Plant Maintenance

RELIABILITY MAINTENANCE ( Chapter Basic ) This Chapter will talk about reliability Maintenance , how to develop and step by step implementation of reliability in practical way. Reliability Maintenance  is a strategy that  implemented to optimize maintenance program of plant or facility. the out put or "goal" of this is the specific maintenance strategy for each assets or equipment in our plant to control break down of equipment and / or to control forced aging of the equipment. what is maintenance Strategy ? nowadays there are 4 maintenance  Run to failure/reactive, Preventive, Predictive and Proactive Maintenance. please see below, chart of best practice for maintenance strategy 10% from the assets with Reactive Maintenance, 20% from the assets with Preventive Maintenance, 50% from the assets for Predictive Maintenance and 20% from the assets for Proactive Maintenance. lets get back to the Reliability maintenance. figure above descr...

Maintenance Planning for daily abnormality findings. This chapter will talk about maintenance planning in more practical way and simple. Most of source  I got from "Maintenance Planning and Scheduling Handbook" by Richard  D. Palmer. and by my experience as Maintenance planner for more than 5 years . What is Maintenance planning ? and how it impact to daily maintenance jobs ? Maintenance planning for daily abnormality is about how we can arrange our daily machine abnormality in the field, create work package, execution, and job priorities. so that it will affected to our daily maintenance performance, less backlog, cost, loss time, and man power arrangement. in this case, daily maintenance planning should be done by Maintenance planner. for planning principle I suggest you refer to Maintenance planning and scheduling Hand book by Richard D. Palmer. Now, I will share simple way to arrange daily maintenance planning for abnormality findings in the field, followed b...

AM is one of TPM pillars, the meaning of AM is Self-Care . Production process operator acts as " First Line Maintenance ",   Machine maintenance is not only the responsibility of maintenance section, but also the production people who run the machine. this part I would like to share how to develop AM  Step 1 - Cleaning by inspection in best practice way. "Cleaning by Inspection" means that operator who run the machine beside doing production control and  parameter setting, they also perform machine inspection that followed by cleaning activities, why ? Deterioration of production and machine efficiency usually cause by less attention to the " Basic Machine Condition " in where basic machine condition consist of contamination, lubrication, tightening, inspection, precision check.  almost root cause of all problem in the machine came from basic machine condition, and of course there is one more thing  that is Man Mistake ( e.g. People not do inspection, ...

what is equipment criticality ? how to determine that the equipment is critical ? Equipment Criticality is a way of determining the level critical of an equipment in the plant maintenance.  equipment critical is something that when destroyed, modified or misused will cause harmful consequences to the organizations or its goals and missions. we should determining all assets critical point through criticality analysis, which output from this is used to determine the maintenance strategy (run to failure, preventive, predictive or proactive) and maintenance planning as well. Many ways we can meet in determining the  crtiticality level. And also many sources that we can make reference to doing critical level analysis. One of them is the matrix criticality. this time i would like to share simple way of  criticality analysis for plant equipment, the flow step , matrix  and calculation. Step to do Criticality Analysis : Download all your function location ;...

5S - Five implementation steps to improve the work place 5S  is a concept of a series of basic operations to organize work areas with the aim of ensuring better quality, safety, and productivity. 2 basic start of 5S ; Sorting out and Set up SORTING  - key point "Only Necessary Goods in the Work Area and In Limited Amount" Flow Process to do Sorting out do identification by sticking red tag label 7 Days Rule -   all red tag should be done in a week. we have to decide what to do for the item with the red tags. Red tag can be sticky by "any one" in that area, and should be review by supervisor or above. SET UP - key point "every Item / Goods clear storage and place" 5 STEPS TOWARDS: Grouping of goods (e.g type,  Size, shape, function) Prep the place Border marking between places Assigning an identifier /  Identification of goods Map / placement plan of goods all above 2 best practice and practical activity to do first two step o...