3. Why is preventive maintenance so important in a capital intensive plant? How

Question

3. Why is preventive maintenance so important in a capital intensive plant? How often it should be performed? How do you justify a preventive maintenance program to top management?

4. What are some of the key indicators in a successful maintenance program? Suggest a method of measuring and collecting the information needed for the metrics. Design the reports that you will use to illustrate the metrics.

5. How can you use the concepts of maintenance planning to enhance a maintenance operation; that is to improve the maintenance productivity and efficiency? In what situations will you prepare a Gantt chart vs. a Network tool (such as the Critical Path Method)?

Explanation / Answer

Why is preventive maintenance so important in a capital intensive plant? How often it should be performed? How do you justify a preventive maintenance program to top management?

Preventive maintenance reduce break down and thereby down time. With correct planning, preventive maintenance reduces over time of crews and provides higher safety of workers. Due to planning and regular maintenance, need to maintain lower standby equipment’s and spare parts. Period of preventive maintenance should be decided basis on life of individual parts, weaker sections in the plant. Thus preventive maintenance frequency shall be planned on optimal point basis preventive maintenance costs vs breakdown cost. With lower cost and higher safety, along with planed time period without disrupting demand requirements, preventive maintenance will score.

4. What are some of the key indicators in a successful maintenance program? Suggest a method of measuring and collecting the information needed for the metrics. Design the reports that you will use to illustrate the metrics.

Indicators should be both leading and lagging indicators -

a. Cost of maintenance

b. Mean time between failure

c. Schedule adherence

d. % of un-planned repair work

e. Maintenance Cost Component of Unit Cost of Production

Reports to illustrate the metrics: Maintenance schedule, Maintenance resource requirement report, Equipment failure analysis reports and Maintenance work forecast

5. How can you use the concepts of maintenance planning to enhance a maintenance operation; that is to improve the maintenance productivity and efficiency? In what situations will you prepare a Gantt chart vs. a Network tool (such as the Critical Path Method)?

Through optimal resource planning, alignment across organization for scheduled maintenance, setting up optimal reports and analysis maintenance operation results can be enhanced. Maintenance planning need to analyze the work performed with the responsible Supervisors and quickly make changes to any items that need attention. Depending on internal processes, before start of maintenance, have fully planned and resourced tasks that can be executed during that period. Gantt charts provide a standard format for showing project schedule information by listing project activities and their corresponding start and finish dates in a calendar like format. Gantt chart over Network tools is prepared to show task wise duration and overlap between tasks. Network tool shows relationships between activities.

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