Industrial Preventive Maintenance & Reliability Services pdf

Industrial Preventive Maintenance & Reliability Services Australasian Maintenance Solutions Pty Ltd was established to offer innovative and practical Maintenance Strategies to the Manufacturing, Mining and Pulp and Paper industries. AMS assist in all facets of maintenance from the development of Preventive Maintenance plans to the reorganisation of a company's maintenance work force. AMS Consulting Services provide Maintenance Benchmarking Reviews, Maintenance Training, Condition Monitoring Advice and Maintenance Inventory Management Expertise. AMS offer exceptional service and value for money in both Maintenance Consulting and Inventory Management Services. Inventory Management Services is one of the most important tasks in any business. Inventory means the storing of materials or stock of the business. And the inventory management is the system of managing the stocks of goods which are in-demand, as well as stocks of goods, those are not in demands. This thing has to be updated every now and then. The basic for inventory management is to make a balance between these in-demand and not in-demand products. Inventories have to be managed properly in order to provide better service to customers. This management of inventories decides whether a business is a high or Low Profile. Without Inventory management it is difficult for any company to meet the customers need. Whatever business you are in, whether its pulp and paper, or mining, or food and beverages, unless you meet the customers demand on time, you will soon lose your business to the competitors. The customers don’t care how you Our Mission "AMS will assist our clients to improve their plant reliability and lower their overall maintenance cost basis." Company Profile Australasian Maintenance Solutions Pty Ltd is a privately owned Australian Company established in 2001. Our Philosophy is to provide practical assistance to maintenance practioners by focusing on maintenance and business results. AMS have a number of core employees and have developed a network of other industry specialists that allow the company to provide flexible, economic solutions to its clients. AMS also utilise the services of accredited suppliers that satisfy our strict supplier accreditation code, encompassing business values and product quality. When appropriate AMS can recommend these suppliers to our clients giving them access to highly reputable suppliers in a number of fields.  AMS staffs have worked extensively in the following industry sectors:  Pulp and Paper  Mining  Food and Beverage  Postal Automation  Mechanical and Electrical Service  Electrical Network Distribution Maintenance Management Solutions - Australia Maintenance is about doing the right thing at the right time, consistently. Consider this thought: "We are what we repeatedly do. Excellence, then, is not an act, but a habit." - Aristotle This range of services assists organisations benchmark their performance (Maintenance System Review), or puts in place coaches and mentors to aid the implementation of Maintenance Improvement Strategies. AMS can also assist in the selection of an appropriate Computerised Maintenance Management System, CMMS, or manage the establishment and implementation of an isolated or totally integrated CMMS with other business functions like:  Maintenance System Review  Maintenance Strategy Development  Maintenance Plan Implementation  CMMS Implementation Maintenance System Review & Audit The Maintenance Review is a comprehensive audit and analysis of the Maintenance and reliability function. The review focuses on four key areas of the Maintenance business and allows our clients to easily Benchmark their performance. This is critical in measuring the effectiveness of any Maintenance Optimisation programs that may be undertaken. The review covers the following business areas: 1. Maintenance Systems Organisation Structure Management Philosophy CMMS Utilisation Financial Integration and Control Safety, Health and Environmental Management 2. Inventory Control Control and Costing system Storage Environment Procurement process Rotable Parts Management 3. Plant and Equipment Life Cycle Planning Standard Work Procedures Condition Monitoring Planning and Scheduling History and Reliability Measures 4. Resources Internal Labour Management External Labour Management Training and Career Development Support Contract Managementt AMS have successfully utilised this approach in several countries with a number of clients. Being a modular approach this program is infinitely variable to cater for special client needs. AMS also undertake an abbreviated version of the program as prelude to assisting clients to implement Maintenance Optimisation programs.  