PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE

AL AYUNI INVESTMENT AND CONTRACTING COMPANYAL AYUNI INVESTMENT AND CONTRACTING COMPANY

TABLE OF CONTENTS

PREVENTIVE MAINTENANCE DEFINITION1

OUR GOAL2

PLANNING AND IMPLEMENTATION3

OUR REQUIREMENTS4

MAINTENANCE DOCUMENTATION5

MAINTENANCE FORM AND DIAGRAM6

4

5

THE DEFINITIONTHE DEFINITION

(“PREVENTIVE MAINTENANCE”) Preventative maintenance (or preventive maintenance) is maintenance that is regularly performed on a component of equipment to lessen the likelihood of it failing. Preventative maintenance is performed while the equipment is still working, so that it does not break down unexpectedly. There are following three meanings of it.1.The care and servicing by personnel for the purpose of maintaining equipment in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects.2.Preventive maintenance tends to follow planned guidelines from time-to-time to prevent equipment and machinery breakdown.3.The work carried out on equipment in order to avoid its breakdown or malfunction. It is a regular and routine action taken on equipment in order to prevent its breakdown. 4.Maintenance, including tests, measurements, adjustments, parts replacement, and cleaning, performed specifically to prevent faults from occurring.

OUR GOALOUR GOAL The primary goal of maintenance section is to avoid or mitigate the

consequences of failure of equipment. This may be by preventing the failure before it actually occurs which Planned Maintenance and Condition Based Maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing all lubricants and filters on time as well as supporting the repair team by informing them regarding worn components before they actually fail.

Preventive maintenance activities include partial or complete services at specified periods, oil changes, lubrication, minor adjustments (will be done by repair team but we will inform them), and so on.  

One of major drawback of our system is also that work shop take care of records of major equipment’s and trucks only. But small cars, small generators and dewatering pumps etc. are out of our preventive maintenance planning. And we are depending on users to take care of them, but unfortunately lot of revenue has been spent on repair because user did not care. We are planning to bring all those equipment maintenance planning and servicing in our hand to avoid failures.

We wish to develop the ideal preventive maintenance program which will prevent all equipment failure before it occurs. How it will work we will show you as below.

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE ADVANTAGEPREVENTIVE MAINTENANCE ADVANTAGE

ConceptConcept ConceptConcept ConceptConcept

1

It is predictable, making budgeting, planning, and resource leveling possible

2

When properly practiced, it generally prevents most major problems, thus reducing Forced outages, “reactive maintenance,” and maintenance costs in general.

3

It assures managers that equipment is being maintained.

MAINTENANCE DOCUMENTATIONMAINTENANCE DOCUMENTATION

• DOCUMETATION PROCEDURE AND MANAGING QUALITY OF WORK DONE

SERVICE TRUCK/ SERVICE STATION DIARY  (right click to open link)

• Each service truck and service station will have a diary to record their daily tasks done.

• This record each page will be scanned and sent to head office on weekly basses so that we have copy of this record, if some diary got damaged or anything happen we will have record copy.

 

MAINTENANCE DOCUMENTATION

• PREVENTIVE MAINTENANCE DAILY REPORT  (Right click to open link)

• This daily report will be sent on daily basses to maintenance head. And it will be encoded in ERP.

 • Below are advantages of this report. • Data encoded in system is being cross checked.• Complete data will be encoded in system so that we can sort each and

every type of maintenance done, also we can sort any oiler complete daily activity from ERP. And this is most important advantage in terms of manpower management.

(Example sheet) (Right Click to open link) 

PLANNING AND IMPLEMENTATIONFor planning of preventive maintenance, we will use below formats. •PM planning monthly report from Site. (Right click to open link)

•This format will give us initial data from which we can make planning. From this data we will create below three reports. •PM schedule all sites (Right click to open link)

•A schedule will be on basses of monthly report planning. This will contain two types of schedule.•Sheet 1:- Equipment maintenance being done in hourly basses (meter reading).•Sheet 2:- Equipment for which service is being done in weekly bases. (crusher trucks, small generators, air compressors Etc.)  •Requirement of parts from store & add stock request  (Right click to open link)

•This plan we will provide to stock controllers every month, for example items needed for February we will provide them during first week of January. So, that they have enough time to arrange stock. 

PLANNING AND IMPLEMENTATION

Weekly Maintenance Task ( (right click to open link)

•This task will be prepared every Friday so that Saturday morning available for each preventive maintenance In-charge to implement at site.•And same format he has to send us back on every Thursday with remarks which tasks were done and which were not done due to which reason (equipment breakdown or idle, any other reason will not have accepted he must inform by mail or call to direct manager so that issue should be solved immediately).

Ensuring the tasks done are properly implemented direct on the machine.

•This is an important task which is highly necessary to make sure that what is documented it is actually done on ground. To do it we have following plan.

PLANNING AND IMPLEMENTATION

SERVICE TRUCK DIARY •It is main hard copy of document which will be saved in service truck/ service station as well as a same hard copy will be in head office as explained earlier in start. This diary consists of driver’s cell numbers too from which we will cross check randomly so that all our workers at site will know that it is being checked and they will not write anything not done.

 STILL CAMERA PER SERVICE TRUCKS/SERVICE STATION.•Each service station & service truck can be providing one still camera. We can use for below two purposes.•Take snaps of each activity done.•Take snaps of any leakage, grease not passing, or any problem in machine and sent to Repair team to arrange.•Note: - this picture data will be very high, and we will keep this Data in online clouds, and later on monthly data we can remove from clouds & save into DVDs.

