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SYSTEMATIC MAINTENANCE APPROACH ABOUT THE SPEAKER ARMANDO R. DIAZ Master of Science in Business Administration (MBA) Registered ASEAN Engineer Professional Electrical Engineer ( PEE ) Certified plant Mechanic( CPM ) Accredited Pollution Control Officer Licensed Professional Electrical Engineer with more than 35 years experience in the field of building and facility design and consultancy, construction, operations and maintenance involving various mechanical, and electrical equipment and systems.
SYSTEMATIC MAINTENANCE APPROACH ABOUT THE SPEAKER ARMANDO R. DIAZ Master of Science in Business Administration (MBA) Registered ASEAN Engineer Professional Electrical Engineer ( PEE ) Certified plant Mechanic( CPM ) Accredited Pollution Control Officer Licensed Professional Electrical Engineer with more than 35 years experience in the field of building and facility design and consultancy, construction, operations and maintenance involving various mechanical, and electrical equipment and systems.
SYSTEMATIC MAINTENANCE APPROACH ABOUT THE SPEAKER ARMANDO R. DIAZ Master of Science in Business Administration (MBA) Registered ASEAN Engineer Professional Electrical Engineer ( PEE ) Certified plant Mechanic( CPM ) Accredited Pollution Control Officer Licensed Professional Electrical Engineer with more than 35 years experience in the field of building and facility design and consultancy, construction, operations and maintenance involving various mechanical, and electrical equipment and systems.
ARMANDO R. DIAZ Master of Science in Business Administration (MBA) Registered ASEAN Engineer Professional Electrical Engineer ( PEE ) Certified Plant Mechanic( CPM ) Accredited Pollution Control Officer Licensed Professional Electrical Engineer with more than 35 years experience in the field of building and facility design and consultancy, construction, operations and maintenance involving various mechanical, and electrical equipment and systems. Awarded 1998 as Most Outstanding Practitioner in Industry of the Philippine 2009 IIEE Vice-President for External Affairs Awarded 2006 as IIEE FELLOW Member : Society of Philippine Accredited Consultant Energy Efficient Practitioner Ass. of the Philippine Recipient of Various Civic Awards : Rotary,REACT,YMCA,LOBSET and MARS SYSTEMATIC MAINTENANCE Speaker Profile
Armando Mandy Diaz is Professional Electrical Engineer with Master in Business Administration (MBA); 1998 Most Outstanding Electrical Engineer Practitioner in Industry of the Philippines, Former Region IV IIEE Governor; with almost 30 years extensive industry experience on Engineering and Maintenance having served as Asst. Vice President of Uni-Lonseal Plastics Inc. and in various positions in different industries such as Universal Robinson Corp., Manila Midtown Hotel, International Rice Research Inst. and Unitech Engineering Corp.
