Bakery Plant maintenance management system - part 2

In continuation of my earlier post on bakery plant maintenance  here  are few more elements for efficient maintenance system in medium to large bakeries .

Root Cause Analysis  (  RCA )methods

 The best method  to eliminate  frequent break downs  in plant and machinery is to adopt Root Cause Analysis method .In this method one confronts issues which causes these break down ,better known as why's  method  and finds solution to stop recurrence of  the  fault .

Few general principles of RCA method are

Root cause analysis is  done to find out the root cause of the problem and remove it to eliminate the problem once for all

There should be a systematic approach with documentary support for the fault  and corrective measures

There is always one single root cause for the failures or break down in machinery

For any event or failure to happen there would be sequence of events which  needs to be recorded for better understanding of root cause

from reactive  to proactive approach by adopting root cause analysis for break downs and failures .

  

OEE ( Overall Equipment Efficiency)

Maintenance deptt need to establish OEE of major equipments  and try  to improve upon it or discard it  performs below standard OEE defined by plant management

OEE is a term used for machinery which perform any function during production and it shows manufacturing efficiency of that particular machine

OEE =  Availability  X Performance X Quality   ( %)

Another term used for performance of  equipment is  total effective equipment efficiency  ( TEEP )

TEEP  = Loading x Availability x Quality x Performance (%)

Loading = Schedule time / Calender Time  (%)

Availability = Available time / Schedule Time (%)

Performance =Parts produced * ideal cycle time /  Available time (%)

Quality  = Good Unit produced/ Total unit produced

Change Over Plans
 Its often seen that  bakery plants production  switches from one product to other product as per the sales requirement  which requires swift change over of machines or switching on to different line . These change overs   does  effect  machine efficiency  as change over parts have to be installed trials needs to be conducted for the new product before handing over machine for production . Change overs  cannot be ruled out  as production has to be sales driven  so what best maintenance team  can do is to reduce the time and process seamless for  any change overs .

Following  steps  can be implemented for change overs

• Be aware of production plan  .Do the preparatory work for  change over during regular time
• If possible switch over to dedicated lines for each product   or having idle plant best suits for quick change over . This line can be altered for change over . 
• Keep change parts ready  at  the equipment itself with tags and marks for location and product s
• Train production people to  do the basic  change overs activity

Work shop
A small workshop could help in reducing cost and time for break downs .Workshop with units like drilling , grinding , Cutting machines can help in many ways. Overhauling and repairs can be done in these workshops Its recommended to have one or two workshop on contract for regular major repair work near to factory .

  

Service Contracts

Plant or maintenance deptt can outsource certain non critical plant and machinery maintenance to maintenance contractors or OEMS for a annual or monthly charges . This would reduce the cost of inventory and overheads .Not all equipments  are critical for production such equipments can be given to maintenance contractors on call basis .
Following equipments can be given to  service contractors

DG Set
Air compressors
Pumps
Cooling towers
Fire Hydrant and safety systems
Air conditioning ( Office )
Air conditioning ( Production /Packaging Hall )
Cold Rooms or Storage's
Fork lift
Waste Water treatment plant
Civil and building repair
Electrical repair ( Non -Plant )

Other option with maintenance deptt is to have  service contracts for  critical equipments  such as 
Printers
Metal detectors
Packing machines



Hot work Precautions and Safety

Safety precautions are to be taken during hot work  such as Gas cutting , Welding ,  Erection of heavy  equipments  and Dismantling , Electrical Jobs . These activities not only affect the person doing it but the plant at large ,hence maintenance personnel to keep extra vigil during such jobs . Maintenance personnel need to wear all protective guards against injury   such  as welding screens , goggles , gloves , ear plugs , safety belts  and  electric and fire proof shoes

   

Automated Maintenance

This concept is gradually gaining ground  as this has been successfully implemented in automobile production line . Here the person running the machine is trained in maintenance and repair  so as to eliminate the need of extra manpower for maintenance . If possible bakeries could adopt this practice for over head cost reduction strategies as well reducing delays in maintenance time.

  

Legal requirements for operations

Maintenance deptt needs to ensure that equipments and operation  adhere to local  legal and statutory requirements  such  as

 Air pollution control ( Standards for discharge of smoke )
 Water Pollution  (  Standards for waste water discharge )
 Boiler Safety
 Pressure vessels and lifting devices safety
 Hazardous waste
 Fire safety - Fire hydrant system



TPM  (Total Productive Maintenance )

For bigger bakeries plant needs to implement total productive maintenance system for better results as  operations are on large sales having more than 10- 15 lines at  one locations  would require a fool proof system for maintenance . This could be done through TPM .Methodical and systematic approach to increase production  efficiencies with less break down and maintenance.The aim of productive maintenance is  to maximize plant and equipment effectiveness to achieve the optimum life cycle cost of production equipment.


