How can you effectively manage plant equipment?

To effectively manage plant equipment in a cement plant, consider implementing these practices: 1. **Regular Maintenance Schedules:** - Establish and adhere to regular maintenance schedules for all equipment. - Conduct preventive maintenance to identify and address potential issues before they lead to downtime. 2. **Condition Monitoring:** - Implement condition monitoring techniques such as vibration analysis, thermal imaging, and oil analysis to detect early signs of equipment wear or failure. 3. **Inventory Management:** - Maintain an organized inventory of spare parts to facilitate quick repairs and reduce downtime in case of equipment failures.

I Plan the work carefully before it goes to starts, ideally using the manufacturer's maintenance instructions or company's SOP, and produce a safe system of work.

Define the Preventive Maintenance plan and work on it. it will helpful to run machine with minimum breakdowns. Proper cleaning & lubrication also much more helpful to enhance the durability of machines.

Planning and considering all aspects of the equipment BEFORE you buy/install is extremely important. This is the foundation and the structure that will set you off on the right foot. If this part is not executed well, it will lead to problems/issues continuously down the line. Some things to consider: - PM requirements, PM schedules, and having all of the necessary materials, tools, and trained personnel to adequately perform routine maintenance, troubleshooting & diagnosis, and complex repairs. - Adequate manning for properly maintaining the equipment. If you purchase an additional 50 of x equipment, do you have the necessary personnel to be able to maintain the added workload of PMs and repairs?

Using the right piece of equipment to carry out a task will avoid unnecessary wear and tear on machinery, as well as assist with completing the job in the best possible way. Suppliers usually should consult with you and advise if you are buying the best piece of equipment for the job on hand, as well as offer bespoke designs and sizes to correctly cater to your needs.

Condition monitoring on the plant rotary and static equipment causes the reliability of each part and increases the lifetime of equipment also make plant has excellent performance.

Set good benchmark points to monitor so you are way ahead of troubles and can prepare far ahead if any disturbing events. And keep teaching and team working by celebrating the success achieved togther

Equipment performance monitoring refers to inspection, analysis, graphing and benchmarking with design data. Data Acquisition: Site field information like vibration, temperature, operation parameters shall be collected with the help of portable device. Analysis: The data from devices need to be analyzed for abnormalities and need to be graphed with respect to the operation curves. Benchmarking: All the plots shall be benchmarked with design graphs and anomalies will be highlighted for further analysis.

One key aspect of maintaining your equipment is the training and capabilities of your maintenance team. I've seen it several times already where your team is not adequately trained or lessons are not passed on shift to shift. This leads to different personnel executing PMs, repairs, and other actions in their own ways and us not having a standardized method. The first key piece is to demand the training, familiarization and accurate technical documents from the supplier/manufacturer. The second key piece is to ensure the ENTIRE team is trained in the same way and using the same procedures.

Continue monitoring, Basic repair, abnormal correction, preventive maintenance, Basic condition monitoring required, identify abnormal imitate repair required.

1.MAKE REGULAR CHECKS Whether you’re using them daily or sporadically, it’s important that visual checks become compulsory with plant machinery. 2.Wear and tear Vibrations when turned on High temperatures when running Loose components 3.LUBRICATE REGULARLY The oils and lubrication used in plant machinery help each component to function properly. Without them, friction can occur which leads to significant damage. 4.SERVICE WHEN STATIONARY Whenever a large machine is being checked, make sure it is in a stationary position and all stored energy has been released. 5.CLEAN YOUR MACHINES Just like you would clean a car, a plant machine needs to be regularly cleaned too. KEEP A MAINTENANCE/REPAIR SCHEDULE

Listen to your maintenance team and schedule repairs when problems are identified. Too many companies postpone basic repairs until they fit into a budget and lose significant profits from lost production. Paying for a maintenance team yet running to fail on equipment with identified repairs needed is a losing strategy.

Reviewing your PM procedures and schedules is an important aspect. Some good practices: Maintaining an audit & surveillance program. Auditing equipment after a PM to ensure all expected procedures were executed correctly. Walkthrough by following up with the maintenance personnel who completed the PM. Performing live surveillances with maintenance team when conducting PM procedures and other major repairs. This will allow you to connect with your team, see where there struggles are and note areas where procedures are not being executed to the standard.

Review your PM strategies. You should actively monitor your equipment but do not want to implement invasive inspections too frequently that can increase the risk of failure by contamination, failure of fasteners and improper reassembly. The better you can monitor equipment condition without disassembly, the better off your company will be and you will minimize maintenance time and production downtime.

You can print work order reports to review information about maintenance work orders. Work order reports can provide the following information: Work order status Detailed or summarized work order costs Project information, including Gantt charts and project status summary Variances between projected and actual work order costs All work orders associated with a particular piece of equipment Work order parts and labor routing information by piece of equipment

It is critical that top management understand the necessity of maintaining equipment over profit declaration. Budgeted maintenance must be adhered to, to ensure equipment remains in good working order. Very often maintenance is overlooked or postponed to benefit bottom line results.