Plant Maintenance

Plant maintenance is a type of module that provides an integrated solution which supports the operational needs of an enterprise-wide system. This module includes all the products that covers all aspects for the maintenance of plant or equipment in good operating conditions to avoid production stoppage and loss. It also becomes integral to access the achievement of the process improvement.

Figure : Organization Structure Of Plant Maintenance

The major subsystems of a plant maintenance are :

1. Preventive maintenance control : Preventive maintenance control enables the organization to lower repair cost by avoidance of down time, machine breakage and process variability. It also provide planning, scheduling and control of facilities.
2. Equipment tracking : An equipment is a useful thing which needs to be protect and monitor. It’s cost constitute the single largest expenditure of an organization.
3. Component tracking : Components are the subsets of larger equipment and also it deserve same amount of cost control expenditure. It enables expenditure managers to identify components with repair problems.
4. Plant maintenance calibration tracking : It allows organizations to fully use their investments in the plant maintenance module.
5. Plant maintenance warranty claims tracking : It is an administrative system to provide control of all items covered by manufacturer and vendor warranties. It includes the ability to establish the type and length of warranty.

Objectives of Plant Maintenance :

• It helps in minimizing the loss of production time due to any equipment failure .
• It helps in quality and product improvement.
• It keeps all the assets in proper working conditions.

Advantages of Plant Maintenance :

• It helps in reduction of breakdown losses.
• It helps in reduction of quality defects.
• It increases net quality profits.
• It reduces maintenance cost.
• Increased equipment life: Regular plant maintenance can help increase the lifespan of equipment and machinery, reducing the need for costly replacements or repairs.
• Improved safety: Plant maintenance helps to identify potential safety hazards and address them before accidents occur, reducing the risk of injury to employees and damage to equipment.
• Compliance: Many industries have regulations and standards related to plant maintenance, and maintaining compliance can help avoid penalties, fines, and legal issues.
• Improved efficiency: Well-maintained equipment and machinery operate more efficiently, which can lead to reduced energy consumption and lower operating costs.
• Better inventory management: Plant maintenance can help identify and manage spare parts inventory, reducing the risk of stockouts and ensuring that replacement parts are readily available when needed.
• Enhanced customer satisfaction: When equipment and machinery are properly maintained, it reduces the risk of production delays or product defects, improving customer satisfaction and loyalty.

Disadvantages of Plant Maintenance :

• It increases investments in diagnostics equipment.
• It also increases investment in staff training.
• Saving potential that is not readily seen by the management.
• Downtime: Plant maintenance requires equipment to be taken offline for inspections and repairs, which can lead to production downtime and lost revenue.
• Cost: Plant maintenance can be expensive, requiring investment in diagnostic equipment, staff training, and replacement parts, which can reduce short-term profitability.
• Over-maintenance: Over-maintenance can occur when unnecessary maintenance is performed, leading to increased costs and reduced efficiency.
• Resistance to change: Resistance to change from employees or management can make it difficult to implement new maintenance practices or procedures, hindering progress towards improved plant performance.
• Lack of expertise: In some cases, maintenance technicians may lack the expertise or knowledge to properly diagnose and repair complex machinery or equipment, leading to longer downtime and higher repair costs.
• Impact on production schedules: Maintenance activities may need to be scheduled during specific periods to minimize impact on production schedules, which can limit flexibility and increase complexity in planning.
• Mismanagement of maintenance activities: Poor management of maintenance activities can lead to inefficiencies, delays, and increased costs, undermining the benefits of plant maintenance.