ENGINEERING CONSULTANCY SERVICES SPECIALIZATION:Engineering,Operation, Repair and Maintenance
8/18/2014 Plant Equipment Building Facilities .. and among others in Maintenance refers to all activities which assists in GOOD CONDITION KEEPING 8/18/2014 Why Is MAINTENANCE so special? Any person in charge of maintenance whether small or large company feels that his is a unique field. It presents as great challenge to a persons engineering abilities as is to his management know how. It requires as much tact and tolerance as it requires patience and persistence - in fact it requires ... 8/18/2014 SUPERMAN 8/18/2014 - What does MAINTENANCE have to achieve? OBJECTIVES Yes No Remarks Operational objectives: 1. To maintain equipment (a) in acceptable condition (b) in top operating conditions 2. To ensure maximum availability for plant and equipment at reasonable cost 3. To provide service that will avert breakdowns at all times at any cost 4. To extend plant life to the last limit? 6. To ensure high - quality performance. 7. To ensure safe and efficient operation at all times 8. To maximize output over the next five years 9. To maintain a reasonably good appearance of plant 10. To maintain a plant spotlessly clean at all times 5. To maintain plant and equipment with maximum economy and to replace at predetermined periods Which is the following objectives apply in your company? 8/18/2014 Yes No Remarks Cost objectives 1. To minimize maintenance expenditure and to maximize profits 3. To provide funds as a ratio of sales volume production investment 5. To allow a certain amount of contingencies, tooling and incidentals at the discretion of the maintenance executive Which is the following objectives apply in your company? 2. To provide maintenance service within the limits of a budgeted amount 4. To have maintenance expenditure on the amount of service required by plant and equipment in view of its age and its rate of utilization. - What does MAINTENANCE have to achieve? OBJECTIVES 8/18/2014 - What do we expect to gain from good maintenance? BENEFITS 1. 2. 3. 4. 5. 6. 7. Expressed in terms of Important for Book value Utilization of capital Higher plant availability Utilization of capital Reduced scrap and inferior grades Value of output On- time deliveries, less delay penalties Customer relations Maintenance costs Maintenance Economy Inventory carrying costs Capital utilization Lower plant cost per unit of product Unit costing Extended plant life Uninterrupted production Improved quality of production Reduced production delays Reduced costs of repairs Less stand- by plant and spares Improved equipment replacement The Factors A. Financial benefits 8/18/2014 - What do we expect to gain from good maintenance? BENEFITS Expressed in terms of Important for 1. Co-ordination between production and maintenance Improved understanding Internal planning 2. Manpower planning Unproductive time Manpower utilization 3. Planning of deliveries Cost of delays Plant utilization The Factors B. Organizational Advantages 8/18/2014 - What do we expect to gain from good maintenance? BENEFITS Expressed in terms of Important for 1. Improved equipment suitability Better choice of machines Optimum production 2. Build up of technical data Better and more accurate information Standard of technical 3. Improved maintenance schedules Minimum maintenance costs Plant availability 4. Improved plant condition Performance and reliability Operating efficiency The Factors C. Technical advantages 8/18/2014 - What do we expect to gain from good maintenance? BENEFITS Expressed in terms of Important for 1. Increased safety Losses due to claims and less production costs Production economy 2. Improved housekeeping Tidiness of shop floors Workers' morale 3. Less friction, better relations Harmonious relationships Staff relations The Factors D. Human considerations 8/18/2014 - What do we expect to gain from good maintenance? BENEFITS Expressed in terms of Important for 1. Reliable delivery dates Improved reputation Sales promotions 2. "Showcase" housekeeping Better public image Company image The Factors E. Customer relations 8/18/2014 - By what means shall we proceed, within limits shall we try to work towards our objectives? POLICIES Maintenance Policies 1 Management Policies Personnel practices Union Relations Financial Objective Production operations 4 6 5 3 2 8/18/2014 MAINTENANCE ORGANIZATION INSTALLATION AND OVERHAULS PLANNED PREVENTIVE MAINTENANCE BUILDING ELECTRICAL MECHANICAL LUBRICATION INSPECTIONS ADJUSTMENT ROUTINE MAINTENANCE OPERATORS ELECTRICAL MECHANICAL PRODUCTION / SHIFT MAINTENANCE REPAIR CREW REPAIR MAINTENANCE BOILER COMPRESSORS TOOL ROOM UTILITIES / FACILITIES MAINTENANCE MANAGER What does MAINTENANCE really do? What constitutes maintenance work?
What are the functions of our maintenance department?
What do we expect of maintenance? What Constitutes MAINTENANCE work? Training of Maintenance Staff Training of Production Operators Testing parts for suitability and availability Planning servicing schedule Improvement and modification Protective painting Spare parts availability Housekeeping Apart from the obvious jobs of repair, lubrication, overhauls, inspection and replacement of parts, there are others which are less immediately evident. Among these duties we find: What are the FUNCTIONS of MAINTENANCE DEPT? The grouping-together of complete plant and equipment inventory is as if we were to say, look, this is what we to maintain
Management and administrative duties which have to be assigned to the maintenance staff to cover the life of plant at its various stage.
