MAINTENANCE WORK MANAGEMENT SYSTEM FOR THERMAL POWER PLANTS: MAINTENANCE WORK MANAGEMENT SYSTEM FORTHERMAL POWER PLANTS

SHIVAJI CHOUDHURY MAINTENANCE WORK MANAGEMENT SYSTEM: MAINTENANCE WORK MANAGEMENT SYSTEM 1.Work Culture. 2.Cost Effective Technology Utilization. 3.Computerised Management System. 4.Preventive and Predictive Maintenance. 5.Work Management Tools. 6.Work Scheduling. 7.Materials. 8.Work Planning. 9.Operation, Maintenance Team Work. 10.Work Order. 1.WORK CULTURE: 1.WORK CULTURE Leadership and goal. Accountability. Active communication channels. Structured problem solving . Delegated decision making. Innovations and continuous improvements Technical and management training . Self managed team and team work. 2.COST EFFECTIVE TECHNOLOGY UTILIZATION: 2.COST EFFECTIVE TECHNOLOGY UTILIZATION Formal failure analysis. Training of operators, workers & engineers. Unit capacity management. Unit availability management. Heat rate control. Fuel use optimization. Network worked information system. Asset management. 3.COMPUTERISED MANAGEMENT SYSTEM(CMS): 3.COMPUTERISED MANAGEMENT SYSTEM(CMS) Work order system and life cycle. Table driven structure. Work management and backing information. Equipment costs and performance indicators. Equipment failure analysis. C M S access and work management training. Materials and purchasing integration. Unit load schedule integration. Accounting and payroll integration. 4.PREVENTIVE MAINTENANCE (PM) AND PREDICTIVE MAINTENANCE(PDM): 4.PREVENTIVE MAINTENANCE (PM) AND PREDICTIVE MAINTENANCE(PDM) Formal preventive maintenance program (PM). Joint resource commitment. Annual preventive maintenance (PM) review. Preventive maintenance (PM) effectiveness indicators. Formal predictive maintenance program (PDM). PDM effectiveness indicator. Streamlined Reliability centered maintenance (RCM). 5.WORK MANAGEMENT TOOLS.: 5.WORK MANAGEMENT TOOLS. Backlog indicators and trends. Job priority review (emergency/urgent/preventive/routine). Work management effectiveness indicators. Labor over time reports. Resource leveling. Equipment history . Top ten problem list Availability and reliability indicators. Financial indicators. Action item lists.

6.WORK SCHEDULING: 6.WORK SCHEDULING Jointly prioritized planned work. Formal scheduling meetings. Contractors and plant coordination. Worker schedule. Schedule compliance review. Periodic purging of backlog. Long range schedules. Outage progress updates. End of outage testing and startup. Post outage analysis. 7.MATERIALS: 7.MATERIALS Accurate and organized inventory. Stock tools issue and returns. Non stock issue and returns. Receiving. Quality assurance and control. Material staging and delivery. Vender stocking. Vender certification and performance. Material effectiveness indicators. 8.WORK PLANNING: 8.WORK PLANNING Work order priority Emergency do it now. Urgent -- with in 48 hrs. Preventive do before routine work. Routine -- do when resources are available. Workers hours planning. Materials and parts planning. Field job scoping. Standard job plan. Planning effectiveness indicators Craft participation in planning. Outage planning. 9.OPERATIONS,MAITENANCE TEAM WORK: 9.OPERATIONS,MAITENANCE TEAM WORK Early work identification . Equipment custody and preparation. Clean up house keeping. Operations check sheets and routes. Safety management. Training. 10.WORK ORDER: 10.WORK ORDER Unique work order number. Equipment identification and label. Complete and accurate symptom. Clear priority system. Labor and materials estimating. Acceptance of completed work. Labor and materials actual. Complete work histories.