Maintenance Strategy Development  Maintenance Plan Implementation CMMS Implementation Maintenance Strategy Development for Reliability Fundamental to the reliability of plant and equipment is a well constructed Maintenance Strategy and associated maintenance plans, detailing the Preventive Maintenance and Predictive Maintenance requirements for all plant assets. AMS take our clients through the development of a sound Maintenance Strategy following tried and proven methodologies The AMS methodology follows the following 10 step process  Determine the business objectives, operational and maintenance requirements,  Carry out an analysis of operational requirements and constraints  Identify all plant equipment and components  Identify the criticality of each piece of equipment in relation to the overall operation and the business  Conduct failure analysis on each piece of equipment  Determine the appropriate strategy for each piece of equipment eg. Run to failure, condition based, time based etc  Determine the most appropriate maintenance actions to predict or prevent failure  Eliminate actions that do not meet the business requirements  Compile appropriate actions in to like categories based on trade type, frequency, access etc  Enter the grouped actions, in an appropriate format, as Standard work the CMMS Our experience has proven that the best results are obtained by utilising a small number of experienced site personnel to work with our consultants on an as required basis to add ownership to the process and also to educate the site personnel in the process of developing maintenance plans. This process has proven particularly effective at developing maintenance plans as a new plant or piece of equipment is being constructed. This allows the equipment to be started with a detailed maintenance plan in place on day one of operation.  Maintenance System Review  Maintenance Plan Implementation  CMMS Implementation Maintenance Improvement Plan Implementation From years of experience working with maintenance organisations throughout Australia and Asia AMS have found that the most effective results come from coaching client personnel in how to implement and maintain results from Maintenance Optimisation programs. AMS personnel act as the coach and mentor for client personnel and provide the drive and motivation to achieve improvement results as well as assisting to implement change via education in the maintenance process. The AMS Maintenance Plan Implementation program follows a 6 step process  Identify the Improvement  Define the areas of change and the associated benefits  Select client advocates  Work with the advocates to plan the changes  Work with the advocates to implement the change  Monitor results and adjust the program accordingly The use of AMS personnel in coaching client advocates has proven particularly successful. The reason for this is that AMS personnel are not distracted by normal day to day plant operational issues and can therefore provide the appropriate time and support required to implement Maintenance Improvement programs. Allowing site personnel the time to absorb the change and gain the ability to sustain the change.  Maintenance System Review  Maintenance Strategy Development  CMMS Implementation CMMS Implementation & Maintenance Plan The last ten years in industry has seen the proliferation of Computerised Maintenance Management Systems, CMMS. There are now in excess of 500 CMMS packages available worldwide, not to mention huge integrated systems combining all facets of business from Maintenance plans to Production Scheduling. This makes choosing and implementing a site or business appropriate system a major task. AMS practioners have worked with a number of major and minor CMMS packages and are adept at assisting clients through the selection and implementation process. Broadly the AMS selection and implementation process follows the following steps  Determine the business objectives and drivers for implementation of a system  Determine the existing business internal processes  Review a selection of CMMS packages  Select a system that most closely meets the business requirements without customisation  Compare system processes with existing business processes  Align the processes across the business  Populate the CMMS with equipment and inventory data  Populate the CMMS with Maintenance Plan data  Commission the CMMS It is most important during this process to capture and align commonality between inter business function is Finance and Maintenance so that confusion is avoided once the system is in operation.  Maintenance System Review  Maintenance Strategy Development  Maintenance Plan Implementation Condition Monitoring Techniques & Outcome Condition Monitoring, an often misquoted term, is a valid Maintenance Strategy typically applied to high value or critical equipment. Typical techniques commonly utilised are Vibration Analysis, Oil analysis and thermography the big question is, when Condition Monitoring should be used and which technique will give the best return for effort. This module is an in depth review of currently employed techniques and examines the logic behind the application of each technique. Infrared Thermography (IRT) is commonly as a NDE tool to identify damages and provide remedial action. The fields of application are vast, such as, materials science, life sciences and applied engineering. The review typically follows these steps  Determine which techniques are used currently,  List equipment in the program,  Establish equipment criticality,  Establish overall business objectives  Determine which other prevent maintenance techniques are in use  Select a technique(s) that meet the business objective  Implement the change to the existing program. This is very simple