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Organic Maintenance 4.0 – 3

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Organic Maintenance 4.0

It includes,

  1. Development of OM 4.0 – We Design & Establish this systematic maintenance system, OM 4.0, at your plant, covering entire plant & machinery.
  • Audit of existing System
  • Criticality Analysis & Categorization all equipment into 3 categories, PdM, PRM & FFR
  • Machines under Predictive Maintenance (PdM) & CBPM
  • Machines under Proactive Reactive Maintenance (PRM) – TBPM & RBPM
  • Machines under Fire Fighting Repair (FFR)
  • Coding & Tagging machines under PdM
  • Development of PdM Strategies,
  • Development of CBM strategy for selected machines
  • Development of CM strategies for Remaining machines
  • Development of Manual CM Strategy
  • Development of Real Time CM strategy
  • Development of PRM strategies
  • Development of Autonomous Maintenance Strategies
  • Development of Condition Based Preventive Maintenance (CBPM) Strategy
  • Development of Time Based Preventive Maintenance (TBPM) strategy
  • Development of Run Based Preventive Maintenance (RBPM) strategy
  • Satisfactory Implementation, Execution of all strategies

 

2. Condition Assessment (CASS) Services – It is always necessary to assess the present condition of each & every equipment, Restore it to best condition (CAPA) & then start CBM or CM. Condition Assessment is 1st step of the implementation process.

 

3. Condition Based Maintenance (CBM) Services –

CBM = CM + PM + RCA + CAPA

CAPA – Corrective Action Preventive Action

We start with Condition Monitoring & after identification of any problem in trend analysis, RCA will be done. CAPA will be taken on the root cause in order to restore equipment back in its best condition.

  • CBM of Bearings – CM + Acoustic Greasing + Replacement of Bearings
  • CBM of Compressed Air Lines – Condition Assessment + Repair/ Replacement of pipelines, valves, joints, bents etc
  • CBM of Motors/ Pumps/ Gearboxes
  • CBM of Electric panels
  • CBM of Steam Traps
  • CBM of Heat Exchangers

4. Condition Monitoring (CM) Services –It is basically a Trend Analysis. We monitor condition of equipment & keep the trend under surveillance.

Equipment not covered under CBM comes under CM, for example,

  • CM of Compressors
  • CM of Furnaces/ Refractory/ Boiler
  • CM of Handling Equipment like Crane/ Conveyor Belt/ Earth Moving Equipment etc

 

5. Periodic Condition Assessment Services (Periodic CASS) – It do not contain Trend Analysis, like in CM. It is periodic assessment of condition in terms of faulty or OK of equipment.

  • Periodic CASS of Transmission Lines
  • Periodic CASS of Electric panels
  • Periodic CASS of Transformers

 

6. Real Time Condition Monitoring System (RTCM) – Supply, Installation, Commissioning – We will identify the need, design RTCM for listed equipment, supply hardware & software, install the system as per design & carry out satisfactory commissioning of it.

 

7. Rectification, Modification, Optimization –

Rectification – It is CAPA and Repair work that needed to restore the condition of equipment to its best.

Modification – It is of 4 types,

  1. Modification for Condition Monitoring Provisions
  2. Modification for Preventive Maintenance Provisions
  3. Modification for compatibility with Operating Condition
  4. Modification for compatibility with Environmental Conditions

Optimization is redesigning the equipment to get optimized results.

 

8. Trainings – These trainings are of 2 types,

  1. Training in OM 4.0 to selected maintenance team members
  2. Training in Level 1 Certification Coarse as per ASNT Guidelines in,
  • Vibration analysis
  • Thermography,

These trainings are in order to make Maintenance Team self reliable after our exit.

9. Supply of Equipment – These are CM equipment like Vibration Meter, Thermal Camera & Ultrasound Equipment in order to carry CM after our exit.

 

10. Supply of Manpower – Level 1/ Level 2, experts in VA & IRT

 

11. Energy Audits (Future Addition)

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