The type of service required by the plant
The degree of planning involved, such as emergencies, periodically, repeated cycles or do-it-any-odd-timejobs
The reasons for doing the jobs e.g. repair of breakdown, prevention of failure detection of faults, etc.. What do we EXPECT of MAINTENANCE? What is expected of maintenance depends on WHO does the expecting. Planning the System of Maintenance Poorly organized maintenance department are not hard to find Here are some of the opinions taken from a rich collection acquired over the years: Our machines are so old that no amount of maintenance will help them. Anyway, we are planning to replace them
The equipment is brand new and highly automatic, all it needs is a few drops of oil in the right place.
We have had no trouble for many years just as we are, these are study machines so why worry?
Our operators have instructions to take good care of their machines and it works!
We have tried to get experienced men for years, but in this area, they are simply not available.
We rely on outside contractors. They are right next door, you know!
Our foremen knows all the machines like the back of his hand, we do not need a system to tell us whats wrong
We have bunch of good labs,they work hard and would resent being tied down by procedures
We get all our figures from accounting.
LOOP OF SYSTEMATIC ACTION will tell us the best way to develop maintenance service
will have us to establish:
WHAT is to be done, and WHY
HOW the work is to be done, and WHEN the job and WHO is to do it 1. Design Improvements 2. Change of schedules 3. Service specifications Plant Data Equipment Utilization Finances Groups Number of Units Condition, etc. Policies Utilization Seasonal Loads Budgets Investment Depreciation Recording of Relevant Data Breakdown Elimination
FOUR SYSTEM OF MAINTENANCE Breakdown Maintenance Dont do a thing until you see smoke rising Normally this approach is referred to as a repair maintenance but it is not in the true sense a system at all because there is no service is carried out unless a failure has occurred. In so doing, what we really needs on this approach is obtaining full information of breakdowns. Having these formations, discussions has to be done for us to arrive a solution to avert recurrence of the same nature by:
Re-designing or improving part or component Re-scheduling maintenance service Altering operating instructions Changing the process Re-training/orientation of Personnel
Breakdown Maintenance Routine Maintenance Simple Service in a regular way or as much as we can afford Under this system, there are two level of maintenance namely FIRST and SECOND. Under the first Level Maintenance, there is no tools or equipment needed. Only the five senses is necessary : Smelling Hearing Seeing Feeling Tasting Routine Maintenance Second Level Maintenance, some activities are: Lubrication on daily, weekly and monthly and yearly basis Changing and cleaning of filters on specified time
Routine Maintenance Servicing of Air Compressor every quarter
Simply, Routine Maintenance is a procedure being followed on a documented procedure known to as CHECKLIST. DATE __________________ TIME __________________ V I B R A T I O N
