How to establish a World Class Maintenance Organization.

I think if maintenance organisation want to become world class organisation, they  must develop a highly disciplined and committed plan of action. Once they develop a plan of action for a change it should be agreed and reviewed by top management. 

After getting approval from maintenance department, they must make changes and implement the plan as rapidly as possible. Some will resist for a change ,but it is important to make changes for the success.

Unfortunately maintenance as a concept is mis- represented and mis- understood in most developed countries. In developed countries this is coined as " Asset care" which is more appropriate. The difference is what would be between "Health check up" and "Medication". The terms it self are and positive and negative. Most of the firms have a mind set up of considering as Maintenance department as ca cost drain and could not come to terms as " Good cost" as against other costs as marketing, sales, distribution etc. Result and cause are not visibly related and measured. Most importantly the time lag is huge.

In developed countries, mostly the maintenance is replacement on a regular time intervals and takes precedence over production targets which is exactly being compromised in India. It is nice to ask question how many times a psare is replaced on time, as per specs and method recommended by the maker. Since the business of spare parts is not rewarding for the OEM suppliers, it's quality gets diluted in due course of time by the company in the name of "cost savings", only to impact its reliability in future. Localisation of process and method is considered to be an edge over the claim of "Patent and confidentiality' of the OEM and unfortunately this is encouraged by companies for short term gain. Yet to see the over all efficiency, loading of the machine VS cost incurred. The optimum efficiency of the machine is achieved at the cost of other variables like safety, quality and not inbuilt in the definition of efficiency. Though the terms like OEE, MTBF etc are being measured, Analysis of cost Vs OEE identification of good and bad cost yet to evolve. Sticking to SOP is considered as non- flexible and non creative. The thin line between Standard operation/Maintenance and Non- flexible/ creative operation/maintenance is mis-understood. Sometimes deviation of standard operation /maintenance is rewarded most of the times for being major “Cost saver and Innovative creator” only to fall back upon the old standards later in 2-3 years down time. It is not common to have history getting repeated in maintenance with respect to vendors, specifications, method and spare parts etc.

Most importantly the 'cost of opportunity lost" Vs cost incurred on the machine in a time duration of 5-6 years also to be considered.

WORLD CLASS MAINTENANCE

Ofcourse at present I am looking for job too.

If Maintenance organisation want to become world class, it must change the way of operation by imparting the technical training on all the equipments and modern technologies on daily busin

Maintenance department has always been an ignored by and large by most of the corporates either by the very reason that it is internal or becuase it is not directly connected to external environment unlike marketing or finance. . It corporates so many things like skill levels, right spare part and right method.

If Maintenance organisation want to become world class, it must change the way that departments conduct their daily business. It has to shift to technology. But to sustain change the organizational and technological shift should occur at the same time and not one after another.

TPM is the answer for it. Otherthan it, design out maintenance always gives a better life to equipments. 

World class maintenance organisation !!!!!!!!!!!

Why we do maintenance. To have consistant operation for production.

Now evrything is in terms on earning and money. There is a major shift in mind set of top organisation in few sectors, esp. in cement. Top managemant want to produce as much as they can. It is very sipmle that if you want a week stoppage for maintenance and the loss due to loss of production is higher than this, no body will care about maintenance. They will throw the old component and replace it with new.

So to have world class maintenance we need to look into following:

1. To have s system where we can check the things without affecting production e,g. condition base monitring etc. So that planning to be made and accordingly the job can be done with minimum time.

2. We must change the mind set of top management from production oriented to the totality which includes schedule inspection and corrective actions.

3. The voice of maintnance head should be strong enough so that it can not be overlooked.

4. Above all, bring cahnge change in technology in such a way that it will have minimum resistant to accept the change. The concern person shhould be buy in first before going to implement any new technology.

5. Simple system to analyse and monitor the failurs. it should be automated one so that the data will not have any subjective interpretation.

Presently i am working towards above said practicess and results are very good.

maintenence to be looked on overall basis. Organisations tend to ignore maintenance as a cost but actually it is an investment in the long run.