Planned Maintenance Services

How would you feel if at the harvest time, you realized that you have put too much effort into your work? Disregarding all contemporary maintenance tools such as SAP products, you might find yourself among a great number of decision makers who had neglected the potential of planned and automated maintenance. In the meantime, top companies which have successfully employed plant maintenance program are losing a lot less time and resources, if any.

The major benefits a company can achieve from PM program are:

• Product quality increase
• Equipment lifespan extension
• Unplanned downtime reduction
• Easy spare parts control
• Maintenance labor costs decrease

When implementing the PM Program, we follow such procedures:

Work instructions creation

Work instruction is a detailed plan containing pictures, drawings and explanations for an operator to show how to perform a process task. According to ISO 9001, it is not obligatory. However, the best practices show that implementing work instructions significantly improves documentation quality. While creating work instructions, we examine plant performance history and its service requirements to predict and prevent machine failure.

Task lists creation

We create task lists for sequential procedures that must be repeated uninterruptedly. With bond connections assigned to all objects, all procedures in the CMMS are scheduled based on their necessity plan (weekly / monthly/ quarterly / yearly, etc.) Tasks are given the following information:

• Performance frequency
• Required number and qualifications of personnel, equipment, and material
• Prerequisites and equipment condition when the task should be performed
• Type of maintenance that should be performed (Predictive/Preventive/Corrective, etc.)
• Procedure number
• Estimated time

In SAP, task lists can be further used in different modules, such as Plant Maintenance (PM), Production Planning (PP), Quality Management (QM) and Project System (PS). In SAP PM, there are three types of task lists:

• General Management task list – includes a cycle of procedures that must be performed within a company.
• Equipment Task List – tasks for separate equipment
• Task list for functional location – tasks for various functions and operations

Task lists are then used for other different purposes, such as serving as an Inspection Plan in Quality Management, helping in Production Planning, or being a standard network in Project System.

Maintenance items

Maintenance plans can be created for equipment classes, groups or each equipment item separately. By virtue of a plan’s adjustability, it can be crafted for particular clients’ needs. The best practice is to develop a maintenance plan for an equipment class and then apply it to all related classes. In case the same equipment is located in different operating environments, different estimations of time, personnel and material are applied.

Maintenance plans

Maintenance plans help to create consistent task lists for all equipment. Each maintenance plan contains different task lists which ensures uninterrupted maintenance and operation of all equipment and processes.

With diligently created maintenance plans, you get estimations of:

• Time and duration of equipment maintenance
• Predicted time of system breach

Depending on the equipment condition as well as business priorities, one of the two types of maintenance is provided.

Time-based maintenance is usually referred to as time- and resource-saving. Despite its costly regular maintenance, it is widely practiced in different industries due to its time-efficiency and uninterrupted equipment functioning.

Condition-based maintenance, on the other hand, helps you to save more time and money by means of providing support only when necessary, thus avoiding unnecessary maintenance. This, however, entails risks of production interruption.

A correctly chosen plan of maintenance reduces life cycle cost and helps you manage your assets more effectively. Therefore, to choose the right approach, we prioritize high risk assets, monitor and identify potential machine failures, and align the best solutions to specific budgets and technologies.

Workload analysis and smoothing

We conduct a robust evaluation of tasks to distribute them in a way that will ensure smooth transition between preventive, time-based or condition-based maintenance. It is important to schedule them correctly, otherwise, a risk of downtime or work overlap may occur.

Lube oil and grease sampling analysis program and optimization maintenance setup

As a part of maintenance, we implement the best practices of equipment lubrication to prolong its life, in such a way significantly increasing your ROI, No matter how effective condition-based or time-based maintenance is, it will fail if lubrication is not done properly.

When dealing with lubrication schedules, we document tasks which include:

• Selection of the most suitable lubricant based on OEM recommendations, equipment environment, technologies, etc.;
• Appropriate inspection and verification, which eliminates the risk of contaminated or incorrect lubricants;
• Proper lubrication storage according to its manual.

As a part of CMMS system development and configuration, Keel professionals have developed Plant Maintenance for 4 drill ships, 16 Jackup rigs, 4 semisubmersibles and 1 onshore oil production facility. We are using the state-of-the-art ERP software SAP S/4HANA for implementing the PM program and can configure SAP Fiori Application to simplify the usage of PM module.