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About Us
Sitemap | Our Academy¿s recent training programmes - 1.Practical Lean Maintenance Our director Mr Varshney conducted 3 nationwide workshops of 2 days each in June at Mumbai,Chennai,Delhi on ‘Practical Lean Maintenance’. Senior maint. managers from Reliance, Siemens, L&T, Escorts, Jindal, Ambuja, Timken, Alstom etc. attended
- 2.For QP - Doha Qatar Mr SK. Varshney conducted in May’10 a 5 days training progr. on Design/selection/maintenance of Heat Exchangers for Qatar Petroleum at Doha. 18 engineers & senior technicians attended.
- 3.For Bhutan company We conducted an international 2 weeks training for stores officers of Penden Cement Co Bhutan June 21 to July 3 on ‘Modern Stores Management & Inventory Control’ at Delhi / ABES-IT
- 4.Our 117 th training programme for NTPC We conducted at NTPC Dadri a 2 days training programme on ‘Steam Turbine Lubrication & Seal Oil System’ July 19-20 in which 24 senior technicians participated.
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Tribology Bearings / Lubrication Vibration In association with the SKF Venue: ABES-IT Institute Aug 30-31, 2010 (mon-tue) 9.30 am to 5.30 pm Non residential. Course fee just Rs 3000. 15% discount to any additional participant from same company. Bearing is Heart of a machine. M/c stops when bearing stops 90% maint. staff are found to make errors in use of bearings This is the basic and our most popular training programme for any industry large or small. Every operation & maintenance man must know the type, application, proper selection, mounting , maint. & troubleshooting of bearing for long troublefree life. Lubricants – oil / grease are the food to bearings. All must know their proper grades / application. Basic knowledge of machine vibration is must today for doing the condition monitoring. | |
Industrial News & Events AMTEX-10 July 23-27, 2010
Recently concluded 5 days Asian Machine Tools Exhibition, was a huge international gathering of exhi-bitors/ visitors with 500 stalls showing all possible type products/equipment to help industry including a large range of main. aids, equipment & instrumentation.
Industrial Maintenance Expo- 2010, Delhi
Augusst 4-5-6, Organized by the Confederation Of Indian Industry CII & Ministry of Heavy Industries at Okhla, this is a big event for industry visitors, especi-ally from maintenance function. On display are wide variety of repair/ maintenance products & services. Our next newsletter (Sep.) will cover review of this Expo | |
Some Of Our Maintenance Training Programmes - 1.Rotating Equipments - Fans, Blowers & Compressors Selection, operation, maint & troubleshooting
- 2.Best Operation & Maint. Practices for modern plants Modern tools, techniques,practices for operation excellence
- 3.Industrial Tribology and Lubrication Management Grades, properties, application, monitoring & testing
- 4.Bearings Maintenance & Effective Lubrication Most basic, popular training topic for most of maint. Staff
- 5.Industrial Hydraulics & Pneumatics Systems Theory, components, circuits for maint. & troubleshooting
- 6.Vibration Monitoring, Analysis & Shaft Alignment Theory & machine defects analysis to reduce break downs
- 7.Electric Motors & Their Control Systems Operation, maint., Troubleshooting of AC/DC motors & controls
- 8.Power Distribution: Transformers, Cabling, Earthing Design features, monitoring, maintenance, troubleshooting
- 9.Basic Automation & Process Control Systems Design, monitoring, control, applications & troubleshooting
- 10.Systematic Preventive Maintenance (SPM) Tips, techniques, short cuts to planned predictive / periodic maint. with check lists, history-cards, breakdown analysis.
