Introduction to Plant Maintenance

Chester Ng
NCPOC (PM)

Oct 2011 1
Course Goal

Obtain an overview of Plant Maintenance

Recognize the types of master data in Plant Maintenance
Recognize the common business processes

Oct 2011 3
Content

Organization of Plant Maintenance

Technical Objects
 Functional Location
 Equipment
 BOM
Maintenance Processes
 Corrective
 Preventive
 Task List
 Maintenance Plan

Q&A

Oct 2011 4
Plant Maintenance

What is Plant Maintenance?

 Is a practice that used to keep an industrial object or factory
running efficiently.

Oct 2011 5
 Plant Maintenance Integration

CPL (Complex procurement Logistic)

Production Joint Venture

Controlling
PS (Project System)

Plant Maintenance
FI (Financial Accounting)
HR System

Investment Management Funds Management

Asset Accounting
Real Estate Management

Oct 2011 6
 Organizational Structure in Plant Maintenance
General Organizational Units in Logistics

Client Company Code

Co. Code
KZ01
Plant

Planning-based Organizational Units

Planning Plant
Planning
Maintenance Plant
KZ01
Planner Group
Maintenance Work
Center

Location-based Organizational Units

Maintenance Plant Maint Maint
Plant Plant
KZ10 KZ20

Location

Plant Section

Oct 2011 7
 Roles in Plant Maintenance

Maintenance planner Maintenance supervisor Technician

Nicole Potter Scott Weiland Kate Stevens

Maintenance manager Maintenance engineer Work clearance planner

Oct 2011 8
James Taylor Harry Meyers James Cameron
Maintenance Work Centers

Is an organizational unit within an operational system.

A work center can be one of the following:
 Machine
 Group of machines
 Person
 Group of people

For example:

Welding
Metalworking
Mechanics

Oct 2011 9
Content

Organization of Plant Maintenance

Technical Objects
 Functional Location
 Equipment
 BOM
Maintenance Processes
 Corrective
 Preventive
 Task List
 Maintenance Plan

Q&A

Oct 2011 10
Content

Phase Contents

1 Identification
Which objects are relevant
to Plant Maintenance?

2 Structuring
Which objects are
mapped?

When starting to map technical objects you need to decide

which objects are relevant to Plant Maintenance.
In second step, you choose the structuring instruments for each
object (i.e. Functional Location, Equipment or Material) and
create the structure.
Oct 2011 11
Technical Objects – Functional Location

Functional Locations are hierarchically ordered structures that

represent a technical system or building.
The aim of creating a functional location is to structure a
technical system or building into units that are relevant for Plant
Maintenance.
Example of Functional Location ID
 EP.KZ.OP1.DRILLING-RIG

Oct 2011 12
 Technical Objects – Functional Location - example

 EP
 Sits at the highest level.

Kashagan Plant
Oct 2011 13
 Technical Objects – Functional Location - example

 EP.KZ
 Kashagan represent one of the OU under EP.

Oct 2011 14
 Technical Objects – Functional Location - example

 EP.KZ.OP1
 OP1 describe one of the area in Kazakhstan (i.e. Atyrau).

Oct 2011 15
 Technical Objects – Functional Location - example

 EP.KZ.OP1.DRILLING-RIG
 The Drilling Rig describe one of the object in the Kashagan area.

Oct 2011 16
Technical Objects – Functional Location in Tree Structure

FL

FL FL FL

FL FL

FL FL

Oct 2011 17
Technical Objects – Functional Location - Example

Oct 2011 18
 Technical Objects – Structure Indicator

 Edit Mask
 Used to control which characters may be used for identification and how
these characters are grouped together or split.
 E.g. AN.ANN.XXX.XXXXXXXX
A = Alpha
N = Numeric
X = Alphanumeric

Oct 2011 19
 Technical Objects – Equipment

 A piece of equipment is an individual physical object that is to

be maintained as an autonomous unit.
 Pieces of equipment usually represent single objects (i.e.
Pumps, Motors, Tank, etc).
 Equipment can be installed at Functional Locations

Oct 2011 20
Technical Objects – Equipment - Example

Oct 2011 21
Technical Objects – Equipment in Tree Structure

FL

FL FL FL

FL EQ

EQ EQ

Oct 2011 22
Technical Objects – Bill Of Materials (BOM)

A maintenance bill of material is a complete, formally structured

list of the components making up a technical object or an
assembly.

3 categories of maintenance Bill of Materials (BOM)

 Functional Location BOM
 Equipment BOM
 Material BOM

Oct 2011 23
 Technical Objects – Bill Of Materials (BOM)

Equipment - Motor
Equipment BOM
as maintenance
Equipment BOM bill of material
10 Casing type A 100-100 1 PC

20 Compressor 100-200 1 PC

30 Seal 100-300 4 PC

40 Spool 100-400 1 PC

50 Screw 100-500 9 PC

60 Spacer 100-600 5 PC

70 Shaft type A 100-700 1 PC

80 Locking pin 100-800 2 PC

90 Valve 100-900 1 PC

Oct 2011 24
Technical Objects – Bill Of Materials (BOM) - Example

Oct 2011 25
Technical Objects – Equipment in Tree Structure

FL

FL FL FL

FL
bom FL EQ

EQ
bom

Oct 2011 26
Content

Organization of Plant Maintenance

Technical Objects
 Functional Location
 Equipment
 BOM
Maintenance Processes
 Corrective
 Preventive
 Task List
 Maintenance Plan

