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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 Organization

  • 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
  • Management

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.

Cement plant

To know more about MMS implementation