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1 EXTRUSION =211+R12-M021 Rotary Valve Big Bag Station Motor =213+R12-M011 Vaccum Feeder MB1 Motor =213+R12-M013 Vaccum Feeder Pearlized Motor =216+S11-M011 Granulate Con. Fan Ext. Feeding =216+S11-M021 Hopper Mixer Motor =311+H12-M131 Main Extrusion Gear Oil Pump 1 =214+S11-M023 Dos. Unit Coex2 MB2 Suction Motor LEGEND : 3 Normal s For Repair / with abnormalities m Not Applicable & Need Urgent repair Checked By: Noted By: SAMPLE DAILY CHECKLIST DESCRIPTION REMARKS EQPT. Item No. PLACE of INSPECTION DESCRIPTION CRITERIA METHOD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 Roll No. 1 WITHIN RATED VISUAL 2 Roll No. 2 WITHIN RATED VISUAL 3 Roll No. 3 WITHIN RATED VISUAL 4 Roll No. 4 WITHIN RATED VISUAL 5 LUB. ROLL 1 TEMP. & FLOW Below 90 & Continous VISUAL 6 LUB. ROLL 2 TEMP. & FLOW Below 90 & Continous VISUAL 7 LUB. ROLL 3 TEMP. & FLOW Below 90 & Continous VISUAL 8 LUB. ROLL 4 TEMP. & FLOW Below 90 & Continous VISUAL 9 LUB. GEAR BOX APPROPRIATE LUBRICATION CONTINUOS VISUAL 10 ROLL CROSS HYDRAULIC HYDRAULIC MARKER 90 KG/CM 2 VISUAL 11 QUICK OPEN HYDRAULIC MARKER 200 KG/CM 2 VISUAL 12 MAIN MOTOR SHAFT & BRG. TEMPERATURE NORMAL HAND 13 WHOLE SOUND SMELL & VIBRATION SAME EYE, EAR, NOSE & HAND 14 WHOLE GOOD VISUAL 15 Legend 3 = NORMAL D =FOR REPAIR O = FOLLOW UP O =URGENT Shift -In- Charge: _________ _________ _________ Section Leader : _____________ _______________ DAILY CHECK LIST__________________________ YEAR ________ MONTH__________________ C A L E N D E R
R O L L S DATE __________________ TIME __________________ V I B R A T I O N
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=214+S11-M054 Dos. Unit Coex2 MB2 Dosing Motor =214+S11-M025 Dos. Unit Coex2 MB3 Suction Motor =214+S11-M056 Dos. Unit Coex2 MB3 Dosing Motor =214+S11-M027 Dos. Unit Coex2 Copo Suction Motor =214+S11-M058 Dos. Unit Coex2 Copo Dosing Motor =214+S11-M040 Dosing Unit Coex1 Mixer Motor =214+S11-M050 Dosing Unit Coex2 Mixer Motor =915+A15-M015 Coextruder #1 DC Motor =916+A16-M015 Coextruder #2 DC Motor =315+A15-M211 Co-extrusion #1 Gear Pump Motor =316+A16-M211 Co-extrusion #2 Gear Pump Motor =321+A72-M021 Air Knife Fan Motor 2 REGRANULATION =392+A92-M031 Waste Grinder Motor =392+A92-M055 Feed Rolls Top DC Motor =392+A92-M075 Feed Rolls Bottom DC Motor =392+A92-M037 Waste Grinder Hydraulic Pump Motor Compactor Hydraulic Pump Motor Erema Extruder Motor =392+A92-M044 Erema Conveyor Belt Motor Erema Pelletizing Head Motor LEGEND : 3 Normal s For Repair / with abnormalities m Not Applicable k Need Urgent repair Checked By: Noted By: ELECTRICAL DAILY CHECKLIST DESCRIPTION REMARKS Planned Maintenance According to the needs of the equipment and utilization, specified on annual time scale. Team effort is the key for the success of the equipment and utilization specified on annual time scale.
Planned Maintenance As a rule the following activities are included on the plan.
Inspections Replacement of parts if found necessary parts and materials preparation
Planned Maintenance Recording after the job is very important Adjustment and calibration
All other activities and lastly
Well do anything to prevent breakdowns Preventive Maintenance Normally this applies to system which strive to reduce the likelihood of failures such as aircraft operation, power stations, or critical installations in case of mines ventilation.
This approach is very costly and need some statistical data and analysis. To established this system immediately, we need information on the manufacturer for the life of their machine.
Preventive Maintenance To achieve the prevention of breakdowns, planned service is carried out with the explicit additional objective of detecting weak points and ensuring perfect functioning by replacing parts which could still be used were it need for the assurance that we required.
Thus after the service a machine is as good as new and high degree of reliability.
