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

6/18/2015 Biosciences eastern and central Africa – International Livestock Research Institute (BecA ‐ ILRI) Hub Mobilizing biosciences for Africa’s development LABORA LABORATORY MANA MANAGEM GEMENT NT AND AND EQUIPMENT O EQ OPERA ERATIONS TRAINI TRAINING W NG WORKS RKSHOP Venue: Rwanda Agriculture Board (RAB) – Rubona Station 15th-19th June 2015 BecA ‐ ILRI Hub Nairobi, Kenya 15 ‐ 19 June, 2015 Maintenance - nance - Gen eneral p eral principles ciples Prese Presentation 1 14 • What is equipment maintenance Eq Equi uipmen ent Mai t Maintenanc nce • Why is it important • Requirements for an effective plan General Principles of Maintenance • Categories of maintenance plan • Implementation • Monitoring and Evaluation Presentation by: Wanjawa W. B. – ILRI Engineering Department, Nairobi, Kenya Equipment Maint Equipment M intenance nance Impor Importance of M ance of Maint intenance nance • Expensive item in the laboratory operating • Continuous Service budget • Extend machine life. • Target for reduction • Cost efficiency • Limitations in achieving any real savings • Safety • Cost of no maintenance • Conserve the environment. • Impact on core business • Meets legal Requirements. 1

6/18/2015 Requirem irements ents Cat Categori gories of M es of Maint intenance nance • Maintenance plan • Budget • Trained and effective team (in- house/outsourced) • Good workshop and tools of trade. • Functional maintenance software. • Good support from management. 1. Pre Preventiv entive maint maintenance nance 2. Co Correctiv ective (R (Reac eactiv ive) m e) maintenance nance Merits Meri ts Meri Merits ts • Planned – time and cost • Maximum productivity • No emergency • Cost not incurred until a breakdown. • Increases machine lifespan • Less work interruption. and accuracy. De Demerits Dem Demeri rits • Initially expensive to set up • Abrupt work stoppage. • Is very labor intensive. • Shortens machine life. • May be unnecessary . • Leads to multiple equipment failure. 3. Predictive Maint 3. Predictiv intenance nance Setting up Setting up a a Maint intenance sc nance schedule hedule Merits. Steps Steps • Don’t perform unnecessary 1. Analyze maintenance system. maintenance. 2. Review you system. • No surprise breakdowns. 3. Prioritize maintenance. 4. Train you people. 5. Come up with PM schedule. Demerits. 6. Support from management. • Increases investment in measuring 7. Implement Your Plan. equipment. • Increases training costs. 2

6/18/2015 Sc Sched heduling: 2. R ng: 2. Revie view y your syst ur system em Sc Scheduling: 1 heduling: 1. An Analyze m alyze maint intenance syst nance system em • Review equipment downtime & production • Determine starting point for your program. logs. • Determine status of each equipment. • Check parts inventory & organize them. • Create downtime log for each asset. • Do book keeping of all parts. • Make Job card as simple enough. • Review Operators manual • Make routine inspection. • List areas that need repair. Scheduling: 4. T Sc heduling: 4. Train Y n Your ur People ople Schedu Schedulin ling: 3. Prio g: 3. Prioritize Maint Maintena nance nce • Safety first • Training must not be an afterthought. • Set operational goal for average time. • Provide the correct operational • Determine which system needs procedures. attention. • Demonstrate procedures of daily • Develop task list per piece. maintenance (operators). • Assign approximate labor time & skill • Train your maintenance staff. level. • Avail safety equipment. • Budget parts required for each task. Scheduling: 6. Impl duling: 6. Implement Y ement Your ur P Plan an Sc Scheduling: 5. Set up P duling: 5. Set up PM sc schedule dule • Do basic lubrications & Inspection. • Do the inventory of all equipment. • Do cleanup after each shift. • Categorize your equipment. • Code all purchase orders. • Draw a budget for the system. • Separate old and new parts. • Get budget approval from management. • 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 3

6/18/2015 Pract Practical / / Demo Demo End o d of Presenta entation 14 on 14 • 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 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 4