Maintenance Management

Total maintenance management embraces all activities necessary to plan, control, and record all work done in connection with keeping an installation to the acceptable standard. This includes preventive maintenance and corrective maintenance, planned overhaul, planned replacement. spares provisioning, workshops functions, repairs and renewals, plant history compilation, plant modification to facilitate maintenance, spare parts manufacture, preventive maintenance on spare-parts etc. In a fully controlled situation only the time spent on emergency work is "unplanned" and this could well be less than 10 per cent of the available man-hours in the maintenance department.

The table below lists the basic elements of a planned maintenance system which is represented diagrammatically on back page.

Assets register

Maintenance schedule

Schedules for inspection, lubrication and preventive maintenance of the items in the register. The schedules may also include planned overhaul.

Work specifications

Instruction cards or documents which identify exactly the tasks to be undertaken within the maintenance system.

Maintenance control system

A "trigger" system which initiates the activities on the maintenance program at predetermined intervals as listed on the maintenance schedule.

Resource schedule

A manpower allocation system to ensure that the resources are available to implement the maintenance requirements of the assets and that optimum use is made of labor.

Maintenance records

A record of maintenance carried out and a system for reporting to management.

The organization of technical information, spare parts and tools, etc.

Liaison with production

An effective system of agreeing with the user management when maintenance work can be done.

Planned overhaul

Provisions for ensuring the planned overhaul of plant, either on a regular basis in accordance with the maintenance schedule or in response to condition monitoring.

Costing system

Costing procedures to ensure adequate cost control and apportionment of costs in the maintenance department.

Training

The necessary training of operatives and supervisors in the operation of the system.

MEConsult have the distinction of pioneering training and outreach services in the field of Maintenance Management which is a relatively innovative concept in industrial management applications in Pakistan. The company has also developed a maintenance management system for a cement industry who are in the process of implementation.