MAINTENANCE MANAGEMENT SYSTEM (MMS) IMPLEMENTATION
MMS achieve the baseline to establish all the maintenance practices and processes to maintain a significant level of operating consistency throughout the production equipment.
MMS includes, among other topics:
- Maintenance Control and General Administration (indicators, delays, costs, planning and scheduling, organization and maintenance roles and functions)
- Autonomous Maintenance and Operating Support (autonomous maintenance, Computerized Maintenance Management System (CMMS), technical training for personnel, safety and security, maintenance management system concepts)
- Maintenance Technology (predictive maintenance and trend techniques, kilns and mills specialized routines, physical conditions of the equipment, maintenance activities execution, lubrication, contractor management; Reliability Centered Maintenance (RCM); Reliability Module; Failure analysis and problem solution, FMEA)
- Spare parts technology (inventory optimization, spare parts list, strategic spare parts)
- Process for evaluating the plant and determining actual vs. the model.
Maintenance in the cement industry is one of the contributors to the production cost and represent typical 15-25 percent of total manufacturing expenditure.
Many companies have tried using standard production methods to control maintenance cost. This is not effective.
The maintenance can increase profits in two principal ways: decreasing expenses and increasing capacity. Maintenance costs consist of two main divisions, labor, and material. By achieving maximum availability (minimum downtime) and the efficiency of the plant assets, a manager ensures a company does not need to invest in excess assets to produce its products.
- Maintenance represents often the largest controllable operating cost in the cement industry and hence a critical business function.
- Maintenance should be regarded in best practice organizations not simply as a cost to be avoided, but a department that controls the assets of the company with a well organize reliability engineering to a high leverage business function. Over the past years, and still in many current organizations, a challenge for a maintenance department is to reduce or eliminate the reactive maintenance cycle. The goal of each maintenance organization is to increase productivity with the effectiveness of its personnel.
- To achieve the overall maintenance targets, various organizations strive for a Preventive and Condition-based maintenance strategy with a high focus on reliability and pro-active maintenance. This strategy requires a powerful and effective organization supporting all activities in a well-organized method.
Key Maintenance Functions
There are a few key functions in maintenance that must be developed and should be part of an organization to achieve the overall targets and strategy.
- Work execution
- Work supervision
- Work planning & scheduling
- Preventive & Predictive Maintenance / Reliability analysis & continuous improvement
The relationship between cost and amount of preventive maintenance
Maintenance Department’s Goals and Success Factors
- Maintenance management. Fulfillment of maintenance activities
- Reliability debottlenecking. Failure documentation, Root Cause Analyses (RCAs), Maintenance Task Analyses (MTAs), Failure Mode Equipment Analysis (FMEA)
- Process engineering. Identification and elimination of bottlenecks
- Operation costs. Budget monitoring and control, identification of high-cost activities
- Working capital. Optimize inventory, secure stock of critical and contingent spare parts
- Optimize assets performance and availability (Overall Equipment Efficiency, OEE)
- Minimize Total Maintenance Costs
What is the scope?
Is a holistic approach of the Maintenance structure and methodology, to assure equipment and facility maintenances comply to increase operational availability, reliability, life-cycle of the assets and performance as well as to optimize the total costs of ownership.
To know more about MMS implementation