Maintenance Management.

Transcription

1 Maintenance Management

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3 What we do Tekna Ltd provides a TOTAL outsource option for maintenance management of process equipment and factory assets. The service can be provided completely offsite. All hardware, software, administration, document generation and archiving are taken care of. The extent of the outsource service is completely bespoke and can be varied in line with client requirements. Consultancy, strategy, advice and support are also available as a service. Tekna are based in the North East of England, providing a cost effective solution for companies throughout the UK.

4 The concept Good proactive management of assets will always relate to effective maintenance of the facilities and equipment. At the heart of an effective maintenance program is a large administrative burden. Large quantities of data are gathered. Many schedules, plans, and documents are produced. Data and results are generated and recorded. Records are archived and stored. Reports are produced and actions taken. Specialised computer databases make the recording and planning simpler and faster. However these systems are often expensive and require considerable training or experience to set up initially. They also need ongoing IT and administrative support for effective operation. The outsourcing of maintenance management to an offsite location is a new and unique approach, made possible by the development in IT and web based software. It is possible to outsource the whole process to Tekna Ltd

5 Factories Production Lines Equipment

6 Components Issues When was the air filter last changed? Is the motor in a hazardous area? When was the motor inspected? Is the pressure vessel logged with the insurer? When did the insurer last inspect? Has the relief valve ever been lifted? Do we have certificates - inspections & tests? When are the next inspections and tests due? Have faults and failures been recorded? Is there a maintenance history available? Does the maintenance comply with legislation ATEX, DSEAR, PV regs, cgmp?

7 Typical CMMS system Computerised Maintenance Management Equipment Data Legal Requirement Service Requirement Service Records & Data

8 Tekna maintenance management service Process and manufacturing industries face a growing burden in relation to the regular servicing and maintenance of all items of plant and machinery. Tekna Ltd provide a complete outsource solution for effective maintenance management The maintenance management centre is located offsite. The overhead is shared across several clients providing a cost effective solution Fully computerised maintenance management (CMMS) can be provided from an offsite location with web based access if required. Hardware, software, printing, archiving and back up issues can all be cost effectively outsourced.

9 Maintenance cycle Equipment CMMS System Reports & Status Maintenance Contracts Schedules Records

10 The motivation Effective maintenance of plant and machinery used in the process and manufacturing industry is becoming increasingly important. Drivers Legislation - HSE, cgmp, COMAH, ATEX Cost unplanned stoppages can incur excessive cost Damage limitation failure of a critical item can pose a threat to personnel and business performance Productivity preventative rather than pro active maintenance reduces downtime Audit trail Complete records are required by ISO standards. In addition the data assists greatly with failure analysis, external authority inspections and incident investigations

11 If this was yours Would you wait until it broke down?? Would you know...? when to service? Would you expect a good standard? d?? Would you keep good records??

12 The process There are 5 basic steps leading to a satisfactory implementation:- Step 1 Step 3 Options Site survey Realistic selection of options and level of assessment of clients current support to achieve requirements status. Step 2 Gap analysis client requirements vs current status. Step 4 Implement Supply of the agreed requirement against a budget and timeframe Step 5 Administer Ongoing maintenance management Following satisfactory initial discussions Tekna are happy to undertake Step 1 free of charge and assist with possible funding and support for Step 2.

13 Site Survey Gap Analysis Options Implement Administer What equipment is installed What maintenance systems are in place What records currently exist What maintenance contracts are in place What level of resource is available Current level of training, co ordinations & understanding Site Tekna Contract Legal compliance Hardware Good Engineering g Practice. Industry Norm Support New legislation issues ATEX/ DSEAR Software Technology issues IT Support systems, IT policy, Web Training Issues IT Web literacy, cultural change, Support Web system awareness, documentation Setup and Data Entry requirements Management requirements Support and expectations Admin System options Cost options Training Recommendations Reporting Maint Contracts Deliverables based on Gap analysis, and selection of options Supply agreement and contract Detailed Project plan Agree timelines GANTT chart Milestones Target Dates Resource requirements Progress reports and project status Monthly production and delivery of maintenance schedules, service records and maintenance documents Scanning and archiving of all completed records Database update and management Reporting of maintenance progress against targets 6 monthly Interim status and performance reports 12 Monthly Annual status and performance reports Annual review and presentation to senior management Recommendations Review and update of maintenance requirements in line with revisions, change, legislation and client policy Maintenance Support Support

14 Portfolio Lundbeck Seal Sands Effective Maintenance management was implemented at Lundbeck by Phil across a 14 year period. Fully computerised systems were employed across three factory units and four utility areas. Over 3000 items were identified, scheduled and planned for service. At peak over 5000 individual service records were generated and completed annually. The extensive record keeping and data storage systems were inspected many times by several external bodies - HSE, EA, MHRA, FDA. Lundbeck UK never received a single observation or improvement notice relating to maintenance across the entire period. Background Phil Baines director and founder graduated from the University of ork in He initially worked with several large chemical and processing companies across the UK with an emphasis on new technology and automation. In 1994 he Joined Danish pharmaceutical company Lundbeck and was centrally responsible for the rapid growth, management and development of the UK site and facilities. In 2008 he left Lundbeck and set up Tekna Limited.

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16 Tekna Limited 2 Reed St Gladstone Ind. Estate Thornaby, Stockton on Tees, TS17 7AF Phone Fax pbb@tekna.uk.com Registered in England and Wales No: Vat registration no: