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MAINTENANCE AND RELIABILITY MANAGEMENT IN YTL POWER SERVICES SDN BHD ( PAKA POWER STATION )
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1.0 Objectives The research will reveal the style of YTL Power Services in maintenance and reliability management of its power station in Paka. Furthermore, the research will also covers method adopted by the management in improving productivity of the maintenance staff. 2.0 Scope and Limitation All the data involved employer and employees of YTL Power Services Sdn.Bhd who manage YTL’s Paka Power Station only. The information that was given to us includes the strategic view of maintenance and reliability management in power station and methods used by YTL Power Services to increase productivity of the staff. The scope of study is mainly focus on the management approach and the impact of the approach to the organization. Beside that, we were unable to collect all the relevant data in details because of the confidential status of the documents. So, we will try to cover the issue thoroughly but efficiently in order to give a clear view of the management style that being practiced at YTL Power Service ( Paka Power Station ). 3.0 Methodology We have conducted interview session (face to face) with the management; Maintenance Manager; Mr Mohd Mahidi, QA Engineer; Pn Suryati, and Special Task Manager; Mr Alan Munro in order to have a better view .We tried to explore the company’s history, vision, mission, performance and the most important part is the way the company manage maintenance and reliability. 4.0 Literature Review 4.1 Maintenance and Reliability The major dictionary define maintain as cause to continue (Oxford) or keep an existing state (Webster). Moubray, J (1991) define maintenance is to ensure that physical assets to fulfill their intended functions. The “intended function” of any asset can be defined in a number of ways, depending on exactly where and how it is being used. Maintenance is also responding to changing expectations. Figure 1 shows the growing expectation of maintenance since 1930’s. The evolution of maintenance can be traced through three generations.[1] THIRD GENERATIONHigher plant availability and reliability.Great safety.Better product quality.No damage to the environment.Longer equipment life.Greater cost effectiveness. SECOND GENERATIONHigher plant availability.Longer equipment life.Lower cost. FIRST GENERATIONFit it when it broke 1940 1950 1960 1970 1980 1990 2000 Figure 1 : Growing expectation of maintenance The modern view of maintenance is that it is all about preserving the function of physical assets. In other words, carrying out tasks that serve the central purpose of ensuring that the machines are capable of doing what the users want them to do, when they want them to do it. The possible maintenance policies can be grouped under four heading viz.[2] q Corrective – wait until a failure occurs and the remedy the situation (restoring the asset to productive capability) as quickly as possible. q Preventive – believe that a regular maintenance attention will keep an otherwise troublesome failure mode at bay. q Predictive – rather than looking at a calendar and assessing what attention the equipment needs, the workers should examine the ‘vital signs’ and infer what the equipment is trying to tell us. The term ‘Condition Monitoring’ has come to mean using a piece of technology (most often a vibration analyzer) to assess the health of the plant and equipment. q Detective – applies to the types of devices that only need to work when required and do not tell us when they are in failed state e.g. a fire alarm or smoke detector. They generally require a periodic functional to ascertain that they are still working. Apart from detective maintenance, the central problem that companies have struggled with is how to make the choice between the other three. This has led to the increasing interest within industry in two strategies, which offer a path to long term continuous improvement rather than the promise of quick fix. These are Reliability Centered Maintenance (RCM) and Total Productive Maintenance (TPM). Two strategies, although having similar names, actually have very different strength. 4.2 Reliability Centered Maintenance Reliability Centered Maintenance (RCM) was created to provide guidelines on monitoring equipment and their failures and how to schedule maintenance tasks and what frequencies to prevent unit malfunction [3]. It is not a mathematical formula. Instead, it is a method by which a company can use its failure data, system design redundancies and operating experiences to develop a flexible and cohesive maintenance design. RCM is being used more frequently in the electric utility industry because it is a cost effective approach to achieve equipment reliability. With the advent of independent System Operators and sanctions for equipment downtime, utilities must re-evaluate routine maintenance practices and think in terms of increasing equipment performance.[4] According to Jack McMahon, this RCM (reliability centered maintenance) approach can "avoid the repetitive maintenance mode that eats up profits.[6] Moubray (1991) devided the RCM analysis process by five parts: PART ANALYSIS CRITERIA Part 1 The Plant Register Part 2 Failure Modes & Effects 1.
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