Preventive Maintenance Naturally, the cost of running this system is high and it is therefore be applied only in the cases of absolute necessity. Preventive Maintenance STEPS IN PREPARATION OF MAINTENANCE PROGRAM 1. Identify and list all equipment installed to be maintained 2. Provide checklist for the equipment and machines (First Level Maintenance) 3. Provide service schedule as per manufacturers recommendation or industry standard (Second Level Maintenance) 4. Prepare Plan Maintenance Schedule for one year 5. Prepare Preventive Maintenance just after you have statistical data or knowledge 6. Attach service control tag to equipment 7. Implement and monitor all maintenance schedules 8. Record all activities to Equipment History Card (EHC)
PAPERWORK Paperwork performs the following important task :
INITIATES action, by identifying the job and the date COLLECTS data, by describing the action taken CONTROLS operation, by recording the input of resources
By taking these tasks, we can ensure:
The RELEVANCE of data Their ACCURACY Their RETRIEVABILITY
FORMS... There is no right or wrong form
Form design is a function for the needs of application
But of course the simple rule is the
simpler the better
PLANNING preparatory work which define the job WHOM or by WHAT craft it should be done and what sequence
PLANNING and SCHEDULING
SCHEDULING refers to the timing of the job WHEN and WHERE it is to be done Maintenance hour is shared among the following a. Routine Schedules
b. Planned Maintenance
c. Preventive Maintenance
d. Irregular and unforeseen jobs
e. overhauls,plant shutdowns or project work
TYPES OF WORKLOAD IMPLEMENTATION
Routine service schedules: lubrication, inspection, replacements
Planned Maintenance
Preventive Maintenance
Irregular Jobs and Emergencies
Overhauls, new installations and/or large-scale jobs
Routine Maintenance / Inspection Tags STORES or STOCKROOM Problems relating to the operation of maintenance stores A.Organizational Problems
B. Procedural Problems C.Physical Facilities D. Items Stocked E. Economics Problems relating to the operation of maintenance stores A.Organizational Problems Staffing Authority to receive , issue , inspect , reject Responsibility to stock Reporting to what function
B. Procedural Problems Issuance and receiving procedures Stock control method ; reordering point Paperwork sequence Dealing with scrapped,salvaged, and reconditioned parts Inventory codes of stock items Inventory taking Problems relating to the operation of maintenance stores
C.Physical Facilities Size of stores,layout,gates,mezzanines,etc. Shelving and marking Lifting and transporting devices Safety measured , security Lighting,humidity control,pest control,etc.
Problems relating to the operation of maintenance stores
D. Items Stocked Supply of tools and instruments Grouping of materials Storing and preservation of spare parts Storing of standby unit Standardization Elimination of obsolete items
Problems relating to the operation of maintenance stores
E. Economics Reordering quantity Turnover rate of stock Depreciation and interest rate Obsolescence Costing of items Contract suppliers Make or Buy decision Problems relating to the operation of maintenance stores Rule-of-Thumb in determining re-ordering point a.Classify into FAST,MEDIUM and SLOW-MOVING items
b.Fixed-interval,fixed quantity orders can be placed as constant consumption rate
