How do you reduce maintenance costs?

posted 8 days ago 16 votes

We replace upfront We replace afterwards During build of a new plant, we monitor Nothing

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We replace upfront 2 (0%)

We replace afterwards 1 (0%)

During build of a new plant, we monitor 12 (0%)

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purwowiroto purwowiroto, vijay patil and 2 others like this You, purwowiroto purwowiroto, vijay patil and 2 others like this 24 comments Jump to most recent comments

Hendra DjatiUnfollow Follow Hendra Djati Hendra Djati Perbowo only by perfect OnM. Record daily OnM activities, monitor repeated abnormalities and defects and solve it, choose the right parts and methods, record equipment history, and all.. 8 days ago Unlike Like

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GeorgeUnfollow Follow George George Vela Maintenance is performed to improve reliability. This is accomplished through testing. to reduce maintenance costs, more companies are relying on their engineers to solve issues and perform maintenance rather than call in the OEM. This can result in substantial savings. 8 days ago Unlike Like

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Hendra DjatiUnfollow Follow Hendra Djati

Hendra Djati Perbowo agreed 8 days ago Unlike Like

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Donald AUnfollow Follow Donald A Donald A Hughes Simple voting buttons are not going to help obtain the information you require to answer this question. First you need equipment history, then frequency of brake down, and required maintenance; factor these into scheduled down time maintenance, and cost of repair to replace, to come up with the correct maintenance at the right time. Chronic equipment problems will require engineering review to analyze the problem and come up with a equipment replacement or improvement to reduce the maintenance on chronic equipment problems. Also the addition of permanent support, such as permanent platforms to scaffold, at location, electrical disconnects, addition of vibration monitoring to detect problems before breakdown. You will need to spend some money up front to save money in the end. 7 days ago Unlike Like

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BillUnfollow Follow Bill Bill Rose RTF then you change the equipment out falling back on BART and pull the money out of your capital budget. :) atleast thats what I'm seeing from one company. :( 7 days ago Unlike Like

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JeremyUnfollow Follow Jeremy Jeremy Culberg None of the above - the quick answer is "it depends" Some equipment we condition monitor, and either proactively replace, or get ready for replacement at time of failure (consequence of failure is the driver). Other equipment simply run to failure. Others use a time based equation to replace. And yet other failures (or potential failures) we design out. The maintenance is tailored to suit the risk profile of the equipment. An example may be a motor - 5 installations of the same motor across site. In the first example, there are 3 compressors - plant only needs 2 operational. So those motors have the basic lubrications and inspections done, but very little additional work (for the sake of the argument these motors are inexpensive). Essentially run to failure. Next pair of identical motors run feed pumps. Both are required for full load - increased inspection regime, and typically earlier intervention when degradation becomes evident. Different strategies for the same motor, as the consequences of failure are different. 6 days ago Unlike Like

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baboolalUnfollow Follow baboolal baboolal vishwakarma interest that I read your recent posting in the THERMAL POWER PLANT ORIENT GREEN POWER BIOMASS CO.LTD. & coal based In response, I enclose my resume for your consideration. Review of my credentials will confirm that I am capable of serving as the catalyst for achieving revenue objectives and organic growth through effective contributions. I am a result-oriented with 37 years of enriched experience in Power Plants Operations, Project Management, Installation & Commissioning and Operations & Maintenance. presently working ORIENT GREEN POWER BIOMASS CO.LTD. with as General Manager

OPERATION & MAINTENANCE Thermal Power Plant I understand that working for your organization requires a candidate who is team oriented and is able to deal with people in various departments. I am confident that I possess these skills, which will help me to perform the job efficiently and effectively. My goal is to transit my enthusiasm, creativity and experience into a position, where I continue to provide the strategic and tactical leadership critical to retaining valued customers of an organization. I am certain that my presence in your team will prove to be beneficial to your organization. As such, I would welcome an opportunity to speak with you to evaluate your needs and share my ideas. Thanking you. Sincerely, BABOOLAL VISHWAKARMA Enclosure: Resume

CONTACT:- 9425885234 vishwakarmabl@ymail.com baboolal vishwakarma Hello Dear * I understand that working for your organization requires a candidate who is team oriented and is able to deal with people in various departments. I am confident that I possess these skills, which will help me to perform the job efficiently and effectively.plz see link as bellow. baboolal vishwakarma " http://www.siliconindia.com/profiles/Baboolal-nil-vishwakarmaLBqwD1i0.html " * I am seeking job for GM(O&M) thermal power plant FBC,CFBC,PFBC,BOILER ,TURBINE expert & given details as below :total exp = 37 years in power current ctc = 18,30,000 p.a exp ctc = as per company norms (negotiations) notice period = immediate availability of interview = as per your schedule thanks & regards B.L VISHWAKARMA Gm. thermal power plant 6 days ago Unlike Like

