STRATEGY TO IMPROVE PLANT

MAINTENANCE PERFORMANCE
AND RELIABILIABILITY AND
LOWER MAINTENANCE COSTS
BY
PRABHAT KUMAR
MECHANICAL ENGINEERINT DEPT
MIMIT, MALOUT
June 10, 2015

Manufacturing
Introduction
Manufacturing industry refers to those industries which involve in
the manufacturing and processing of items and indulge in either
creation of new commodities or in value addition. The
manufacturing industry accounts for a significant share of the
industrial sector in developed countries. The final product can
either serves as a finished good for sale to customers or as
intermediate goods used in the production process.

Strength of Indian manufacturing

India has already marked its presence as one of the fastest

growing economies of the world.

The country is expected to rank amongst the worlds top three
growth economies and amongst the top three manufacturing
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Strength of Indian manufacturing continueddestinations by 2020.

Favorable demographic dividends for the next 2-3 decades.
Sustained availability of quality workforce.
The cost of manpower is relatively low as compared to other
countries.
Responsible business houses operating with credibility and
professionalism.
Strong consumerism in the domestic market. Strong technical
and engineering capabilities backed by top-notch scientific and
technical institutes.

June10, 2015

GROUP PROFILE
Since its inception in the year 1983 it has turned into the multi

June 10, 2015

billion company.
It enjoys formidable market presence in more than 85
countries.
It has ISO 9001 & ISO 14001 certification and has FDA &
BGA approval for its products.
It has received WordStar awards for packaging excellence.
FPA, AIMCAL & DUPONT are latest in the series.
It has Asias largest state of art packaging plant & allied
Infrastructure at Noida, UP spread over 70 acres.

Group Values
Trust and respect: Actively build relationships with all the

stakeholders, fostering trust by listening, following through

and keeping word in an open and inclusive environment and
treating each person with respect.
Customer value creation: Enabling customers to become
high-performance businesses through our total packaging
solutions and creating long-term relationships by being
responsive, relevant and by consistently delivering value.
Innovation: Strive to be the best- in technology and business,
actively contributing to the evolution of best practices and
striving to develop new packaging solutions to address
customer needs.

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 Global perspective: Leveraging the power of global insight,

relationships, collaboration and learning to deliver exceptional

packaging solutions to the clients wherever they do business.

Speed in all directions: To set the principle of Speed and

efficiency in every activity in responding to internal and

external customers with a sense of urgency. Anticipating
market opportunities and continuously striving to practice
"quick decision quick investment quick execution quick
adaptation and quick customer service".

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Business Divisions
Film Division
Holography Division
Packaging Division
Cylinder Division
Engineering Division
Chemical Division

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Chemical Division
Product Summary
Ink - that play a key role in adding color to our everyday lives.
Synthetic adhesive - that help difficult substrates to bond.
Coatings - for various applications like holography, UV, etc.
Polyols - for wide range of uses.
Antifreeze coolants - for automobiles and other engines.
Adhesives and lacquers - for the footwear industry etc.
Re-closeable zippers, using special grade of raw materials

with "state of art" manufacturing facilities.

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Target Segment
The Uflex Chemical Divisions wide range of products target the
following segments:
Flexible packaging industry
Footwear industry
Sports goods industry
Holographic film industry

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Maintenance Department
Objectives
Direct and coordinate the operations and activities of the

physical plant maintenance, including but not limited to:

facilities engineering administration, layout, design, and
construction, equipment maintenance, utilities operations and
maintenance, building and grounds maintenance, facilities
protection and security, departmental safety, and environmental
compliance.
Provide engineering consulting services, surveys, and
recommendations
to
all
Departments,
to
outside
architect/engineer firms performing services for the facility and
to public utilities.

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Objectives continued
Ensure compliance with applicable federal, state, and local

laws, regulations, statutes, and codes, securing required

permits, and coordinating with appropriate local authorities.
Contract with and oversee the activities of various contractors
and consultants for the fulfillment of facility engineering
responsibilities.

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Types of Maintenance
Breakdown

maintenance: This is one of the earliest

maintenance program being implemented in the industry. The
approach to maintenance is totally reactive and only act when
the equipment needs to be fixed. This strategy has no routine
maintenance task and also described as no scheduled
maintenance strategy. To rectify the problem, corrective
maintenance is performed onto the equipment. Thus, this
activity may consist of repairing, restoration or replacement of
components. The strategy is to apply the corrective
maintenance activity only, which is required to correct a failure
that has occurred or is in the process of occurring.

