What steps can you take to develop a maintenance plan for a new plant?

In addition, maintenance plan for reliable operation must define critical plant equipment, losing any of them means losing plant production. To define maintenance objectives, company or specifically operation strategy has to be defined and used as clear reference while defining maintenance objectives.

Developing a maintenance plan for a new plant involves several key steps like; 1.Asset Inventory 2.Risk Assessment 3.Maintenance Strategies 4.Scheduling 5.Training programs 6.Documentation 7. Spare Parts Management 8.Condition Monitoring 9.Budgeting 10.Continuous Improvement

Apart from manufacturer recommendations, historical data, and industry best practices following things to be considered. -Perform a criticality assessment to identify the most crucial assets for the plant's operation as well as legal/environment. Prioritize maintenance efforts based on the criticality of each asset. -Conduct a risk assessment to identify potential hazards and failure modes associated with each asset & develop mitigation plans to reduce or eliminate identified risks, considering operational, safety, legal & environmental consequences. -Develop detailed maintenance SOPs highlighting safety precautions, particular tools and tackles, and any special considerations or permissions.

Planning maintenance needs a lot of input, for a new plant, early equipment management is what is suppose to be the focus at this point. Getting a well developed FMECA serves as a reliable input coupled with the recommendation from OEMs is a good start. Also note that spares availability of a new plan should be factored as you can not plan a maintenance without resources.

Building effective maintenance strategies begins with aligning Business Objectives and Operations objectives. By understanding operating patterns and market dynamics, we can shape Maintenance Objectives to create a synergy known as Business-Centered Maintenance. This approach ensures maintenance efforts are directly tied to broader business goals, fostering efficiency and sustainability.

For new plant listing out all single point failure equipments is important followed by frequent inspection at regular intervals to analyse data collected to eveluate the equipment health to plan outage for maintenance to avoid emergency conditions, for non single point failure need to follow OEM recommendations

Defining the criticality of the equipment properly at the beginning helps you focus the resources correctly (time, manpower, budget) from the start

Agree, using an Asset Criticality exercise you determine a baseline of your equipment from there you can determine the correct maintenance strategy and put the right maintenance resources to the right assets from there break down the fault modes from the critical assets to create good PMs also add which PdM technologies to use on the most critical . Another benefit from the Asset Criticality is now you can tie it into your MRO for critical parts to stock.

"To develop a maintenance plan for a new plant, start by identifying assets or equipment, scheduling regular inspections, creating preventive maintenance tasks, setting up a tracking system, and establishing emergency response protocols. Regularly review and update the plan to ensure its effectiveness."

- Asset criticality assessment is one of the first steps in developing a robust maintenance plan. Defining the criticality of assets upfront will help you decide where to direct your resources effectively to achieve top-notch equipment reliability with minimal cost. - Identification of assets for Condition monitoring. you cannot apply online condition monitoring tools on all equipment as it is costly and time-consuming. As a Reliability engineer, you should analyze which equipment is ideal for applying condition-based maintenance and which equipment can be managed with PM/Time-based maintenance. Collecting the above data will help you in avoiding the cost of CBM tools, reducing inspection time and human resources.

Think about this. If you perform an RCM study of your assets and their placement/function in the process and their criticality to the process and the consequences of the various potential failure modes you will have the basis for the specific maintenance strategy for that particular asset and its function within the system/process, and the level of resources (labor and materials) will be required to complete that defined strategy. Of course those strategies/tactics will need routine review and adjustments as you learn more about your strategy choices and their effects. Doesn't that RCM process cover just about everything, PM, PdM, CbM, Basic Care, RTF. A single process for defining the best strategy for each asset. What more is needed?

Suitable maintenance strategy can be selected by the help of FMEA analysis. After the potential failure had been identified, the suitable maintenance strategy can be planned.

Além de escolher a estratégia de manuten??o adequada ativo é preciso que ao longo do tempo a estratégias de manuten??es sejam ajustadas, pois a eficiência do ativo tende a baixar conforme a vida útil do equipamento, diminuindo a disponibilidade e a confiabilidade, o acompanhamento do ativo e ajuste adequado da estratégia de manuten??o ao longo do ciclo de vida proporciona a manuten??o da eficiência do equipamento.

Based on urgency and importance which affecting efficiency, effectiveness those are things to be resolved firstly Keeping in eyes Customer relationship at top priority.