methodology but surprisingly many Condition Monitoring programs are never reviewed to establish their continued relevance to the organisation. This can sometimes lead to overspending and in the worst case the program becomes outdated. Procurement and Inventory The procurement and management of Maintenance Inventory is traditionally not understood as of strategic importance to many purchasing and maintenance areas in today’s organisations. Maintenance rarely considers it as part of their core business, and Purchasing often do not identify the importance of the management of inventory with their customers. This often leads to a lack of focus on inventory accuracy, cost control and plant performance. AMS recognise this and offer the following services  Successful Maintenance Procurement Strategy  Inventory Management Procedures and Audit  Supplier Accreditation  Stores Management Procedures and Audit  Inventory Cataloguing  Rotables Management Program  External Labour Management  External Services Management Successful Maintenance Procurement Strategy AMS offer plain and simple basic solutions that will be capable of being implemented immediately to help your organisation move forward quickly. To do this AMS will develop sound Policy and Procedural documentation, with a Total Quality Control process within. AMS will develop a Training Development document to enhance skills. AMS believe that the overall process must always remain simple and transparent. To develop this it is necessary to step through and look at the following process.  Organizational Structure  Environmental Structure  Business Plan  Process Documentation  Quality Documentation  Training Documentation  Support Systems There are also several important aspects that must be dealt with to develop a Successful Procurement Strategy.  Customer Expectation Level  Professional Relationships  Product Design Criteria / Specification  Inventory and Materials Management  Occupational Health, Safety and Environment It is important to identify that while the organization may be performing many of the procurement functions successfully, in today’s global business environment it is critical that all facets of the procurement cycle are carried out with the greatest effectiveness and efficiency, if the organization is to gain that business edge that defines it as a leader and not a follower. “Any decision to change or challenge is always at the least a decision to explore new strategies and cross over existing boundaries. It is about the future.” In order to develop a Successful Maintenance Procurement Strategy let AMS help you and your procurement team identify areas for improvement, and help you develop an implementation plan that will work for your organization. Inventory Management Procedures and Maintenance Audit Service - Australia Maintenance Inventory Management is one of the more important process required if organisations are to reduce inventory levels and costs. AMS have experience in the three main areas of assessing plant criticality, determining inventory levels and managing suppliers. Many organisations understand this it is critical that if these three processes are managed as one, they will bring about financial reward to any organisation. AMS will work with your organisation to set up the procedures necessary to bring:  About a change that many organisations are looking for – lower overall costs.  In order to set up a Maintenance Inventory Management Procedure a base line audit is required.  AMS offer a total solution to meet lower cost and stored inventory requirements, while maintaining a smooth and uninterrupted manufacturing process.  AMS believe that we are able to significantly lower inventory, using our “Toward Zero” model.  As an interim AMS will help you better manage the flow of your inventory.  AMS are a useful tool, not the definitive answer; providing support, advice, creating a mix of ideas, and being impartial in presented options.  The three Main Stages of our Audit Process are;  Agree to the Terms of Reference of the Audit and specify the overall Outcomes of the Audit  Identify Areas of Greatest Scope for Improvement or Potential Loss, by identifying Situations out Of Control, and by Assessing the Ability of the Organisation to Measure Its Performance  Develop business models of the Organisation which depicts “Where We Are Now”, “Where We Want to be” and a plan of “How we get there” Supplier Accreditation Living with an Excellent Supply Partner Very few organisations today can perform business excellence without the help and support of its own suppliers. This fact has been documented successfully and sometimes repeatedly by many of the excellent manufacturing organisations. But does it hold true for maintenance inventory? Supplier accreditation programs are being practiced in many manufacturing organizations, but not as successfully for maintenance materials as has been achieved for raw materials and finished goods. AMS have developed a supplier accreditation program that will help your organisation to form strategic relationships with all your suppliers of maintenance materials. Success Factors  Communication  Top Management Support  Trust  Strategic Direction  Shared Goals  Quality Control  Up Front Planning  Conflict