Q&A

Oct 2011 27
Maintenance Processes – Corrective Maintenance

1 Notification

2 Planning

3 Scheduling

4 Execution

5 Completion

Oct 2011 28
Maintenance Processes – Corrective Maintenance

Notification
 Initialize a damage, a malfunction or some other request.
 Usually refers to a technical object and contains a description
of the malfunction or requirements.
 Functional Location / Equipment
 Dates
 Damage location and cause of damage

Oct 2011 29
Maintenance Processes – Corrective Maintenance

Planning
 Create Work Order from Notification
 Information will be retrieve from notification to work order.
 Manage the operations to describe the work to be performed.
 Manage the materials (spare parts) which are required when the
maintenance order is executed.
 Maintain the settlement rule, which provides information on who usually
bears the cost.
 View the estimated, planned and actual costs.

Oct 2011 30
Maintenance Processes – Corrective Maintenance

Scheduling
 Material availability check
 Release Word Order
 Print shop papers
 Withdraw material
 Post goods receipts
 Enter time confirmations
 Complete task

Oct 2011 31
Maintenance Processes – Corrective Maintenance

Execution
 Involves the withdrawal of spare parts from the warehouse and
the actual execution of the order.

Oct 2011 32
Maintenance Processes – Corrective Maintenance

Completion
 Time confirmation
 Technical confirmation
 Cause of damage
 Work executed
 Technical Complete (TECO)
 Closure of work order and notification

Oct 2011 33
Maintenance Processes – Corrective Maintenance

1 Notification
• Technical object • Date
• Description • Malfunction

2 Planning
• Work to be performed
• Internal/external resources
• Material
• Tools

• Order release • Capacity leveling

3 Scheduling • Printout • Availability check

• Planned/unplanned material withdrawal

4 Execution • External procurement

• Time confirmation • Order settlement

5 Completion • Technical completion • Technical confirmation

History
Oct 2011 34
Content

Organization of Plant Maintenance

Technical Objects
 Functional Location
 Equipment
 BOM
Maintenance Processes
 Corrective
 Preventive
 Task List
 Maintenance Plan

Q&A

Oct 2011 35
Maintenance Process – Preventive Maintenance

Types of preventive maintenance

Preventive
maintenance

Time-based Performance-based Condition-based

2000
30 40 50
20 60
10 70
80
Pressure
Pressure
Temperature

Thickness
Oct 2011 36
Maintenance Process – Preventive Maintenance

Types of preventive maintenance

 Time based
 Preventive maintenance work is due at specific intervals (i.e. monthly)
 Performance based
 Preventive maintenance work is due when a specific performance level
has been reached (i.e. every 10,000 km)
 Condition based
 Preventive maintenance work is due when a condition is outside of a
specific value range (i.e. temperature higher than 85 degree Celsius)

Oct 2011 37
Maintenance Process – Preventive Maintenance

Phase Contents

1 Task list
Create task lists for different
objects

2 Maintenance
Create maintenance plans
plan

3 Schedule Schedule maintenance plans

Maintenance
4 order
Process maintenance orders

Technical Technically complete

5 completion maintenance orders

Oct 2011 38
Maintenance Process – Preventive Maintenance

Task List
 Maintenance task list describe a series of individual
maintenance activities.
 Can be used for routine and preventive maintenance work.
 Also specify what operations to be performed and which spare
parts and tools are required.

Oct 2011 39
Maintenance Process – Preventive Maintenance

Maintenance Plan - Types of Plan

 Single Cycle Plan
 The same activity must be executed at regular intervals\
 Example:
 Annual inspection of fire extinguishers
 Acceptance test every six months

 Strategy Plan
 Maintenance work and inspections are performed in different cycles
 Example:
 Check fan belt: every 12 months
 Change fan belt: every 24 months
 Change oil: every 6 months
 Change oil filter: every 12 months

Oct 2011 40
Maintenance Process – Preventive Maintenance

Maintenance Plan
 Define a maintenance item (i.e. Functional Location /
Equipment)
 Choose the type of maintenance plan
 Assign a relevant task list
94 96
98
2000
K ED
EC
CH yea
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e ve

Oct 2011 41
Maintenance Process – Preventive Maintenance

Schedule Maintenance Plan

 Allows you to define a start date for maintenance orders.
 Work order will be automatically created when the date is due
(depending on the maintenance plan).

Maintenance item report, sorted by equipment (no.)

1998 1999

Oct 2011 42
Maintenance Process – Preventive Maintenance

Phase Contents

1 Task list
Create task lists for different
objects

2 Maintenance
Create maintenance plans
plan

3 Schedule Schedule maintenance plans

Maintenance
4 order
Process maintenance orders

Technical Technically complete

5 completion maintenance orders

Oct 2011 43
Q&A

Oct 2011 44
Key Points

Have an overview of Plant Maintenance

Learn the types of master data
Learn the example of business processes

Oct 2011 45