Maintenance Management System Effective Tool to Progress and Reach Total Productive Maintenance & Six Sigma Business Development Strategies.

Abstract

This paper presents the review/monitoring history of all kind of service equipment organization on common platform with identical format for information entry. The equipment covers ranges of all sizes, cost, portability and its use for different applications like emission measurement, safety measurement, environmental conditioning, on road measurements, etc. Micro level information data consists of equipment information (Installation date, cost etc), daily usage, observation of condition of equipment, maintenance solution, down time etc. This also provides information on availability of equipment, its actual use and tracking of maintenance data with fault processing. Recording of technical and financial information of ongoing activities including utilization is done on daily basis. The information is linked to various analysis tools. It has Inbuilt feature to measure, calculate and compare the equipment performance, to move towards achievements of TPM (Total Productive Maintenance) and six sigma business development strategy. Analysis module consists of age analysis to follow bath tub curve in its full life cycle (Infant Mortality Rate), uncertainty in breakdown faults, cause- effect analysis, root cause analysis, time and condition of component failures, With the help of analysis tools the module is allowing us to review and draw action plans to remove all root causes, update preventive maintenance plans, proper planning step to move towards predictive maintenance and zero breakdown. It gives effective input to improve user vigilance for use of equipment. It also gives us equipment classification based on age, time, periodic utilization and /cumulative utilization, technological change by Stochastic dynamic programming solutions. By this module we can correctly quantify and assess break-down status and thereby reduce breakdowns significantly. We also can analysis reliability, availability, failures, machine up time, cost analysis for asset utilization like fix capital intensity, cost of repairs, equipment utilization % turn over, etc. This total data of all equipment (organization) are on one platform so we can go through all equipment history with analysis in one look. This platform consists of crew of equipment users, maintenance engineers & managers, so all are connected with each other with their responsibility. The module provides operational backbone and used to provide inputs to management on: 1. Emergency plans to overcome critical equipment areas. 2. To draw maintenance plans and various budgetary provisions with the help of factual data.3.Supplier control of services and spare parts.4.Corporate planning for new equipment, facilities.