c.Maximum/minimum methods for costly items requiring yearly reviews for obsolescence and turnover STOCK CONTROL Analytical Method in Determining Re- ordering point Number of machine using the same parts Average rate of usage Restocking lead time(delivery period) Cost of tied-up capital Available storage space Cost of order(economic batch size) Risk of obsolescence STOCK CONTROL An Approach to Replacement Procedures Replacement problems of plant equipment and machine relate to the following managerial functions: PRODUCTION - the user of equipment MANAGEMENT - the provider of money MAINTENANCE -the adviser on replacement STOCK CONTROL An Approach to Replacement Procedures A good maintenance system will enable MAINTENANCE MANAGER to fulfill the role exceptionally well especially in providing relevant data of service STOCK CONTROL Instances relating to replacement as direct outcome of mechanical/electrical deterioration Wear and Tear In-accuracy and lack of uniformity of product Low degree of reliability High frequency of stoppages Increased safety hazard Excessive power consumption Rising maintenance cost STOCK CONTROL HUMAN ELEMENT Maintenance personnel gets upset because of frustration EXPRESSIONS OFTEN HEARD Theres nobody to talk to.They simply wont listen Its dead-end job,no use in trying Why hurry?the stores/parts/tools/supervisors will hold up anyhow Its a dirty job , they blame you for everything Factors that will help in creating proper mind-set good morale Management Policies- which relates directly or indirectly to maintenance
Working Conditions and Relationship- under which work is perform
Personnel Policies-which are in force Areas that can be profitably investigated to improve current situation The available manpower potential(experience,training and skill) Morale boosters Competence of supervisors Maintenance Manager job performance Incentives to good workers performance A GOOD MAINTENANCE WORKER He must be inquisitive and resourceful
He must be adaptable and self-sufficient
He must be dependable and responsible
He must be keen to learn and interested to his trade
He must be able to observe and visualize
He must be co-operative and helpful He must be healthy in body
He must be emotionally stable
He must be safety conscious for himself and to his fellow workers
He must able to work under pressure
He must be alert and posses keen senses
He must always try to do a good job
A GOOD MAINTENANCE WORKER DATE: TIME: LEGEND : 3 Normal s For Repair / with abnormalities m Not Applicable k Need Urgent repair 1 2 3 EVAPORATOR PRESSURE 1 CONDENSER PRESSURE 1 EVAPORATOR PRESSURE 2 CONDENSER PRESSURE 3 EVAPORATOR ENTERING WATER TEMP EVAPORATOR LEAVING WATER TEMP OUTDOOR AIR TEMP CHECKED BY: NOTED BY: FIRST SHIFT SECOND SHIFT THIRD SHIFT CHILLER T H I R D
S H I F T ACTIVE CHILLED WATER SET POINT(SP) S E C O N D
S H I F T PACKAGE DISCHARGE PRESSURE (RATED) FIRST STAGE DISCHARGE TEMP (250 C) SECOND STAGE INLET TEMP( 60 C) PACKAGE DISCHARGE TEMP (60 C) BEARING OIL TEMP( 76.7 C) TOTAL HOURS LOADED HOURS OIL LEVEL NOISE / VIBRATION WHOLE OTHER / REMARKS AIR COMPRESSOR AIR COMPRESSOR OIL PRESSURE (2.7 TO 3.5) LEAKS NOISE / VIBRATION FUEL PRESSURE (22 TO 30) UTILITIES DAILY CHECKLIST HOT OIL BURNER F I R S T
S H I F T SMOKE/ STACK SET POINT (SP) vs PROCESS VARIABLE(PV) ALARM OIL FLOW (.25 TO .34) DATE : F l u i d
L e v e l F l u i d
T e m p e r a t u r e G a s
P r e s s u r e
( A c c u m u l a t o r ) E x t e r n a l
l e a k s D a m a g e N o i s e B l o c k a g e
I n d i c a t o r s D i r t A i r
C o o l e r s W a t e r
C o o l e r s R E M A R K S Main Extrusion Gear Oil Pump 1 Main Extrusion Gear Oil Pump 2 Co-Extruder 1 Gear Oil Pump Co-Extruder 2 Gear Oil Pump Waste Grinder Hydraulic Pump Compactor Hydraulic Pump Motor TDO Chain Lubrication Pump Inlet TDO Chain Lubrication Pump Outlet TDO Bolt Lubrication Pump TDO Hydraulic Pump Chain Tension TDO Edge Guide PneumoHydralic Pump OS TDO Edge Guide PneumoHydralic Pump DS Edge Trim Grinder Hydraulic Pump Motor Winder Hydraulic Pump Motor Main Slitter Hydraulic Pump Secondary Slitter 1 Hydraulic Pack Secondary Slitter 2 Hydraulic Pack Secondary Slitter 1 Edge Guide Hydraulic Secondary Slitter 2 Edge