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CarlosUnfollow Follow Carlos Carlos de Vos Thanks for all comments so far! Of course I realize simple voting buttons will not be enough to get all information. But it helps to start this very interesting discussion with experienced engineers! 6 days ago Unlike Like

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baboolalUnfollow Follow baboolal baboolal vishwakarma Preview: BABOOLAL VISHWAKARMA Contact: +918989139763 E-Mail: baboolalvishwakarma@rocketmail.com Dated: 17/1/13 Dear Sir/ Madam, It was with great interest that I read your recent posting in the THERMAL POWER PLANT ORIENT GREEN POWER BIOMASS CO.LTD. & coal based In response, I enclose my resume for your consideration. Review of my credentials will confirm that I am capable of serving as the catalyst for achieving revenue objectives and organic growth through effective contributions. I am a result-oriented with 37 years of enriched experience in Power Plants Operations, Project Management, Installation & Commissioning and Operations & Maintenance. presently working ORIENT GREEN POWER BIOMASS CO.LTD. with as General Manager OPERATION & MAINTENANCE Thermal Power Plant I understand that working for your organization requires a candidate who is team oriented and is able to deal with people in various departments. I am confident that I possess these skills, which

will help me to perform the job efficiently and effectively. My goal is to transit my enthusiasm, creativity and experience into a position, where I continue to provide the strategic and tactical leadership critical to retaining valued customers of an organization. I am certain that my presence in your team will prove to be beneficial to your organization. As such, I would welcome an opportunity to speak with you to evaluate your needs and share my ideas. Thanking you. Sincerely, BABOOLAL VISHWAKARMA Enclosure: Resume

CONTACT:- 918989139763 vishwakarmabl@ymail.com baboolal vishwakarma Hello Dear * I understand that working for your organization requires a candidate who is team oriented and is able to deal with people in various departments. I am confident that I possess these skills, which will help me to perform the job efficiently and effectively.plz see link as bellow. baboolal vishwakarma " http://www.siliconindia.com/profiles/Baboolal-nil-vishwakarmaLBqwD1i0.html " * I am seeking job for GM(O&M) thermal power plant FBC,CFBC,PFBC,BOILER ,TURBINE expert & given details as below :total exp = 37 years in power current ctc = 18,30,000 p.a exp ctc = as per company norms (negotiations) notice period = immediate availability of interview = as per your schedule thanks & regards B.L VISHWAKARMA Gm. thermal power plant 5 days ago Unlike Like

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MohUnfollow Follow Moh Moh Ali Get the experiences engineer and teams, put them in the right position ... may be help 4 days ago Unlike Like

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Phillip W.Unfollow Follow Phillip W. Phillip W. Davis Get to the basics. Eliminate errors which includes human errors. Get all personnel involved. Let the men doing the work talk to you about waste that can be quickly eliminated. 4 days ago Unlike Like

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josephUnfollow Follow joseph joseph hanna Nothing means nothing of the above. Watching, collecting data, analyzing then decide how and when to interfere. this is about reliability.

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UdhayakumarUnfollow Follow Udhayakumar Udhayakumar Venkataraman Use Standard Guide lines as per OEM, proactive maintenance, avoid repetitive failurs by root cause analysis, best planning of all resources like right man power, spares consumables, verification of quality, Effective operation with prudent practices with SOPs etc will help. regards 4 days ago Unlike Like

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LuisUnfollow Follow Luis Luis Rodriguez There are several ways to reduce maintenance costs. 1) Implementing an agressive inspection program. This program should feed the daily or weekly maintenance jobs; 2) Your should concentrate your efforts in those equipment that represent the major impact in your plant reliability, it does not matter their size; 3) Work orders priorities are very important aspect in this matter; 4) The Operations Department should participate in the discussions when the maintenance jobs are being schedule in order to help identifying which of the discussed aspects could affect the plant or equipment reliability; 5) The outside contractors should be screened and well selected. Many of the maintenance costs are coming from re_works from external contractors; 6) The maintenance people should know the maintenance progress or delays to encourage them to be responsible for their results and discussing how to prevent them. You could implement a monthly recognition program to the most excellent employee chosen by a committee; 7) You could reduce costs when a budget controlling culture is spread in all the maintenance staff. There are many works that are being done as extra budget that could be

planned for the future. I hope these observations could help you. There are many other things that should be taken in account, but the space is limited (i.e. materials purchase process that include the PO, specifications and reception). 3 days ago Unlike Like

