MAINTENANCE IN THE CEMENT INDUSTRY
Time：2021-07-12
MAINTENANCE IN THE CEMENT INDUSTRY
Maintenance in the cement industry is one of the contributor of the production cost and represent typical 15 – 25 per cent of total manufacturing expenditure. Many companies have tried to use standard production methods to control maintenance cost. This is not effective. The maintenance can increase profits in two main ways: decreasing expenses and increasing capacity. Maintenance costs consist of two main divisions, labor and material. By achieving maximum availability (minimum downtime) and efficiency of the plant assets, a manager ensures that a company does not need to invest in excess assets to produce its products.
The objective of maintenance is not only to prevent the plant machinery and equipment from failure and breakdowns, increasing reliability, maintainability, and availability of the operating system for maximizing production, but also to improve quality and boost higher productivity through improving capacity, faster and more reliable throughput, reducing inventory, and lowering operating cost.
The Cost and Benefits of Maintenance
The cement manufacturing is continually shifting with new technologies and standards being swiftly developed. Companies create competitive advantages using their knowledge, skills, supply chains, and processes to create greater products at lower prices. In such a competitive environment, efficient machinery maintenance methods can mean the difference between a thriving profitable company and one that loses money and sales.
Maintenance Organization
Maintenance is 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 control the assets of the company with 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 reduce or eliminate the reactive maintenance cycle. The goal of each maintenance organization is to increase productivity with the effectiveness of their personnel.
To achieve the overall maintenance targets, different organization strives 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
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 Effectiveness, OEE)
Minimize Total Maintenance Costs
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