Guide Hydraulic Cigarette Slitter Hydraulic Pump LEGEND : 3 Normal s For Repair / with abnormalities m Not Applicable k Need Urgent repair Checked By: Noted By: WEEKLY HYDRAULICS CHECKLIST EQUIPMENT MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY DATE: ACU Location Full Load Ampere Capacity Ampere Voltage Phase Remarks: Remarks: Compressor d Leak of R-22 /Oil d Fan Motor 1 Water Leak 1 Fan Blower 1 Drain Fan 1 Fan Blade 1 Suction Pressure 1 Air Filter 1 Electrical Control 1 Thermostat 1 Vibration 1 Legend: O - Normal X - Need Repair RC - Repair Completed RECOMMENDATION Maintenance Planner Checked By: Noted By: AVFM MONTHLY AIRCONDITIONING CHECKLIST TRUCK MODEL TRUCK ALLOW. LOAD TRUCK OWNER Date: CHECK HERE CHECK HERE r r Slide View Mirror r Leaks of oil, fuel or water r Shift Lever(s) r Tire inflation pressure FL/FR r Loading Levers RL/RR r Parking brake levers r Hub nut torque FL/RR r Monitoring lamps RL/RR r Meters and Gauges r Overhead guard r Fuel Level r Brake & clutch fluid level r Lights and Lamps r Battery electrolyte level r Turn Signal r Coolant level r Horn button test r Engine Oil level r Clutch pedal r Fan belt tension r Brake pedal free travel r Rear combination lights r Mast test r Hydraulic oil level r Lift chain tension r Piping and cylinders r Steering handlewheel free play r Powershift Transmission fluid level r Exhaust gas condition r Load backrest r Clutch test r Forks and fork stoppers r Brake test r Headlights and front combination lights r Steering test r Operator's seat adjustment r Parking brake test r Back-up lamp / back-up alarm test Legend: m Normal l Repair completed X Need repair T Not applicable Checked By: RECOMMENDATION FORKLIFT MAINTENANCE CHECKLIST Result of remedy found, if any, on previous checking AVFM 1 2 3 4 1 2 3 4 1 2 3 4 1 Material Supply Aerzen Blower Rotary Valve Mixer 2 Extrusion Twin Screw Extruder Metering Extruder CoExtrusion 3 Chill Roll Chill Roll Air Knife WaterBath Nip Roll 4 MDO Dancer Roll MACHINE/ EQUIPMENT JAN Lubrication Schedule NOV DEC No. ____________ Date : Time Started : _______ Location : Time Finished : _______ ITEM REMARKS Prepared By: _____________ Concurred By : ________________ WORK TURN-OVER REPORT MAINTENANCE DEPARTMENT DESCRIPTION Cost of service provided D Operation of the maintenance dept. Departments' Economy Work-order progress The amount of service Assessment of the service C F G MAINTENANCE PERFORMANCE (a) E (b) Manpower utilisation M A I N T E N A N C E
Plant and equipment performance Degree of planning B A MAINTENANCE PERFORMANCE Total man-hours allowed on jobs Total man-hours worked on same jobs Total craft hours worked Total craft hours clocked Number of jobs completed Total number of jobs handled Job-week of delays Number of jobs handled Total maintenance costs C Total direct maint. Hrs applied Total overhead costs Total maintenance expenditure Manpower efficiency = Craft hrs utilisation = A B = = = Completion delays Departmental overhead Cost of maintenance hours Work-order turnover = MAINTENANCE PERFORMANCE Total downtime for service Total stream hrs. Hours Worked Number of Breakdowns Total hours on regular services Total actual maint. Hrs Total hours spent on breakdown repairs Total clocked maintenance hours D E Routine services workload = Breakdown workload = Downtime = Breakdown frequency = MAINTENANCE PERFORMANCE Total maintenance direct hours Total direct production hours Total maintenance expenditures Number of units produced Cost of scheduled services Total production costs Total cost of supplies and spares Total maintenance expenditure Total maintenance expenditure Total Investment value Maintenance costs on investment = F G Cost of scheduled service = Cost of supplies and spares = Maint. To prod. Ratio = Maintenance cost component =