 
Read more on Bakery Plant maintenance

Bakery Plant Maintenance Management System - part 1

Bakery operations need a very  good maintenance management system for efficient running of plant . Maintenance activity  needs  regular monitoring and records to evaluate  problems and their solution . Bakery maintenance has its own features which need attention apart from  regular maintenance practices .Break down s lower production out put and have to be reduced to minimum .To achieve lower  down time  a robust maintenance system with skilled manpower  are  required .

Major equipments in bakery are Mixers , Ovens , Packing machines , Air Compressors , Material Handling equipments ,Fire Hydrant Systems , Bulk Handling systems ,Grinders ,Motors ,Gear Boxes , Fans , Screw Conveyors , Gears and Chain, Burners  and Sprockets .

A good maintenance system would have following  elements of  maintenance system  in place

Manpower

A bakery  plant would have an engineering head / plant manager / maintenance manager  who is responsible  for all activity  related to  plant and machinery . Depending upon  the size and hours of operation, factory needs to have skilled technicians who would perform maintenance jobs . Planning and scheduling is done with machine history  .Idle time available for maintenance and  requirement of machinery in accordance with production planning .

Manpower requirement varies as per size of the plant  . We can have

Three shift coverage  - 8 hr Shift
Two shift coverage  - 12 hr Shift
General shift coverage - 8/12 hrs

Each shift coverage needs to have  Foreman , Fitters/technician( Elect/Mech )   and Helper s . Now days concept of outsourcing  of maintenance part are being implemented  but this concept is yet to take ground as factories still prefer to have their own maintenance personnel.

Tools
Maintenance  work force requires  all  basic to advance tools to perform their job efficiently . I has been  observed few task which could have been done  are  executed by people from outside as the maintenance team lack latest or basic tools to perform . Training for maintenance personnel by the machine manufacturers / tool manufacturer  should be included  in factory hr programs .

Critical Spare Inventory

A small store  to cater all critical and regular spares   with a person responsible for monitoring /inspection/liaising  for stock out material /indent  with purchase  deptt  is  must for any medium to big bakery plants .Concept  of making spare available  at work station or production hall are popular in many factories.


Predictive Maintenance
This methods utilises  prior diagnosis of any aberration from ideal operations with help of  sensing equipments  through  Inspection .
Heat
Noise
Smell

Equipment used are  Multimeter , Ultrasonic  equipments , Vibration analyser , Decibel Meters ,Infra red  equipments .Now days PLC  based  systems are common hence system health can be checked through various software .

Preventive Maintenance

This is the most common practice for plant maintenance as  this  is based on equipments life  preventive maintenance can be scheduled by number of hours  or  days such as weekly /monthly/half yearly/annually
Preventive maintenance is done with schedules in hand  and  could be planned and required spares could be ordered as per plan .Preventive maintenance main activity can be divided into C-O-T

C  -Cleaning  of equipments .Very Important as majority of break downs happens due to lack of proper cleaning

O - Oiling  or topping  for gearboxes , chain and sprockets , moving parts , lubricating systems .

 T -Tightening of  all fastener which have loosened in operations  or which could  not be done in course of production .

Normally for bakeries  a day is fixed  in a week  for preventive maintenance . Maintenance jobs are listed in the course of the week and all critical repair , replacement and modifications are done on preventive maintenance alongwith regualr maintenance job ( COT )


Break Down Maintenance

Break Down maintenance requires immediate actions as to run the production with quick fix solution or what ever best in that circumstances . Break down maintenance would need to be- re  done when we take preventive maintenance of the equipment. This may require certain by pass , modification and alternation from basic set up.For such type of maintenance skill  and level of experience of the technician comes into  role .Therefore training and seminars must be conducted to improve the analytical and trouble shooting skills of the technicians .





Records  or Log books

Maintenance log book should be filled or written by shift technicians on observations during  break downs such as action taken ,material repalced or repaired  and  job to be done by the next  shift personnel . The log book should be the basis of any major overhaul during  preventive maintenance . Other important documents and records which are to be maintained are

Checklist for equipments

Layout Diagram of Machinery

Operations and Maintenance Book from Manufacturers

Circuit Diagram
Cross Section Diagrams

Safety Precautions during maintenance

These also helps in root  cause analysis  of the problem
Circuits //layout / cross section diagrams  along with Operation and  Maintenance manual to be  kept handy and to  ensure that they are available  for study . This is very important for maintenance activity.

Bakery  Plant Maintenance Management System -part 2 
How to be more productive at work place