CII Naoroji Godrej Centre of Excellence Workshop on Predictive & Preventive Maintenance Basics & Practices

12 13 April 2013: Pune

Preventive Maintenance (Time based) Maintenance repairs are performed on a regular schedule to minimize component degradation and extend the life of equipment. Preventive maintenance is performed after a set amount of elapsed calendar time or machine run time, regardless of whether the repair is needed. While more cost-effective than reactive maintenance, preventive maintenance still requires substantial human resources and replacement parts inventories.
Preventive maintenance which was chosen as an improvement step over Breakdown Maintenance is of immense importance in industries. The output & quality of next step process is quite dependent on previous process. Hence it is very important that all processes are managed efficiently. Preventive maintenance plays important role here in upkeep of all process equipments.

Predictive Maintenance (Condition based) Predictive maintenance can be defined as measurements that detect the onset of degradation mechanism, thereby allowing causal stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability. Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule. Preventive maintenance is timebased. Activities such as changing lubricant are based on time, like calendar time or equipment run time. For example, most people change the oil in their vehicles every 5,000 to 8,000 Kms travelled. This is effectively basing the oil change needs on equipment run time. No concern is given to the actual condition and performance capability of the oil. It is changed because it is time. This methodology would be analogous to a preventive maintenance task. If, on the other hand, the operator of the car discounted the vehicle run time and had the oil analyzed at some periodicity to determine its actual condition and lubrication properties, he/she may be able to extend the oil change until the vehicle had travelled 15,000 Kms. This is the fundamental difference between predictive maintenance and preventive maintenance, whereby predictive maintenance is used to define needed maintenance task based on quantified material/equipment condition. The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance programme will all but eliminate catastrophic equipment failures. In fact, independent surveys indicate the following industrial average savings resultant from initiation of a functional predictive maintenance programme. Return on investment: 10 times Reduction in maintenance costs: 25% to 30% Elimination of breakdowns: 70% to 75% Reduction in downtime: 35% to 45% Increase in production: 20% to 25%. Advantages Increased component operational life/availability Allows for preemptive corrective actions Decrease in equipment or process downtime Better product quality Improved worker and environmental safety Improved worker morale Energy savings. Estimated 8% to 12% cost savings over preventive maintenance programme

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Considering their unquestionable utility, ISO / TS 16949 standard includes Preventive & Predictive Maintenance in clause 7.5.1.4 which states that : The organisation shall identify key process equipments & provide resources for machine/ equipment maintenance & develop an effective planned total preventive maintenance system. Also it describes at least the inclusions like Planned Maintenance activities & use of Predictive Maintenance methods to continually improve effectiveness & efficiency of the production equipment.
Workshop Objectives : To understand the concepts & methods of Preventive & Predictive Maintenance To understand how to Implement Preventive & Predictive Maintenance To understand how to gradually replace TBM activities by CBM activities To appreciate use of modern technologies in equipment maintenance Workshop Contents : The workshop contains ten modules as follows. Module 1 Historical Background & Types of Maintenance Reactive (Panic), Preventive, Corrective & Predictive Maintenance, Reliability Centered, Proactive Maintenance Module 2 Objectives of Maintenance & Documents of Maintenance General Objectives P,Q,C,D,S,M : MTTR, MTBF & MTBQF Documents : Master List of Equipments, Equipment History Cards, Spare Parts Ledger, Preventive Maintenance Charts & Schedules Module 3 Preventive Maintenance Calculation of Maintenance Manpower, Load Leveling, Preparing & Monitoring of TBM Schedules Module 4 Condition Based - Predictive Maintenance Substitute characters, Static & Dynamic Equipments, Approach & Contents of Predictive Maintenance Module 5 Vibration Analysis Vibration analysis is used primarily with rotating equipment to find problems such as misalignment, out-of balance conditions, and bearing defects. Prior to using vibration analysis, maintenance technicians have to wait until a bearing failed to realize there was a problem Module 6 Ultrasound Ultrasound functions primarily for leak detection, particularly for steam and air leaks. These leaks can be expensive and many companies let them go unnoticed Module 7 Oil and Wear-Particle Analysis Some people equate oil analysis and wear-particle analysis. Actually, they are two very different technologies. Oil analysis determines the condition of a lubricant. Wear-particle analysis determines the condition of equipment based on the concentration of wear particles in the lubricant Module 8 Thermography Thermography serves primarily to find electrical components that are hotter than normal. Such a condition usually indicates wear or looseness. Thus, thermography allows technicians to perform maintenance on only the electrical components that need attention without requiring that all components get the same level of attention Module 9 Additional Components As has been shown, a Predictive maintenance programme is not a stand alone strategy, but needs to be integrated into an overall asset management strategy Module 10 How to Develop a Predictive Maintenance System Teams work to develop TBM & CBMs for select equipments using learning in Workshop Quiz Test Methodology : Classroom sessions & Videos with many examples of industrial life. All methods of Preventive & Predictive Maintenance will be discussed with their comparative strengths & weaknesses. There are three tests & discussions between modules to reinforce learning, exercises, experience sharing & case studies followed by Quiz Test at the end to reinforce understanding. It is expected that participants bring data from their workplace for critical equipments so as to develop TBM & CBM schedules. Who Should Attend: Managers, Engineers, Supervisors, Process Specialists, Senior Technicians involved in Maintenance, Process Control and Improvement activities. Faculty : Mr Shekhar Deshpande, Director, Shilpa Consultants He is an MBA in Operations Management + Industrial + Electrical Engineer with more than 34 years experience in reputed companies like L & T, ABB, Crompton Greaves, Associated Capsules Group & EIPL. He has conducted more than 200 result oriented programmes on Tools of Lean i.e. 5S, Kaizen, TPM, SMED, VSM, Poka Yoke, and Quality Management tools such as SPC, FMEA, MSA, GDT, for organizations like Bajaj Auto, TitanTime Products, Hindustan Coca Cola, LG Electronics, Asian Paints, Hindustan Lever, Siemens, Kirloskar Brothers, Videocon International, Fairfield Atlas, Tata Motors etc. He has hands on experience in shop floor improvements on six sigma projects & time & method studies.
Dates / Schedule of Sessions : 12 13 April 2013 12 April 2013 Registration - 9:15am to 9:30 am 12 13 April 2013 Sessions - 9:30am to 5:00pm