MAINTENANCE PRACTICE UNDER RCM
RELIABILITY CENTERED MAINTENANCE (RCM) REACTIVE (BREAKDOWN) PREVENTIVE (TIME-BASED) PREDICTIVE (CONDITION-BASED) PROACTIVE (RELIABILITY-BASED) GUIDELINES FOR EQUIPMENT MAINTENANCE Fans: 1.Check for excessive noise and vibration. Determine the cause and correct as necessary. 2.Keep fan blades clean. 3.Inspect drive belts. Adjust or replace as necessary to ensure proper operation. Proper tensioning of belt is critical 4.Inspect and lubricate bearings regularly 5.Inspect inlet and discharge screens on fans. They should be free of dirt and debris at all times. PUMPS: 1.Check for packing wear which can cause excessive leakage. Re-pack to avoid excessive water wasted and shaft corrosion 2.Inspect bearings and drive belts for wear and binding. Adjust, repair or replace as necessary AIR HANDLING UNITS (AHU): 1.Inspect duct work for air leakage.Seal all leaks by tapping or caulking. 2.Inspect duct work insulation. Repair or replace as necessary. 3.Utilize duct work access opening to check for any obstruction such as loose hanging insulation, loose turning vanes and accessories and closed fire dampers. Adjust, repair or replace as necessary 4.Inspect damper blades and linkages. Clean, lubricate and adjust them on regular basis. 5.Inspect air valves in dual duct mixing boxes to ensure full seating and minimum air leakage. 6.Inspect mixing dampers for proper operation. 7.Clean or replace air filters on regular basis 8.Inspect cooling coils for cleanliness. Coils can be kept clean by using a mixture of detergent and water in a high pressure portable cleaning device 9.Inspect for leakage around the coil or out of the casing. Seal all leaks 10.Inspect all room air inlets and outlets (diffuser, grilles and register) They should be kept clean and free from all dirt and obstruction.Clean and remove obstruction as necessary. COOLING TOWERS: 1.Perform chemical treatment to determine the solid concentration are being maintained on an acceptable level 2.Check overflow pipe clearance for proper operating water level 3.Check fans by listening for any unusual noise or vibration. Inspect condition of belts. Align fans and motors as necessary. 4.Clean intake strainer. 5.Keep surrounding clean to minimize both air and water pressure drop 6.Check spray filled or distributed tower for nozzle performance.Clean nozzle as necessary. 7.Inspect gravity distributed tower for even water depth in distribution basin 8.Monitor effectiveness SUMP PUMPS: 1.When possible,check with operating personnel for any known deficiencies 2.Clean exterior of units. 3.Check operation of the units for noise, vibration and overheating 4.Check alignment, clearances and rotation 5.Check for leaks 6.Tighten or replace loose, missing or damage nuts, bolts or screw coupling. 7.Clean,prime,paint any corroded or base surfaces 8.Clean or remove foreign objects from sump bottom 9.Check float, float rod and switches for proper operation 10.Lubricate pump, motor and any moving parts as required 11.Check packing gland assembly and shaft seal 12. Make minor adjustment within allotted time to keep unit in good operating condition
DIESEL STANDBY GENERATING SET: 1.Maintain a ten to fifteen minutes warm-up test weekly. 2.Run engine to rated no-load speed and observe for any vibration or unusual sound 3.Observe smoke color and record 4.Check lube oil level, add or top off as necessary and record the approximate quantity of oil added 5.Check fuel day tank level 6.Check belt tension if applicable and radiator debris 7.Check for leaks on lube oil, fuel and coolant on all connections 8.Check battery condition including terminals and post 9.Switch on generator automatic voltage regulator for no-load voltage and frequency
THANK YOU E Mail : ard4len@yahoo.com Cellphone No. 0918 909 4164