1. Ensure each Stakeholders is given thorough training on respective jobs and Machines. 2. Ensure Proper repair tools, measuring tools and calibration tools are available with Concern Stakeholders. 3 Overall effectiveness equipment implemented. 4. Roles and responsibilities are clearly defined. 5. RACI matrix implementation is a must 6. All perform activities must be recorded and reported to Stakeholders and also perform activities are recorded in log books

Durante a cria??o dos planos de manuten??o é preciso calibrar as periodicidades das inspe??es, que podem ser dias, semanas, horas, km, etc. Depende da característica de opera??o de cada ativo.

The NFPA has a great starting point for preventative maintenance and the required periodicity. I also find if you take the failure rate and would backward, you can find the most efficient replacement criteria to prevent breakdown.

For your plan to be executed as planned, you must implement an efficient scheduling and execution process. If you do not have an efficient execution plan, your maintenance plan will not deliver the expected results. For most industrial sectors, like O&G, Power generation, utilities, manufacturing, etc., the multi-week scheduling process is the most efficient way to ensure the maintenance work will be performed on time according to your plan. It must be an end-to-end process, to deliver the expected value.

Implement plan and see what variation is observed against the given plan when in actual activities are performed. Implementation of Plan strategies very precisely is an important ask as within Implementation we can not achieve our requirements.

Sin duda es un gran desafío mantener una planta en la mejor disponibilidad pero también es importante mantener, La confiabilidad, confiabilidad de equipos de trabajo, equipos mecánicos, equipos humanos, donde el compromiso esté bien definido que mientras los equipos trabajen a su mayor capacidad, mejor será para la empresa y se podrá siempre estar más seguros, así la confiabilidad se mantendrá en los mejores estándares. Para bien del negocio y de las personas.

It is great to see training take the forefront of this process. If the technician does not understand what is asked, they will not succeed. The first time they go to perform a maintenance item is when the mindset of usefulness is set. DO NOT miss the first impression.

Um enorme desafio para implementar os planos de manuten??o de um novo equipamento, é adequar as paradas de manuten??o de acordo com os processos de produ??o, além disso é de suma importancia o treinamento de toda cadeia de manuten??o e opera??o, pois é preciso manter a eficiência do equipamento e otimizar produ??o.

Assets continuous improvement by plan through documentation ensures that our maintenance plan evolves effectiveness recorded for analysis and future reference. By feedback on maintenance tasks, performance matrices - KPIs, digital documentation CMMS, real time performance data, cost projections review and update regularly as well as considering other factors to track. As maintenance plan expands, consolidate accurate documentation ensures that these changes are recorded, replicated, and used to improve future planning cycles/strategy.

Podría, pedir feedback de sus clientes, Operarios, para complementar y la información de diario, comparada con las pruebas puntuales que se hacen, en cada mantenimiento preventivo, correctivo, así como monitorear el deterioro natural de los equipos, por ejemplo al inicio se hacen planes de servicio o mantenimiento de un equipo nuevo, pero por muy buena planeación servicios que se ejecuten al pie de la letra del fabricante, siempre habrá una pérdida de eficiencia, resultado del desgaste natural de los equipos, entonces ahi es donde opino que entra la opinión de los operarios, que revisan los equipos a diario.

Os planos de manuten??o de vem ser acompanhados e ajustados ao longo do tempo, pois sempre existem oportunidades de melhorias e ajustes ao longo do ciclo de vida do ativo, pois os modos e as taxa de falhas dos ativos tendem a aumentar ao longo do tempo.

The key to developing practical technical strategies is to not get caught up in the various tool sets and processes. Do not lose sight of the basics. 1. Do you know all of the equipment you have? 2. Do you know why it is important? 3. Do you know how it will break? 4. What are you going to do about it?

é importante treinar regularmente as equipes de manuten??o e opera??o afim de garantir as melhores práticas de manuten??o e manter o ativo funcionando dentro dos parametros esperados por todo o ciclo de vida do ativo.

Utilizing your CMMS is critical. Develop teams to use CMMS classifications correctly. Will help with reporting down the road.

Ensure your maintenance strategy and maintenance plans are practical and align with the resources available i.e people and budget. A good maintenance plan identifying critical assets can be used as a bottom up approach to gaining additional resources to complete effective maintenance

For the maintenance plan to succeed you must know properly your assets and follow the suppliers manual requirements. Involve your machine operators in the maintenance plan and train them accordingly on each asset as the maintenance plan may differ from one asset to another. Follow downtime failure history cards in executing your maintenance plan