Venue : Orbett Hotels, 1238/2, Apte Road , Deccan Gymkhana, Pune - 411 004 Tel: 020-30244800/01/02

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Participation Fees (on non-residential basis) :

Type of Organisation CII Members (Large & Medium) CII SSI Members Non Member Companies

Fees per Participant Rs 9500/Rs 7500/Rs 10500/-

Service Tax (12.36%) Rs 1174/Rs 927/Rs 1298/-

Total Participation Fees Payable Rs 10674/Rs 8427/Rs 11798/-

Fees include participation, course material (hard copies), breakfast, working lunch and tea / coffee. Advance payment of fees is to be drawn in favour of Confederation of Indian Industry payable at Mumbai. A discount of 10% on fees will be admissible on three or more nominations from an organisation only where payment is received in advance (on or before 4 April 2013). Participation fees is non-refundable / non-adjustable against any other programme of CII, but change in nomination(s) is accepted. Registration : Prior registration for participation by the sponsoring companies is necessary. Number of admissions will be limited to 25. Certificate of Participation will be given to the participants. Nominations & Enquiries : S D Puranik, Executive Director CII Naoroji Godrej Centre of Excellence Godrej Station-Side Colony Opp Railway Station, Vikhroli (East) Mumbai 400 079

Tel : (022) 2574 5146 / 5148 Fax : (022) 2574 3361 Email : s.d.puranik@cii.in / ciicoe@vsnl.net

Residential Facilities : Although the programme is being held on non-residential basis, residential facilities are available at Orbett Hotels, the venue of this workshop, at reasonable tariff. Those interested may get in touch with Mr Sanjay Tipnis Orbett Hotels 1238/2, Apte Road Deccan Gymkhana Pune - 411 004 Tel: 020 30244800 / 01 / 02 Cell : 09922773699 Email : reservation@orbetthotels.com

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CII Naoroji Godrej Centre of Excellence

Workshop on Predictive & Preventive Maintenance Basics & Practices

12 13 April 2013 : Pune

We nominate the following manager/s to attend the Workshop

Name 1 2 3

Designation

Email / Telephone

Our Cheque / Demand Draft dated __________ No. _________ for Rs. ________________ drawn in favour of Confederation of Indian Industry payable at Mumbai is enclosed. Name:______________________________________________ Designation : ____________________________ Organisation : ________________________________________________________________________________ Address : ____________________________________________________________________________________ ____________________________________________________________________________________________ CII Membership No : _________________________ Telephone : _______________________________________ Fax : _______________________________Email : __________________________________________________ Signature & Stamp of the Nominating Authority : _____________________________________________

Participation fee is non refundable / non-transferable against any other programme of CII. However change in nomination(s) is accepted. Workshop is non residential.

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