6/18/2015 Biosciences eastern and central Africa International - - PDF document

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Biosciences eastern and central Africa – International Livestock Research Institute (BecA‐ILRI) Hub

Mobilizing biosciences for Africa’s development

BecA‐ILRI Hub Nairobi, Kenya 15‐19 June, 2015

LABORA LABORATORY MANA MANAGEM GEMENT NT AND AND EQ EQUIPMENT O OPERA ERATIONS TRAINI TRAINING W NG WORKS RKSHOP

15th-19th June 2015

Venue: Rwanda Agriculture Board (RAB) – Rubona Station

Prese Presentation 1 14

Eq Equi uipmen ent Mai t Maintenanc nce

General Principles of Maintenance

Presentation by: Wanjawa W. B. – ILRI Engineering Department, Nairobi, Kenya

Maintenance - nance - Gen eneral p eral principles ciples

• What is equipment maintenance
• Why is it important
• Requirements for an effective plan
• Categories of maintenance plan
• Implementation
• Monitoring and Evaluation

Equipment M Equipment Maint intenance nance

• Expensive item in the laboratory operating

budget

• Target for reduction
• Limitations in achieving any real savings
• Cost of no maintenance
• Impact on core business

Impor Importance of M ance of Maint intenance nance

• Continuous Service
• Extend machine life.
• Cost efficiency
• Safety
• Conserve the environment.
• Meets legal Requirements.

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Requirem irements ents

• Maintenance plan
• Budget
• Trained and effective team (in-

house/outsourced)

• Good workshop and tools of trade.
• Functional maintenance software.
• Good support from management.

Cat Categori gories of M es of Maint intenance nance

• 1. Pre

Preventiv entive maint maintenance nance

Meri Merits ts

• Planned – time and cost
• No emergency
• Increases machine lifespan

and accuracy. De Demerits

• Initially expensive to set up
• Is very labor intensive.
• May be unnecessary.
• 2. Co

Correctiv ective (R (Reac eactiv ive) m e) maintenance nance

Meri Merits ts

• Maximum productivity
• Cost not incurred until a breakdown.
• Less work interruption.

Dem Demeri rits

• Abrupt work stoppage.
• Shortens machine life.
• Leads to multiple equipment failure.
• 3. Predictiv
• 3. Predictive Maint

intenance nance

Merits.

• Don’t perform unnecessary

maintenance.

• No surprise breakdowns.

Demerits.

• Increases investment in measuring

equipment.

• Increases training costs.

Setting up Setting up a a Maint intenance sc nance schedule hedule

Steps Steps

• 1. Analyze maintenance system.
• 2. Review you system.
• 3. Prioritize maintenance.
• 4. Train you people.
• 5. Come up with PM schedule.
• 6. Support from management.
• 7. Implement Your Plan.

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Sc Scheduling: 1 heduling: 1. An Analyze m alyze maint intenance syst nance system em

• Determine starting point for your program.
• Determine status of each equipment.
• Create downtime log for each asset.
• Make Job card as simple enough.
• Make routine inspection.
• Review equipment downtime & production

logs.

• Check parts inventory & organize them.
• Do book keeping of all parts.
• Review Operators manual
• List areas that need repair.

Sc Sched heduling: 2. R ng: 2. Revie view y your syst ur system em Schedu Schedulin ling: 3. Prio g: 3. Prioritize Maint Maintena nance nce

• Safety first
• Set operational goal for average time.
• Determine which system needs

attention.

• Develop task list per piece.
• Assign approximate labor time & skill

level.

• Budget parts required for each task.

Sc Scheduling: 4. T heduling: 4. Train Y n Your ur People

• ple
• Training must not be an afterthought.
• Provide the correct operational

procedures.

• Demonstrate procedures of daily

maintenance (operators).

• Train your maintenance staff.
• Avail safety equipment.

Sc Scheduling: 5. Set up P duling: 5. Set up PM sc schedule dule

• Do the inventory of all equipment.
• Categorize your equipment.
• Draw a budget for the system.
• Get budget approval from management.

Scheduling: 6. Impl duling: 6. Implement Y ement Your ur P Plan an

• Do basic lubrications & Inspection.
• Do cleanup after each shift.
• Code all purchase orders.
• Separate old and new parts.
• Create storage room for house parts and

manuals.

• Out source some if any which are not within your

capacity.

• In conclusion, PM reduces costly emergency

repairs

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Pract Practical / / Demo Demo

• Developing a maintenance schedule for a

laboratory complex…..

• 30 minutes work
• 30 minutes presentation

Also…

• Practical equipment installation, basic

maintenance and user operations (10.00am to 5.00pm)

• Q&A first

End o d of Presenta entation 14

• n 14

Thank you

Barack Wamkaya Wanjawa Engineering Maintenance Coordinator ILRI Nairobi Kenya Engineering Department b.wanjawa@cgiar.org Mobilizing biosciences for Africa’s development http://hub.africabiosciences.org