABILITY

8. KEY PERFORMANCE INDICATORS
INCREASE EQUIPMENT RELIABILITY
NUMBER OF UNITS REJECTED BY QUALITY INSPECTION
ZERO DEFECTS
SIX SIGMA
ZERO ACCIDENTS
MAXIMIZING O.E.E.

9. MAINTENANCE KEY PERFORMANCE INDICATORS
OVERTIME WORKED AGAINST PLAN
PM SCHEDULE COMPLIANCE
TIME TAKEN TO ATTEND MAINTENANCE CALLS
BUDGET COMPLIANCE
PM BACKLOG MANHOURS
CRITICAL EQUIPMENT EFFECTIVESS
NUMBER OF BREAKDOWNS
PRODUCTION EQUIPMENT PERFORMANCE
AVAILABILITY AND RELIABILITY

10. MAINTENANCE PERFORMANCE ANALYSIS
WORK SAMPLING TECHNIQUES
JOB AUDITING
SWOT ANALYSIS
EVALUATION BY REPORTS
EVALUATION PROCESS OF PLANT ENGINEERING - BENCHMARKING

11. MANUFACTURING BASED MODEL
PLANT OUTPUT
MAINTENANCE INPUTS
SERVICE BASED MODELS
QUALITY BASED PERFORMANCE PARAMETERS – AVAILABILITY, RELIABILITY, WAITING TIME
OPERATION BASED PERFORMANCE PARAMETERS – OVERTIME, REPAIR MEAN TIME ETC.

12. MAINTENANCE PERFORMANCE MEASURE INDICATORS
QUALITY BASED INDICES
AVAILABILITY
EQUIPMENT RELIABILITY: MTBS, MTTF, MTTR, MTBM, FAILURE RATE
EQUIPMENT MAINTAINABILITY: MTD
EQUIPMENT UTILIZATION
MANPOWER EFFICIENCY
REACTIVE REPAIR RATIO

13. PERFORMANCE BASED INDICES
MAINTENANCE COST PER UNIT PRODUCTION
MAINTENANCE COST / HOUR
TOTAL PLANT MAINTENANCE PRODUCTIVITY
% COST SCHEDULED MAINTENANCE
% MAINTENANCE COST TO INVESTMENT

14. % SCHEDULE COMPLIANCE
SCHEDULE LOADING FACTOR
WRENCH TIME
MAINTENANCE WORK CAPACITY INDEX

15. MAINTENANCE OPERATION AUDIT
MAINTENANCE OPERATION PROCEDURE
MAINTENANCE ORGANIZATION AND COMMUNICATION
PLANNING AND SCHEDULING COMPLIANCE
PLANT SHUTDOWN PROCEDURE
MAINTENANCE PERSONNEL COMPLIANCE TO PROCEDURE, ROLES AND RESPONSIBILITIES
INVENTORY MANAGEMENT
COST COMPLIANCES TO APPROVED BUDGET
CONTRACTOR PERFORMANCE
REGULATORY AND STATUTORY COMPLIANCES

16. MAINTENANCE PLAN AUDIT
WORK REQUESTS / ORDERS
EQUIPMENT FAILURE HISTORY
EQUIPMENT LIFY CYCLE PROFILE
FAILURE AND ROOT CAUSE ANALYSIS
EQUIPMENT MAINTENANCE PLAN/SCHEDULE COMPLIANCE
MAINTENANCE IMPROVEMENT PLAN
ASSET CARE MANAGEMENT

17. TECHNICAL AUDIT THERMAL AUDIT ELECTRICAL AUDIT ENERGY AUDIT
INDUSTRIAL WATER USAGE AUDIT
COMPRESSED AIR AUDIT
PLANT HYDRAULIC SYSTEM AUDIT
PLANT CENTRALIZED LUBRICATION SYSTEM AUDIT

18. MAINTENANCE BENCHMARKING
STRATEGIC BENCHMARKING
PERFORMANCE BENCHMARKING
PROCESS BENCHMARKING
FUNCTIONAL BENCHMARKING
INTERNAL BENCHMARKING
EXTERNAL BENCHMARKING
INTERNATIONAL BENCHMARKING

19. MAINTENANCE COSTS FIXED AND VARIABLE COSTS
FIXED COSTS: READY TO SERVE MEN AND FACILITIES
VARIABLE COSTS: COST OF MAJOR REPAIRS AND OVERHAULS, SPARES, MATERIALS AND FACILITIES
DIRECT COSTS – APPARENT COSTS: BUDGETED COST AFFECTING THE CASH FLOW OF ORGN.
MATERIALS, MAINTENANCE LABOR, OVERTIME, CONTRACT SERVICES, OVERHEADS ETC.