June 10, 2015

CIBC - Testing

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Types of maintenance continued

Preventive maintenance: This is a time-based maintenance

strategy where on a predetermined periodic basis, equipment is

taken off-line, opened up and inspected. Based on visual
inspection, repairs are made and the equipment is then put back
on-line. Thus under this equipment maintenance strategy,
replacing, overhauling or remanufacturing an items is done at a
fixed intervals regardless of its condition at the time. Although
this is a well-intended strategy, the process can be very
expensive as typically 95% of the time everything was alright.
Nevertheless, some preventive maintenance is necessary as
some regulation such as DOSH regulation require that
annual/bi-annual boiler inspection to be conducted.

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Types of maintenance continued

Predictive maintenance: Predictive maintenance is a more

condition-based approach to maintenance. The approach is

based on measuring of the equipment condition in order to
assess whether an equipment will fail during some future
period, and then taking action to avoid the consequences of
that failures. This is where predictive technologies (i.e.
vibration analysis, infrared thermographs, ultrasonic detection,
etc.) are utilized to determine the condition of an equipment,
and to decide on any necessary repairs. Apart from the
predictive technologies, statistical process control techniques,
equipment performance monitoring or human senses are also
adapted to monitor the equipment condition. This approach is
more economically feasible strategy as labors, materials and
production schedules are used much more efficiently.

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Types of maintenance continued

Proactive maintenance: Unlike the three type of maintenance

strategies which has been discussed earlier, proactive

maintenance can be considered as an another new approach to
maintenance strategy. Dissimilar to preventive maintenance
that based on time intervals or predictive maintenance that
based on condition monitoring, proactive maintenance
concentrate on the monitoring and correction of root causes to
equipment failures. The proactive maintenance strategy is also
designed to extend the useful age of the equipment to reach the
wear-out stage by adaptation a high mastery level of operating
precision.

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Equipment Maintenance Plan (EMP)

The Equipment Maintenance Plan, or EMP as it is commonly
called, is a document, in table format, that is used when
developing the tasks needed to properly maintain facility, plant
or process equipment. The EMP helps lead the person or
persons developing the required maintenance tasks by ensuring
that the development is done consistently for all equipment.
Each EMP should include one or more maintenance tasks
designed to ensure the continued operation and maintenance of
an equipment item, process or system. Each of these tasks has
the following characteristics:
A descriptive title for each maintenance task to be performed.
A frequency assigned for performing of each task.

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EMP Continued
Assignment of a specific craft or workgroup and the number of

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each craft or workgroup required to perform the task.

Equipment condition required for performance of the task (i.e.
running or shut down).
Type of Work Preventive Maintenance (PM), Predictive
Maintenance (PdM), Corrective Maintenance (CM), Situational
Maintenance (SIT), etc.
Procedure number Unique identifier for the task, or file name
if linked to another document that gives the individual task
instructions.
Estimated time to perform the task.

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Project
Summary
My association
with Uflex Group started on 20 th January 2015. I
was assigned to undergo project based training at the Chemical
Division, Maintenance Department of the group. I was given
the project Strategy to improve plant maintenance
performance and reliability and lower maintenance costs. I
am working closely with the associates in order to complete
my project without causing any hindrance to their work. When
I researched for my work I have found out poor maintenance
strategies for production machines lead to shorter equipment
lifespan, cost overruns and longer delivery times. Then I
started to look for the ways to maintain equipment at the right
time in an optimal manner, while lowering production costs
and use of resources. Concept of Value Engineering has been
extensively used during this process.
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CIBC - Testing

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Actions to be taken
Actions for immediate improved results
We should have a lubrication regime where everything is
lubricated when due and we know right lubricant gets all the
way to where it should be.
We should have 50% of the plant or maintenance engineers
time spent out working with the plant operators and
maintenance trades teaching them engineering and learning
from them about the problems they have to face in their day to
day activities.
We should have proper shaft alignments done on all pumps and
gearbox drives including eliminating soft foot.
We should have good coordination with vendors and suppliers
best technical people and get their advice on fixing problem of
plant.
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Actions for immediate improved results continued

We should have equipment watch-keeping lists and trouble-

June 10, 2015

shooting check sheets for plant operators and read them

regularly to see what they notice.
We should make plant and equipment choices and selections
with a 20 to 25 year time span in mind.
We should have vibration monitor rolling bearings on critical
equipment often enough to stop any failures.
We should have chat with the operators and maintainers the
simplest way they can think of to fix the problem.
We should arrange get together of production and maintenance
planners, managers and supervisors to meet each day and plan
the works to be done in the coming days and weeks.