PLANNING AND IMPLEMENTATION

COLLECTING USED ITEMS AND TAGS ON THEM WHILE FIXING.

•All filters when they are handed over to oiler before fixing will be marked by permanent marker with date and equipment code. Those filters will be checked randomly by our maintenance head or quality persons while visiting sites. Also, used filters will be collected back to workshop by maintenance in-charges.

•Oil changes will be stickered or tagged near the drain plugs by date and meter reading to so that during site visit we can check documents and physical proofs. •We will provide facility of collecting used oil to all service trucks and if used oil quantity found 75% of oil consumed means all oils where be replaced correctly as system

OUR REQUIREMENT’SOUR REQUIREMENT’S

S.NO DISCRIPTION QTY REMARKS01 300 liters compressor 01 for running pneumatic tools

02 water tank 1000 ltr or as per capacity of service truck 01

to clean the equip in regular intervals if st truck are short then we will fix only washer

pumps capacity depend on st truck03 high pressure washer 250 bar

pressure 01

04 oil drum with reeling's hoses and meter 06

lubricants and greasing separate pumps reeling's and

qty meters for each type of lubricants to avoid the mixing

of oil

05 coolant drum with manual pumps 01 for coolant levelling

06 mechanical tool box and tools 01 carry out jobs

07 spare parts and filter box 1x1.5x5m 01 materials safety

08 box for collecting used filters 01 to maintain quality of work and to save money

OUR REQUIREMENT’SOUR REQUIREMENT’S

S.NO DISCRIPTION QTY REMARKS09 tank with motor for collecting used

oil 01

10 dc to ac inverter 01to convert the vehicle battery for any electrical tools (for this we have to modify the dynamo

11 service truck diary 01 for daily work record

GREASING & AIR ELEMENT CLEANING VEHICLE

We should use separate greasing and filter cleaning vehicle. This is to reduce burden on service truck and ensure quality of greasing and filter cleaning which is most important part of PM system.

We will use single cabin pickup with air compressor and grease pump.

OUR REQUIREMENT’SOUR REQUIREMENT’S

Separate preventive maintenance In-charges

Right now, our R & M in-charges at site are much busy on daily repairs. We should appoint separate preventive maintenance in charge for each workshop, who will implement our plan and give us feedback reports. From his reports, we will analyze quality of preventive maintenance plan for future and bring more improvements.

STATIC PREVENTIVE MANTENANCE & SERVICE STATION

We will ensure availability of static preventive maintenance stations with complete tools as well as cleaning facilities. It will be used for trucks, medium and small vehicles at projects

OUR REQUIREMENT’SOUR REQUIREMENT’S

UNIFORM MODEL OF SERVICE TRUCK•Below is advised model of service truck. We will add some improvements then it will be uniform model for all available service trucks.

OUR REQUIREMENT’SOUR REQUIREMENT’S

1 Pick up 1For installation of Grease Drum & Air

Compressor

2Air Compressor With Reeling &

Hose1

 For Grease pump operation & Cleaning Air Elements

3Pneumatic Grease

Pump With Reeling & hose

1 For Greasing

4 Oiler 1 Greasing & Air Element Cleaning

5 Driver 1 Pick Driver

Each Area should have Diagnostic tool with operator to calibrate and evaluate each equipment once a month and submit report for further action.

PREVENTIVE MAINTENANCE MANPOWER

OUR REQUIREMENT’SOUR REQUIREMENT’S

PREVENTIVE MAINTENANCE MANPOWER

Note: - One Truck would cover 50 Equipment's PM per month based on Project area and carry out PM for only for Earth moving Equipment's not the vehicles

1 PM Foreman 1

For Service Truck Operation to Carryout PM

2 Mechanic 1

3 Asst. Mechanic 1

4 Tire man 1 Tire man and Auto Electrician should be working in workshop5 Auto Electrician 1

Trained and skilled manpower play important roll to carryout proper PM, Existing employees should be re-trained. Without proper training, employees could damage the machinery or even injure themselves or others.

PREVENTIVE PLAN DIAGRAM

P/M PLANNERP/M PLANNER

BB

EE

CC

DD

AAPM planning monthly report from Site. (Right click to open

link)

PM schedule all sites (Right click to open link)

Requirement of parts from store & add stock request  (Right click to open link)

PM Team additional tools (camera and diary

for reporting)

Weekly Maintenance Task (right click to open link)

IMPORTANCE OF OIL ANALISYS

01 02 03

Oil analysis is like a blood test. A blood test can tells if cholesterol is too high, for instance, which allows the doctor to treat the problem before it reaches stroke or heart-attack level.

Oil analysis allows technicians to treat the problem before it becomes a catastrophic failure.

We can assure also that required oil refill in specific engine , transmission differential and hydraulic system

“Workshops should recognize the value of oil analysis and understand it. Lot of chrome may be a ball bearing problem”

IMPORTANCE OF OIL ANALISYS

04 05 06

Everything we do, every component, every drain interval is sampled, trend everything and also do particle counting on every PM, especially on Heavy Equipment's and large hydraulic system. Also re filter to keep the machines clean."

Oil analysis helps determine if one element in an engine is rising or not, If it is, that element in anEngine might come from rod bearings, cam bearings or oil cooler. "Oil analysis could be used to pinpoint the problem..

It's the cornerstone of any preventive maintenance program. It's also a key that tells when to replace or rebuild a piece of equipment."

“Oil analysis is meaningless if we don't train the Mechanics to analyze the data properly."

THANK YOU

AL AYUNI INVESTMENT AND CONTRACTING COMPANYAL AYUNI INVESTMENT AND CONTRACTING COMPANY