20. INDIRECT COSTS – HIDDEN COSTS
START-UP LOSSES
MISSED SCHEDULES
RIPPLE EFFECT ON PRODUCTION
COST OF IDLING OR RUNNING AT REDUCED SPEED
EXCESS INVENTORY
WASTE GENERATION
EMERGENCY PURCHASES
EXTRA CLEAN – UP
CUSTOMER COMPLAINTS
REGULATORY/STATUTORY FINES
LOST BUSINESS
ENVIRONMENTAL CONTROLS
ACCIDENTS

21. REVENUE / CAPITAL COSTS
COST COVERED BY REVENUE BUDGET ALLOCATED FOR VARIOUS NORMAL MAINTENANCE ACTIVITIES FOR A GROUP OF EQUIPMENT / SECTION / SHOP
UNUTILISED BUDGET AMOUNT CANNOT BE CARRIED OVER TO NEXT YEAR

22. CAPEX – CAPITAL EXPENDITURE
COVERED BY CAPITAL BUDGET
SPECIFICALLY SANCTIONED FOR SPECIFIC JOBS, EQUIPMENT – ADDITION, MODIFICATION, REPLACEMENT SCHEMES GENERALLY NOT TAKEN IN REGULAR COURSE OF MAINTENANCE
NO ADJUSTMENT OF CAPITAL BUDGET PERMISSIBLE FROMMONE EQPT. TO ANOTHER OR FROM ONE JOB TO ANOTHER

23. MAINTENANCE COST COMPONENTS
READY TO SERVE
CONDITION MONITORING – FACILITIES
PM, PdM, CBM
CORRECTIVE MAINTENANCE
MAJOR REPAIR, OVERHAULS, REVAMPING
MATERIALS – SPARES, CONSUMABLES, TOOLS, TACKLES
DIAGNOSTIC AND MEASURING EQUIPMENT
CAPTIVE SHOPS, CENTRAL SERVICES
EXTERNAL AGENCIES – TESTING, AUDIT ETC.
CONTRACTORS , MAINTENANCE OUTSOURCINGS
TRAINING AND DEVELOPMENT

24. REGULATORY / STATUTORY EXPENDITURES
INSURANCE LIABILITES
NON WORKING MAINTENANCE LABOR
MAINTENANCE WORK DONE BY PRODUCTION EMPLOYEES
NON CAPITAL PLANT IMPROVEMENTS

25. MAINTENANCE COST ANALYSIS
UNDERSTAND THE COSTS TO MAINTAIN EQUIPMENT
IDENTIFY FAILURE MODELS
IDENTIFY OPPORTUNITIES TO REDUCE COSTS
VALUE Vs. COST OF SPARES INVENTORIES
DEVELOP RELIABILITY MODEL DIRECTLY FROM MAINTENANCE RECORDS

26. COST CONTROL IN MAINTENANCE
KEEP BREAKDOWN COST DIFFERENT FORM PM, PdM, CBM
COST-CONSCIOUS MAINTENANCE PERSONNEL
MAINTENANCE PREVENTION
USING COST REDUCTION TECHNIQUES – REPAIR Vs REPLACE, LIFE CYCLE COSTING
WASTE REDUCTION AND WASTE RECOVERY
SALVAGING OF SPARES SUB-ASSEMBLIES

27. MAINTENANCE BUDGET BUDGET IS A FORECAST OF EXPENDITURES AND REVENUES
APPROPRIATION BUDGETS: LUMPSUM AS THE MAX. AMOUNT THAT CAN BE SPENT FOR A GIVEN ITEM
FIXED BUDGETS: SPECIFY ALLOWABLE AMOUNT OF COST FOR A PERIOD OF TIME
FLEXIBLE BUDGET

28. PREPARATION OF MAINTENANCE BUDGET
ALLOCATE REVENUE AND EXPENSES USING TOP DOWN / BOTTOM UP
PRODUCTION MAINTENANCE SCHEDULE APPROACH
LABOR ALLOCATION APPROACH
INTEGRATED APPROACH