Maintenance Services

The Maintek Group specializes in providing first-class maintenance programs for heavy equipment and vehicles used in the mining, oil and gas industries, in Indonesia. The Maintek Group also provides infrared thermographic inspections for timely detection of hazardous electrical infrastructures, CMMS maintenance software and programs for breakdown, planned and proactive maintenance services.

 

 BASICALLY THERE ARE THREE TYPES OF MAINTENANCE.

  • Breakdown Maintenance. Also known as "Run to Fail" (Repair only when the breakdown occurs).
  • Planned Maintenance (Plan ahead for the repair and servicing by calendar time, hours of use or unit of measure eg. kms).
  • Proactive/Condition Monitoring Maintenance (Monitoring condition of equipment in anticipation of possible breakdown).
     

Breakdown Maintenance is the least expensive to implement but very expensive in terms of equipment availability (down time), spare parts and equipment replacement. CATERPILLAR estimate that a breakdown repair as opposed to a planned repair will on average be two thirds more expensive.

Planned Maintenance is good for general maintenance or servicing such as oil changes, greasing, regular adjustments and so on. It can also be used satisfactorily for other maintenance tasks such as planned overhauls, where there is a good strong knowledge that certain parts will require replacement after a certain number of hours of operation. The down side of strict planned maintenance is that in some cases a component or piece of equipment will be overhauled when there is still many hours of serviceable life left causing unnecessary down time.

Proactive/Condition Monitoring Maintenance is ideally suitable for critical major items of equipment and components and can be achieved by using online monitoring or regular checks.

 

The right MAINTENANCE PROGRAM to have is a CONTROLLED COMBINATION OF ALL THREE SYSTEMS.

  • Breakdown Maintenance would be used for minor or not so important components or equipment. For example if there is a breakdown of minor components or equipment a major problem to production would not result and unsafe conditions or environmental damage would not be an issue.
  • Planned Maintenance would be used for nearly all the general type of maintenance or servicing tasks and also for overhauls where suitable.
  • Proactive/Condition Monitoring Maintenance would be used for all of the major or critical pieces of equipment and components. Equipment and components that, should they breakdown, may have a serious effect on production, produce unsafe conditions or result in environmental damage.  

 

  • INFRARED THERMAL IMAGING (THERMOGRAPHY):

Infrared thermal imaging (Thermography) is a tool used to check the condition of installations and assets where a change or difference in temperature indicates fault or failure. Thermography is primarily used on electrical installations (panels, circuits, connections, high voltage transmission, transformers and so on) but is also extremely effective on rotating equipment (detects overheating bearings, misalignment, gearboxes and so on), pipeline condition and much more.

Maintenance departments use thermography as part of their proactive maintenance (condition monitoring) regime. Thermography is NON-INTRUSIVE, other methods used to check the integrity of electrical assets can introduce faults and failures.

The implementation of thermography into a company’s maintenance routine is extremely cost effective as production is not stopped or reduced during the survey. The advance warning of a fault can prevent the cost involved from an unscheduled shutdown and in extreme cases can prevent loss of life or total asset destruction through fire. 

 

  •  MAINTENANCE PROGRAMS:

A program designed to maintain a fleet of equipment could be called a Fleet Maintenance Program. For a factory it may be called a Factory Maintenance Program. Whatever it is called, the program will consist of two parts, control and implementation. 

 

Control of planned maintenance would usually be achieved by using a Maintenance Software Program. In some small operations, the control can be achieved by using a white board.

Implementation is the actual servicing and repair work. Greasing, oil changing, parts replacement and so on. 

  •  MAINTENANCE SOFTWARE PROGRAMS:

 There are many, off the shelf, Maintenance Software Programs available and some research is required by a company to select a program suitable for their needs. In some cases a company will elect to have a program designed specifically for their requirement's.

 

BRIEFLY A PROGRAM WILL CONSIST OF THE FOLLOWING KEY ATTRIBUTES:

 

  •  Equipment Register: Equipment technical details, ID number, Make, Model.
  •  Asset Register: Purchase details, date, price, depreciation rate.
  • Preventive Maintenance Scheduling: Issue of service sheets at pre-determined schedules. Schedules based on calendar time, hours, kilometres or other units of measure such as litres. Service sheets would include a check list for the applicable scheduled service. Checklists would normally be based on manufacturer (s) recommendations and local conditions.
  •  Work Order: Issue of work orders for repairs and servicing. Service sheets would be included with work orders.
  • Maintenance and Cost Records: Running costs, fuel, tyres and repairs. Recorded to the equipment ID number.
  • Reports: Standard reports produced as a matter of course and others by request. Reports would provide information such as equipment availability, equipment costs, tyres, fuel and repairs. The reports would provide information as to the availability of the equipment, costs per hour, kilometre, litres etc.  The reports would be available in both numeric and graphic formats. The graphic format allows management to quickly scan the reports noting only the high or low points.

  Implementation of an efficient and reliable maintenance program with the main purpose of providing HIGH equipment availability at a cost effective price, depends on several aspects, as follows:

  •  Support and co-operation for the maintenance program is required from management down to the operational and maintenance staff.
  • Adequate workshop/repair facilities.
  • Technical skills of the maintenance staff to be sufficient to accomplish all required tasks.
  • Timely supply of spare parts.

 

Maintek's extensive years of providing cutting-edge maintenance assistance and advice is available to you. Please CONTACT us at your convenience for a no obligation discussion on how we can provide maintenance solutions for your plant & equipment.