Professional Documents
Culture Documents
CT 6.3 Maintenance
CT 6.3 Maintenance
CT 6.3 Maintenance
3 Maintenance
In the exercises following session 3.1 of our course we calculated the mean time between
stops for the kilns of the participants on the course. This is the way the reliability of
cement kiln operations is compared. In general it is fair to say that the reliability
performance of cement kilns is very poor.
+1000 hours
<24 hours
+1000 hours
<24 hours
Whitehopleman
Cement Technology 6.3 Maintenance
General
Management
Administration
Production Maintenance
Each discipline will require their own skilled workforce, workshops and tools.
Spare parts holding falls naturally under maintenance and therefore stores, although this
may report to purchasing.
Whitehopleman
Cement Technology 6.3 Maintenance
The organisation and the systems are not the issue, rather the things people do within the
organisation and the use which is made of the information captured in the maintenance
management systems. There is generally insufficient cause and effect analysis to identify
the underlying causes of unreliability. Is the periodic maintenance which is set out in the
maintenance master schedule addressing the real needs of the equipment?
Each equipment failure needs to trigger a formal cause and effects analysis.
Whitehopleman
Cement Technology 6.3 Maintenance
Pareto Analyses focus efforts on the elimination of the most frequent causes of failure.
Data needs to be gathered on the frequency and typical time to failure for major
equipment items and components.
Time
Is time to failure random?
Meaning it is impossible to
predict statistically when
the system of component Failure
will fail. Density
Whitehopleman iv
Cement Technology 6.3 Maintenance
The maintenance people on the cement factory need to focus on machine condition
monitoring and predicting the maintenance needs of the equipment, rather than
responding to compelling events - equipment that won’t start, high bearing temperatures,
low oil pressure…etc.
How will the maintenance people on the cement factory have time to do this and do the
maintenance tasks in the maintenance master schedule and respond to breakdowns of the
equipment? This can only be done by transferring responsibility for all first line
maintenance, inspection, lubrication, equipment adjustment to the production department.
The maintenance people on the cement factory need to focus on “reliability centred
maintenance” (RCM), while the production people take on the responsibility for “total
productive maintenance” (TPM).
Whitehopleman