Improving Asset Effectiveness through Maintenance Process Re-design

摘要

Reliable operation on continuous basis for achieving the highest asset effectiveness is a dream for any continuous process plant operator. But to achieve reliability without failure is a task requiring extra ordinary drive for systematic structured maintenance programme.Gujarat Narmada Valley Fertilizers Company Limited (GNFC) in its endeavour to achieve this, went for bench mark assessment of existing processes and practices, leading to performance gaps identification, and transformation using computerisation for automated maintenance programme. Further understanding criticality of various plant and equipment machinery, Risk Priority Numbering (RPN) was taken up for which "Failure Modes and their Effect Analysis" (FMEA tool) was employed in reliability engineering. FMEA forms headwater for virtually subsequent reliability analysis and assessment because it forces an organisation to systematically evaluate equipment and system weaknesses and their inter-relationship that can lead to unreliability of operation. GNFC could achieve considerable progress in implementation of Reliability Centered Maintenance (RCM) for countering the aging plant.