The Engineering Department’s prime responsibility is to optimize plant reliability so that the company achieves its planned production, sales and cost targets. This is achieved by implementing asset management systems that maximize the utilization of production and supports equipment to ensure optimal plant safety, operation and utilization.
The computerized maintenance management system (CMMS) software facilitates the key functions of planning and scheduling of all maintenance activities, the logging of predictive and fixed time inspections feedback, details of maintenance work done and equipment failure statistics. The analysis of this information assists in identifying corrective actions to continuously improve the plant reliability.
Predictive maintenance is a key component in the “maintenance mix”. It enables the identification of failures before they occur, as well as carrying out maintenance on equipment only when it is required. This in turn allows planning the required corrective actions with minimum disruption to production.
Key performance indicators such as net availability (NA), overall equipment efficiency (OEE) and mean time between failures (MTBF) and Maintenance costs are periodically analysed, gaps identified and further actions for improvement are identified and implemented. Plant reliability improvement and optimization is carried out continuously.
Shutdown maintenance is planned throughout the year and carried out annually for between 2 to 4 weeks per annum depending on the nature of the shutdown. This shutdown is also necessary to enable scheduled statutory and non-statutory major repairs which are due as well as those identified through predictive maintenance and fixed time planned inspections. This ensures that the plant runs with minimum interruptions between each annual shutdown.