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Actions for improved results in few months time

We should start measuring performance with key performance

indicators and measure both the equipment performance and

the business systems performance. Use this knowledge to
continuously improve.
We should have training programs for all Production and
Maintenance Supervisors on a compulsory asset management
course at diploma level.
We should have a basic condition-monitoring regime
vibration, oil analysis, thermography or see-touch-hear
inspections.
We should perform a thorough engineering review of plant
changes and upgrades to make decisions based on engineering
and business facts. First design and engineer, or model and
simulate, or pilot-test plant changes and ideas before putting
them into place permanently.
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Actions for improved results in few months

We should look outside the company and bring in the training
continued

June 10, 2015

and teaching that our people need to become leaders in their

field.
We should make efficient use maintenance planners to plan
jobs in detail so we get labor efficiency and job quality.
We should monitor and track-down all galvanic corrosion
between dissimilar metals in contact and get rid of them.
We should share the knowledge with operators how the
equipment works and give idea to our maintenance people how
the production process works.
We should provide the technical knowledge on plant and
equipment our trades need, in a place they can find it.

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Actions for improved results in few months

continued -

We should conduct an equipment criticality rating and set up

condition monitoring to identify risk of failure in important

equipment and plant.
We should eliminate the defects - use Root Cause Analysis, 5Whys, etc on equipment and systems failures and get the
problems out forever.
We should be proactive and imagine problems so that we can
solve and eliminate them before they happen.
We should develop sense of ownership, build and develop
skills, make competent people at shop-floor level.

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Actions for improvement in coming years

We should align the capital project groups output to the on-

going needs of maintenance and operations. E.g. Ensure all

asset and instrument tag numbers have procurement and design
information catalogued in individual files; have drawings and
manuals easy to access for maintenance; etc.
We should show and introduce the benefits of world class
practices to managers, supervisors and leading hands. And
show and introduce corporate and senior managers to world
class practices and methods so that can see the benefits to their
bottom lines.
We should align operations and maintenance efforts through a
production plan and schedule that covers both producing
product and maintaining equipment well enough to make
product.
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Action for improvement in coming years continued We should follow all our statutory obligations well with full

documentation and excellent procedures and practices.

We should select the best vendors and suppliers and form a
long-term partnership and alliance with them. This will not
only save time, gives us access to good prices, lets us to use
their expertise to solve problems and let us focus on our
business.
We should introduce proactively build flexibility and
redundancy into the plant so we have options to address
problems quickly. E.g. install tie-ins to processes in readiness
to use mobile plant if the installed item fails.

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Actions for improvement in coming years continued We should apply Failure Mode and Effects Analysis and

Reliability Centered maintenance on new and old plant and

equipments. On new equipment get the vendor to do the
FMEA/RCM based on our industrys historical maintenance
problems.
We should select and use equipment that does not breakdown
when it fails. We should implement design protection into
equipment that stops it breaking if it is overloaded or run
wrongly and make use of the grade of material that is not
affected by the failure mechanism.
We should buy equipment that can be supported and
maintained locally, otherwise we will have to pay a lot more
for parts and also will have to wait for the service.

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Conclusion
The requirement for maintenance process has change drastically
from the old concept of fix-it-when-it-broke to a more complex
approach, which entailed adopted maintenance strategy of a
more integrated approach and alignment. Nowadays,
management has become aware that maintenance will also be
part of the investment decision-making, thus prompting
managers to take into account the sources of funding and the
impact investment has on credit lines and taxes and not only to
focus on upfront cost and depreciation rates. The goal of
maintenance program is also changing and with the rapid
technological development, improvement of equipment and
technology will be one of the key aspects of improved
maintenance practiced for better productivity, effectiveness and
profitability.
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Thank You!

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