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CHANDRA PRAKASHUnfollow Follow CHANDRA PRAKASH CHANDRA PRAKASH PANDEY Maintenance cost is directly related with availability of equipment. Hence availabilty is to increase. Verious supports are available. Fast wearing parts be replaced instead of repair. Vibration analysis is done regularly of moving parts.New technology & on line repairs be preferred while running of unit. Repair/ replacement be clubbed together to avoid down time. 3 days ago Unlike Like

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baboolalUnfollow Follow baboolal baboolal vishwakarma Repair becomes a significant percentage of the cost of replacement, it becomes economically favorable to simply order a replacement part. In such cases, the part is said to be "beyond economic repair 2 days ago Unlike Like

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GaryUnfollow Follow Gary Gary Melrose Stop doing pointless (often destructive) tasks and concentrate on criticality and risk optimised maintenance which are directly aligned with corporate strategy. Refer to the Physical Asset Management Handbook by John S Mitchell, the Institute of Asset Management website ( http://theiam.org/ ) and the John Woodhouse Partnership white papers section ( http://www.twpl.co.uk/ ) for further details. 1 day ago Unlike Like

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baboolalUnfollow Follow baboolal baboolal vishwakarma utilized many factor for reducing the cost of manufacturing kindly contact as privately 1 day ago Unlike Like

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N.K.Unfollow Follow N.K. N.K. Agarwal Hi Carlos, Pl donot make it sound as simple as you have put in to vote the factor to reduce maintenance cost. There is no one factor which is responsible of which will give you a reduced maintenance cost. It is a strategy combining all the above and many more factors which help in reducing maint costs. Starting with, to create a maintenance culture in the organisation which involves doing the job without any mistakes, so that the fault does not repeat. This saves unnecessary manhours in repeating repairs on the same equipment. Avoid unnecessary maint by adopting condition based maint so that you do maint only when needed. Use of genuine spare parts which is possible only if you plan properly and organise the spares supply in advance. Last minute rush always end up in duplicate spares. Reducing spare parts inventory reduces the total maint cost substantially. Doing Route Cause Analysis for establishing route cause of the problem always helps in avoiding the unnecessary efforts of doing the same job over and over again. Maintain history cards for all the jobs done on major equipments to know the background before attempting any work on the same. Allow sufficient time for training of manpower for the various jobs.These are few of the many aspects that a maintenance team has to look into in order to reduce the cost of maintenance. And ultimately, for all maint activities follow, STAR philosophy. 1 day ago Unlike Like

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abdelaaliUnfollow Follow abdelaali abdelaali badache To reduice maintenance cost you should have the following organisation . 1/ high level competence or skilled employees 2/ well planned, EPC and commissioning welle monitored 3/ High level of O&M 4/ data base of all equipement 5/ act just at the right time to avoid failure

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baboolalUnfollow Follow baboolal baboolal vishwakarma To operations and maintenancebudgets are among the first to be cut. Fewer personnel working fewerhours are expected to operate and maintain more equipment at lower cost 14 hours ago Unlike Like

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DavidUnfollow Follow David David Garbe As far as we are concerned in our field of expertize, we provide online cleaning of fired heaters, boilers (fire-side) and fin fan of air coolers for major oil refineries. Our dry chemical process allows to optimize the energy efficiency of production units without the need of a shutdown, nor waste management (see www.furnace-solutions.com). Our customers are able to anticipate online cleaning campaigns on a yearly basis, according to their energy performance analysis. This is one example of preventive maintenance with a viable and safe solution, representing huge savings for our customers. Thanks to the other people who posted very interesting information in this subject.

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sinnaduraiUnfollow Follow sinnadurai sinnadurai sripadmanaban By condition monitoring 2 hours ago Unlike Like

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RiyadhUnfollow Follow Riyadh Riyadh Alsadoon Riyadh Alsadoon: many factors can be implemented in maintenance to reduce the cost Such as 1) high qualified well trained and motivated team star from their manger , engineers and technicians.2)always act in proactive mananer to upgrade operation systems 3)look for every required support for your maintenance team including required hand an power tools and safety equipment.4)implement SAP or CMMS system for planned and unplanned maintenance 5)planned maintenance should bevas required and even OEM program can be reviewed 6)encourage reverse engineering for your in house workshop or outsourcing for operational spares7) minimize the waste in time of maintenance with proper planning and coordination between O&M 8)separate a team for PM and CM follow up.8)proper contractor qualification procedure 8) outsource bulk work which requires more manpower 9)repeated machinery failures to be analyzed and to act to set straegy to reduce it to minimum 10) separate team to be assigned for spare parts ordering and stocking. Thanks 58 minutes ago