Maintenance planning & control


It is necessary to device appropriate maintenance systems. In planned maintenance, maintenance request emanating from production staff details the defect and the possible rectification required. There is an assets / facilities Register where there is detailed description of each physical asset: name, code, vendors, spares vendors, interchangeable parts etc. The register is maintained on the basis of asset classification in terms of usage, technical category and maintenance methods.

Scheduling of maintenance work:

Scheduling refers to the timings and sequences of operations. It is an important segment of the production planning and control activity. However, it is equally important for the service operations like plant maintenance. The scheduling of the plant maintenance is desirable for the following reasons:

1. Scheduling facilitates the optimum use of the highly paid maintenance staff. Proper scheduling reduces the idleness of maintenance crew.

2. The plant maintenance equipment can be utilized effectively through scheduling their uses.

3. It eliminates undue interruptions in the production flow. Maintenance works schedule on night, week-end day, holiday etc can ensure smooth flow of production operations.

4. Proper scheduling of the maintenance service eliminates the chances of abrupt breakdowns and equipment failures.

5. It is sometimes necessary to maintain the sequences in providing the plant maintenance service e.g. clearance of clogged pipes and waste disposal. Scheduling facilitates the proper sequence in the maintenance service.

Maintenance schedules lead us to work / job specifications. It is a link between the engineer and the tradesman. It gives guidance in respect of method, and presents a work-load.

These are important steps for programming the annual and weekly maintenance programs. After maintenance, an Inspection Report is produced. Other historical records are also kept pertaining to maintenance on manual or EDP basis for better planning.

Maintenance calls for planned lubrication, where what is to be lubricated, when it is to be lubricated, the lubrication of operation or how it is to be lubricated is decided.

Planned maintenance reduces emergency cases (they remain hardly10%). We also have to determine work priority into several classes, facilities priority into several classes and arrive at priority Index for any job (work priority x facilities priority) and can be expressed as a percentage.

Safety is always an important consideration It is ensured by providing guards, protective clothing, power isolation fuses, safety valves for pressure systems, and issue of a permit to work on a particular machine by the maintenance staff.

Cost control of plant maintenance:

Plant maintenance is an inevitable service function and so it should be provided with the lowest possible costs. Generally plant maintenance cost is controlled through budgets. The amount of the budget provision largely depends on the management policy to have either over-maintenance or under-maintenance. The policy of under-maintenance reduces the cost of maintenance but increases the chances of breakdowns and the resultant losses. While the policy of over-maintenance increases the over consciousness of maintenance at high cost, efforts should be made to strike a balance between the two with a view to have the optimization of this service. The distinction should be made between the revenue expenditure and capital expenditure on maintenance. The foreman of each department should try to keep his revenue maintenance cost within the budgeted limits. The complete records of the maintenance cost should be maintained. The actual maintenance cost should be compared with the budgeted one and the discrepancies should be found out.

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