Cement Energy and Environment

World Class Maintenance Work Management Process One of the immediate benefits of implementation of maintenance planning and scheduling is "Wrench Time, improvement. Wrench time is defined as the actual time spent by a workman doing value added work. The World Class standard for wrench time is 60% to 62% and the Best in the Class is 50%. Unfortunately, this figure is dismal and often observed to be as low as 22% to 32% in most of the cement companies in India. It is easy to find a lot of time of the maintenance crew being lost in travelling, waiting and searching spares, tools, materials, permits, services etc. Thus even any half hour job often takes more than an hour or two to complete. By following planned maintenance, the wrench time gets increased by over 50 % to 100% of the current level within a span of 6 to 12 months. With increased wrench time, the maintenance execution team is able to carry out all the necessary preventive, predictive, corrective, modifications and safety related work in a systematic way and As a thumb rule emergency maintenance work costs 3 to 5 times and unplanned work costs 1.2 to 1.5 times the planned work. With implementation of effective planning and scheduling process, there is a continual drop in all the emergency and unplanned work resulting in 20% to 30% reduction in maintenance costs within 12 to 18 months. Some of the major benefits of maintenance planning and scheduling are: • Reduced asset downtime • Reduced manpower requirements • Reduction in overtime • Reduced spares and material inventories • Improved asset integrity • Improved plant safety • Improved maintenance and repair quality • Improved employee moral time bound manner. Consequently, there is a • Improved work relations between departments momentum shift from reactive to planned and • Improved work life balance proactive work culture with continuous reduction in asset failures. • •••• 5