Organized data can add to our understanding of our asset performance This is what GRIHA can do

Maintenance Performance Analysis

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

S. No.

Plant

Equipment ID

Location ID

Equipment Description

Maintenance Type

Maintenance Task List No.

Work Permit Safety No Lockout No

Supervisor

Technicians

Work Start Time

Work Done

Work Complete Time

Man Hours and cost of labour

Spares Used and cost

Total Cost of Maintenance

Tools Used

Safety lockout Closed

work permit closed

Remarks

Griha converts the maintenance history of each equipment to this format If the data is fully available from either log books or the work order details. From this format the following analysis is possible

Plant-wise Analysis
Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

S. No.

Plant

Equipment ID

Location ID

Plant-wise analysis can give comparative maintenance performance between plants. Repetitive failures of a particular type can indicate lack of trained personnel. Key Performance Indicators Plant Availability as %

Equipment performance analysis

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

S. No.

Plant

Equipment ID

Location ID

Searches of one particular ID can add to our understanding of the equipment behavior. Comparing similar equipment can give us insight into the problem area such as location faults, service faults, operational defects, lack of training and others KPI Overall Equipment Effectiveness - OEE

Can the location throw some light?

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

S. No.

Plant

Equipment ID

Location ID

There are particular locations which prove to be adding additional problems to the equipment such as dusty locations, presence of acidic vapors, inherited construction faults, and many others

Descriptive fields
Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Equipment Description

Equipment type

Maintenance Type

This being a descriptive field does not aid analysis unless some standardized texts are used

Analysis by equipment type can give us many clues

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Equipment Description

Equipment type

Maintenance Type

Equpt. Type code if not already available is added by GRIHA and failure analysis type-wise can add valuable input to our trouble shooting capability, particularly with regard to skill levels of the workmen , equipment selection criteria and others

Maintenance type can tell us if we have too many breakdowns

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Equipment Description

Equipment type

Maintenance Type

Maintenance type like Preventive, Breakdown, corrective, condition based etc., are clear indicators of our maintenance work performance. The ratios of one with the others say plenty on our ability to create an optimum Asset Management Strategy KPI PM Effectiveness B/D Vs PM Ratio Condition Monitoring Effectiveness

Training is most important

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Supervisor

Technicians

Work Start Time

Repetitive failures under a supervisor or technician can indicate training needs Repetitive failures are sure indicators of poor reliability

Is our MTTR (Mean Time To Repair)good?

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

Work Start Time

Work Done

Work Complete Time

Duration of work computed from start and completion time indicates the time to repair. MTTR, Mean Time To Repair is an important performance measure. This can lead to strategic decisions on improving repair facilities or adding Rotables The average run time between failures is MTBF, a very important measure of the reliability of the equipment

Description of the work done

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Type Task List No. No Lockout No Supervisor Technicians Work Start Time Work Done Work Complete Time Man Hours and cost of labour Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout work permit Closed closed Remarks

Work Start Time

Work Done

Work Complete Man Hours and Time cost of labour

The description of the work done is the backbone of our analysis. Supervisors and technicians have to be trained to include all relevant facts to facilitate complete analysis and effective decision making which is crucial to asset management

Crew Size and Cost of Maintenance

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Type Task List No. No Lockout No Supervisor Technicians Work Start Time Work Done Work Complete Time Man Hours and cost of labour Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout work permit Closed closed Remarks

Work Start Time

Work Done

Work Complete Man Hours and Time cost of labour

Key input to determine the crew size and reduce the Mean Time To Repair MTTR Cost of labor is key to the economics of asset management Forms a significant part of the total cost of maintenance

Spares Consumption Analysis

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Type Task List No. No Lockout No Supervisor Technicians Work Start Time Work Done Work Complete Time Man Hours and cost of labour Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout work permit Closed closed Remarks

Spares Used and cost

Total Cost of Maintenance

Tools Used

Safety lockout Closed

Cost of Spares used is another significant factor for the total cost of maintenance Repetitive consumption of a particular component can trigger investigations on component life/ procurement source/maintenance requirements

Total Life Cycle Cost and Replacement Planning

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Type Task List No. No Lockout No Supervisor Technicians Work Start Time Work Done Work Complete Time Man Hours and cost of labour Spares Used and cost Total Cost of Maintenance Tools Used Safety lockout work permit Closed closed Remarks

Spares Used and cost

Total Cost of Maintenance

Tools Used

Safety lockout Closed

Helps Planning THE Most Important criteria for assessing cost effectiveness of maintenance Will play a major part in the Total Life Cycle Costing of the asset Replacement decisions are based on this analysis KPI Cost Maintenance Vs Budget Vs Replacement Cost of Equipment

Failure Analysis is key to successful asset management

Date Plant Equipment ID Location ID Equipment Description Maintenance Maintenance Work Permit Safety Supervisor Type Task List No. No Lockout No Technicians Work Start Time Work Done Work Complete Time Spares Used Tools Used Safety lockout Closed work permit closed Reason for failure - indicate failure code Remarks

work permit closed

Reason for failure - indicate failure code

Remarks

The single most important data for analysis. MAINTENANCE IS NOT COMPLETE UNLESS WE KNOW WHY AN EQUIPMENT FAILED AND TAKE CORRECTIVE MEASURES TO AVOID RECURRENCE GRIHA uses standard failure codes