Organic Maintenance 4.0 Solutions

Organic Maintenance 4.0 – Solution – The Asset Integrity Management Program

OM 4.0 solutions are a complete solution of Uptime Management for your company. Under OM 4.0, we develop an AIM (Asset Integrity Management) strategy for all the equipment/ machines/ infrastructure in your company, implement the strategy successfully by teaming up with your maintenance engineers, train your maintenance team in a state of the art maintenance techniques & then exit your company by handing over the maintenance program to your maintenance team.

The aim of this AIM (Asset Integrity Management) program is to,

1. Increase Uptime by reducing unwanted functional failures in production machinery.
2. Establish ultimate maintenance culture in your company – More Maintenance Less Fire Fighting Repairs
3. Reduce your expenditure on maintenance
4. Achieve Zero Accidents in your company
5. Reduce Energy Losses
6. Improve Machines/ equipment’s life
7. Improve Product Quality

There are 5 stages of OM 4.0,

Establishment of OM 4.0

• • Introduction of Concept
  • Data Collection (Listing all the machines/ equipment/ Infrastructure in the plant)
  • Segregation of all equipment under three groups, PdM – PRM – FFR
  • FMECA

Development & Implementation

• • Development of PdM/ CM Strategies
  • Development of PRM strategies
  • Development of TBPM/RBPM strategies
  • Development of Autonomous Maintenance Strategies
  • Designing Real Time Condition Monitoring System, Supply of hardware, Installation & commissioning
  • Implementation of these strategies successfully

Exit

• • Training to your maintenance engineers in CM Techniques like Vibration Analysis, Thermography, Ultrasound Analysis
  • Selection of Analyzers/instruments suitable for CM of your plant (Cheaper & effective models)
  • Handing over the Maintenance Program & Exit

After Exit

• • Data Analysis support whenever required
  • Yearly/ Half Yearly Audits of Implementation of Maintenance Program
  • Support in Procurement of New Machinery
  • Support in Installation of New Machinery

Before Exit (During Contract Period)

• • Support in Procurement of New Machinery
  • Support in Installation of New Machinery

Figure 1 herewith is a PIPF Curve and representing Organic Maintenance 4.0. Our OM 4.0 services are based on this PIPF Curve.

The basic model of OM 4.0 includes Procurement Support, Installation Inspection, I – P Interval of the Curve & I – F Interval of the Curve.

OM 4.0 covers the entire plant & machinery in any type of company. It reduces the heavy expenses and longer implementation time as in RCM & TPM.

OM 4.0 is a soigné blending of Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM), & Business Centered maintenance (BCM). OM 4.0 has the best things from RCM, TPM & BCM and over to it something more than it, a practical approach.

If you think of RCM & TPM, the most popular concepts in today’s time, didn’t go beyond Preventive Maintenance. They are although great concepts of their time, RCM & TPM are outdated concepts today. Really speaking these concepts are more theoretical, remain on paper & takes years to implement and hence, abortive. The results after implementing these concepts are not really lucrative. These concepts were innovated in the 1970’s decade and till 2020 the scenario of maintenance management is moved further to Prescriptive Maintenance.

The major difference between these concepts & OM 4.0 is the implement ability. OM 4.0 is the most practical solution today, covering almost all parts/ sections of maintenance & easily implementable. OM 4.0 starts at plant & machineries whereas RCM/TPM starts at conference room/training hall & mostly ends there. OM 4.0 is a practical approach towards maintenance, whereas RCM/TPM is moreover a theoretical approach. OM 4.0 starts with development & implementation of maintenance strategies, whereas RCM/ TMP remain till consultation of the concept. OM 4.0 can be implemented in a year or two but it takes many years to implement RCM/TPM.

Organic Maintenance 4.0 gives a guarantee of results. A company starts getting benefits of implementation of OM 4.0 within a couple of years of implementation. If you are interested in knowing more about Organic Maintenance 4.0, please write to us.

Let us have a look at some of the major points in OM 4.0,

Our Engineers & Instruments

While under the implementation of the OM 4.0 maintenance strategy, we give support of our Level 1, 2, 3 certified Vibration Analyst, Thermographer, Ultrasound Analyst & Oil Analyst and our state of the art instruments, Vibration Analyzers, Infrared Thermal Cameras, Ultrasound Analyzers, Motor Current Signature Analyzer (MCSA), Tan Delta & Capacitance Testers, Hi-Voltage Testers, Surge Comparison Testers & Oil Analysis Machines.

Exit Policy

We have an exit policy. After getting the strategy properly implemented, we leave your company by parting training to your selected maintenance engineers & by supplying you the required instruments.

Certification Training

We part Level 1 certification training in Vibration Analysis & Thermography to your maintenance engineers & handover the complete process to them. The certification course is as per ASNT SNT TC 1A guidelines.

Supply of instruments

We select the best-suited instrument (Vibration Meter, Vibration analyser, Infrared Thermal Camera, Ultrasound Instrument) for you and supply you those. The selection is based on the real practical requirement looking at your machinery/ equipment needs & the lowest possible prices.

After Exit

After exit, we continue the following support to your company,

Analysis of the data (Vibration FFT graphs/Time Waveforms, Thermograms, Ultrasound Graphs) given by your – Your maintenance team engineers may face problems in analyzing vibration, thermography data collected during Condition Monitoring. They can send that data to us and our experts will do the analysis and send you the report.

Half Yearly/ Yearly Audits of system implementation – The implementation of the strategy will be audited on half-yearly/ yearly basis. There may be a requirement of changing the strategy/ part of the strategy or further training to your engineers or need of any instrument, that gap would be found out in an audit & changes will be suggested.

Manual Periodic Condition Monitoring Services (CM) – There may be a requirement of manual CM services to you, might be because of the shortage of manpower or requirement of higher skill to you, in CM of few of the machines/equipment. We render these services as required by you on a yearly contract basis.

Condition Based Maintenance Services (CBM) – There may be a requirement of CBM/PdM services to you, might be because of the shortage of manpower or requirement of higher skill to you, in CBM of few of the machines/equipment. We render these services as required by you on a yearly contract basis.

Supply & installation of Real Time Condition Monitoring System – Even after development & implementation of OM 4.0 strategies at your entire plant, there may be further need of Real Time CM system for some of the existing machines or new plant. We will supply & install RTCM system as per your requirements.

Modification & Optimization of the machines – We will keep giving you the support in modification & optimization of your machines/ process/ equipment, as per your requirement, as and when required.

Root Cause Analysis Support – You may face failures of machines/ equipment or processes. We will be rendering Root Cause Failure analysis support as per your requirement to find out the exact cause in order to save the machine/ equipment/ process again from functional failure.