Welcome to ENGM03Advanced Maintenance Practices

►Dr David Baglee► david.baglee@sunderland.ac.uk► Phone: 515 2869

AMAP The Industry Centre Wessington Way

►Wednesday 1pm-4pm► Lectures and lab. ►One assignment and one exam?

Introduction to Maintenance

Dr David BagleeSchool of Computing and Technology

Maintenance Spending

► Europe £100 Billion Annual Spend Employs 2 million people

► United Kingdom £14 Billion Annual Spend 5% of sales turnover 3 × Value of new plant investment 18% of book value

Trends

► Assets Assets must run longer (>3 years between

turnarounds) Impact of asset failure can be very large

► Expertise Downsizing and aging workforce has caused ‘skill

gap’ at plant sites Technology is evolving faster than it can be adopted

► Working Practices Asset management is moving from reactive to

proactive Abnormal situation management procedures are

improving operations effectiveness

Recent Events

► Tube Crash - Chancery Lane, London► Electricity Supply Failure - USA, Italy, UK► Rail Crash - Hatfield, UK► Concorde Crash - CdG Airport, Paris► BP Refinery Explosion, Texas

Example: Car Maintenance

►What must be done to maintain your car? Change the oil every 6,000 miles Check and/or change air filter Check and/or change hoses and belts Rotate tires every 12,000 miles Clean inside/wash outside Replace brake pads Regular inspection

Example: Car Maintenance

► Implications of poor car maintenance? Premature failures Increased running costs Unexpected breakdowns Poor operator morale Personal injury or death Government shuts you down

Barriers

► Limited staff► Lack of training► Inadequate diagnostic equipment►Missing technical documentation► Budget issues► Inadequate monitoring of equipment ► Lack of management commitment► Poor morale

Neglected Maintenance

►Operating equipment in manual override

► Incorrectly adjusted equipment► Inefficient operations► Inoperative equipment► Steam, air, water leaks► Faulty control systems►Damaged HVAC equipment

Results of Poor Practices

► Short and Long term effects: Increased energy costs Increased major maintenance work Increased capital costs due to shortened

equipment life Continued morale degradation

Costs Involved

► Equipment purchase► Training► Extra staff

► Costs can be insignificant when compared with cost of not improving maintenance methods

► Industry loses per year are huge due to inadequate maintenance activity

Benefits

► Improved equipment efficiency► Increased product quality► Identify equipment defects► Reduced equipment failures► Increased production► Improved safety► Minimize damage to equipment► Provide guidelines for new equipment purchase► Effectively prioritize decreasing resources► Improve staff morale

Self Study

►Do the exercises on the self study sheet► Take time to examine the Glossary of

Terms provided on the following web site: www.skf.com/aptitudexchange/

glossary.html