Management  Regular Meetings AMS believe that the there is a very simple process hindering the success that is lacking in this area of management and that is:- ……………. “The understanding of the organisations supplier’s capabilities, together with the suppliers understanding of the organisations expectations.” Stores Management Procedures and Audit AMS have developed a program that looks at the key processes of Developing and Managing a Maintenance Inventory Store, and will work with your organisation to develop documented procedures that will ensure that the capital invested is utilized effectively and efficiently. The main processes audited are  People  Systems  Receipt, issue, inspection and returns  Transport  Handling  Storage  Stocktaking  Training  Housekeeping  OHS&E and Quality systems Inventory Cataloguing AMS has extensive experience in cataloguing your inventory to meet all the requirements of the stores, purchasing, maintenance and suppliers. AMS has had extensive experience with the AUSLANG discipline, and is capable of also developing systems that can be tailored to meet your organisations individual requirements. AMS is also experienced in setting up or assisting with the development of maintenance Bills of Materials in line with inventory cataloguing requirements, or as an individual process for all maintenance organisations, using the same basic cataloguing procedures. AMS has found that a good cataloguing discipline will enhance the use of the Computerised Maintenance and Materials Management Systems, by making it easier to develop by making it easier to develop training documentation to meet the individual requirements of all customers. Rotables Management Program AMS has found that the repair of Rotable Inventory often fits into the non-core production task category. For this reason repairs, stock levels and traceability end up getting out of hand and become unmanageable for many companies. This wastes not only time and money but can seriously affect business volume and viability when repaired parts go back into the plant and fail prematurely. AMS Rotables Management drives down inventory levels and ensures the quality of repairs. External Labour Management AMS has a great deal of experience in major plant shut downs and overhauls, as well as project management. Our labour force consists of high quality reliable individuals with outstanding safety performance that require minimal external supervision. AMS has developed a specialised labour force who has worked extensively in the following industry sectors;  Pulp and Paper  Mining  Oil and Gas  General Manufacturing AMS can also assist your organisation in setting up labour contracts for day to day labour requirements caused by leave, sickness and any increased workloads. External Services Management AMS has found that the external site services are often poorly managed with inconsistent or nonexistent contracts. Often this leads to duplication of effort and poor control over expenses with no drivers in place to reduce cost and maintain safety and quality control. AMS assist organisations to add value to their business by encouraging innovation and by negotiating mutually beneficial contracts. AMS has a number of accredited Service providers that have proven service standards and reliable delivery. Trained staff to Increase Maintenance Reliability Well trained Maintenance practioners are the key to increased reliability as in the end people still carry out the work and these people must understand the relevance of their task before they can begin to develop improvement ideas. AMS staffs have many years experience in maintenance reliability and believe that many of the fundamental maintenance concepts are still misunderstood. Getting the basics right is still the most effective way to gain sustainable improvement in Reliability. AMS offer training in the following maintenance fields  Machine Alignment  Planning and Scheduling  Preventive Maintenance Techniques  CMMS utilisation Maintenance outsourcing Services & Infrared Thermographic Survey - Australia Australasian Maintenance Outsourcing Solutions have been providing support and services for clients large and small for ten years. During this time we have offered and executed solutions from a simple review through to an outsourced solution. By establishing good working relationships with a number of industry partners we are able to offer services that can be scaled up or down according to your business requirements. Our main service offerings are listed below:  Machine vibration analysis  Oil analysis  Thermal Imaging surveys  Maintenance Inventory Procurement  Inventory Stores Management  Maintenance Management . Industrial Preventive Maintenance & Reliability Services Australasian Maintenance Solutions Pty Ltd was established to offer innovative and practical Maintenance Strategies. all facets of maintenance from the development of Preventive Maintenance plans to the reorganisation of a company's maintenance work force. AMS Consulting Services provide Maintenance Benchmarking. Reliability Fundamental to the reliability of plant and equipment is a well constructed Maintenance Strategy and associated maintenance plans, detailing the Preventive Maintenance and Predictive Maintenance requirements