MAINTENANCE ASSESSMENT
We analyze your maintenance data
Measure maintenance work flow & management
Measure present levels of proactive and reactive maintenance
Identify gaps between current status & objectives
Suggest a revised maintenance methodology to fill gaps
RELIABILITY CENTRED MAINTENANCE - RCM
Determine your equipment maintenance strategy by a structured & scientific approach
Determine equipment criticality, function, functional failure, failure modes & failure consequences
Eliminate unnecessary invasive maintenance, choose condition-based maintenance over time-based maintenance where appropriate
Reduce hidden failures & safety related failures
RISK BASED INSPECTION - RBI
Assess your equipment to deliver
Inspection plans optimization based on individual damage mechanism
Operational boundaries definition, which prevent unexpected equipment damage mechanisms / rates
Risk mitigation measures and other actions to safeguard integrity
Plan to shift resources to provide a higher level of coverage on the high-risk items and an appropriate effort on lower risk equipment
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INVENTORY ANALYSIS
Review catalogues
Review procedures
Review stocking policy
Fast / Slow moving, Insurance & critical spares
Shelf-life & ageing analysis
Lead time
Ordering and carrying cost
Stock-out cost compared to Stocking cost
Identify the risk associated with not stocking the item
Commonize / Generalize, Standardize and reduce variety
Review Vendors
Review IT / Technical support to Materials / Maintenance
Develop / Document correct procedure / methods
SPARE PARTS INTERCHANGEABILITY
Review initial spares (for new projects & expansion) and recommend two years' operating spares based on
Criticality
OEM components / Indigenous availability
Wear parameters
Mandatory renewable spares
Repairable / machinable items
Identify equipment / component interchangeability within the system / plant
CATALOGUING
Classify and group your material database by their common function/applications
Cleanse, extract attributes and standardize the data
Analyze duplicates and De-duplicate
Enrich and enhance your data
Review Data Consistency & Standards
Perform quality check
Export data as per your format
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CMMS IMPLEMENTATION
Help you select the best ERP / CMMS depending upon the budget, usage
Help implement CMMS
Migrate / input initial data CMMS
Master tag list preparation
Criticality analysis
Data population (if Maximo - Equipment, Inventory, Preventive Maintenance, Plans, Labour and Resources
Maintenance strategy build
1. Assess current maintenance strategy
2. Compare with best in class to identify the gap
3. Revise strategy
4. Define Key Performance Indicators (KPI)
5. Establish maintenance performance monitoring
ERP - PM/MM IMPLEMENTATION
We provide implementation support for Maintenance and Materials modules of ERP's like SAP, JD Edwards, Peoplesoft, Baan etc.
Migrate / input initial data in ERP / CMMS
Master Tag list preparation
Criticality analysis
Data population
1. If SAP - Technical objects, Bill of Material & PM
Planning
2. If Maximo - Equipment, Inventory, Preventive
Maintenance, Plans, Labour & Resources
Maintenance strategy build
1. Assess current maintenance strategy
2. Compare with best in class to identify the gap
3. Revise strategy
4. Define Key Performance Indicators (KPI)
5. Benchmarking
6. Establish maintenance performance monitoring
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