- 11.Total Productive Maintenance (TPM) and 5- S Japanese technique to systematically improve productivity
- 12. Material Management/Waste Reduction/ Cost Control Modern concepts for inventory, waste, & cost control
- 13. Creative Kaizen Centered Innovation Eliminate plant problems in small innovative steps
- 14. Reliability Centered Maint-RCM & Failure Analysis Tools, techniques to identify, analyze, & eliminate m/c failures
- 15.Value Engineered Kaizen for Manufacturing Excellence
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Systematic Preventive Maintenance Periodic & Preventive Maintenance Techniques Sept. 6-7,2010 (mon-tue) 9.30 am to 5.30 pm Non residential. Course fee just Rs 3000. 15%discountto additional articipant romsameorganization. 15% An absolutely essential basic course for each & every maintenance man - mech.l elect. I civil I or utilities Will cover Proper steps, short cuts, tips, techniques on how to effectively plan & organize periodic & predictive maintenance with check lists, history-cards, condition monitoring and breakdown analysis. Covers Proven ways to avoid machine breakdowns. Nomination: Please inform us at least 4 days in advance thru your company email to··Quremail: maintocare@gmail.com Advance payment to be by 001 company Cheque 'Based on response, there may be change in venue I schedule Main Tips: Bearing Vibration Activates Grease Failure Vibration -in- bearings may be from internal or external source. High bearing vibration can have the same effect as irregular greasing of bearing contact surfaces. Vibration typically causes the grease to be broken down into oil and thickener, that is, the oil separates out from the thickeneL ROOT Cause Analysis - RCA Tip Root cause analysis is a great way to detect a fault before it results in premature machine failure, Determine why the part failed. Whether due to lubricant problem, design problem, incorrect operation, high vibration levels ( misalignment I Imbalance etc) or bad environment conditions The goal of RCA is not only to eliminate recurrence of the failures, but to also transfer knowledge of how the event was solved using RCA. We know that the same failures are occurring at our other factories and that other people are duplicating the same repair or analysis process over & over again. This can be avoided | |
Main To Care Our first issue of Main to Care on the occasion of national 'Industrial Maintenance Expo-201 0' New Delhi has brought tremendous response from industry managers at all levels with good comments, suggestions & offers to help us. All indicate that there is need for a regular bulletin as voice of Indian maintenance. We carry here below review of important things of this Expo for benefit of those unfortunate to miss it. | |
Industrial Tribology Tribology is the science of Friction, Wear, Lubrication Most machine maintenance functions relate to tribology Any machine has some relative motion between two mating surfaces which creates friction. Friction is harm- ful as it causes resistance, wears out surfaces and generates heat besides consuming more energy. All these reduce performance and useful life of a machine. To reduce friction therefore we put some soft substance between the 2 surfaces -called a lubricant. Lubricants may be liquid, semi solid (grease) or even solid (Teflon) Viscosity is the most important property of Lub oil and can be defined as ‘Resistance to Flow’. It is expressed in ISO VG grades. Generally, higher the viscosity grade (VG) number, thicker the oil. Next MaintoCare issue will give full series of ISO-VGs which have wide application in all industries. | |
Maintenance Marshall Institute USA has given this vital information Last year industry in the US alone spent over $ 600 billion on plant / equipment maintenance. - 200 billion was wasted
- Bad maint was responsible for equipment failures
- Too many Production schedules were disrupted
Why is industry wasting 1 out of 3 dollars on maintenance The answer is simple - poor management & poor systems Focused training by experts is the key to plug profit leaks | |
Industrial Maintenance Expo 4 - 6 August 2010 For those who could not attend this big, first ever national exhibition on Industrial Maintenance 100 exhibitors showcased their best and latest products & aids to help make industrial maintenance easier. INDUSTRIAL MAINTENANCE EXPO 4 - 6 August 2010 The Expo was a huge success with good response to the first ever 3 days national show on Industrial Maintenance The show was jointly organized by the CII & ministry of Heavy Industries, at NSIC's Okhla exhibition ground Delhi. Also were there 1 day corlferences on "Maintenance Practices through TPM to achieve ZERO Breakdowns". and the War on Industrial Corrosion Mr Vilasrao Deshmukh,Minister of Heavy Industries & Public Enterprises, Govt of India while Inaugurating the Expo, said that maintenance is really the backbone of any industry. Serious industrial accidents have happened due to poor maintenance. We need to strongly encourage & promote the culture of maintenance in our country. He said that improved plant maintenance to achieve zero break downs needed a different and new mind-set. Calling upon industry not to adopt a penny-wise pound-foolish approach to the specialist area of equipment maintenance, he announced that Government and industry should jointly wage a war on breakdowns and corrosion as he noted with concern the 15 to 20% loss to production costs through maintenance breakdowns and corrosion. Through awareness and incentives, he estimated that such loss prevention could further contribute 3 % to the national GOP. ( amounting to severallakhs of rupees ). Mr B S Meena, Secretary, deptt.of Heavy Industries underlined the larger role of internal competitiveness and capacity utilization as a part of growth strategy. He hailed the first ever Industrial Maint. Expo as excellent example of Government-CII partnership. | |
Electric Motor - Repair or Replace This is one important frequent decision of a plant manager affecting the plant productivity. To start with, ask, Is the motor of over 30 hp ? Compare first the cost of new motor to its repair. If repair IS 50% or more, better to purchase as MTBF of rebuilt motors is low. At < 50%, it's better to repair. Some repair shops specialize in small motor repair and may do quality work so it pays to investigate. For < 30 hp, better buy a new motor, with warranty. Consider also the additional cost of handling I paperl admin work. It is profitable to replace low efficiency motors with higher ones- if annual run hours are high - no matter how low the repair bill be (for less efficient motor).Remember-Purchase cost is just 2 "10 of total Life Cycle Cost of a Motor Next is ROI and reliability. Will the difference in cost & efficiency payout over the expected MTBF of motor ? The best motor repair is the one that you do not need to do For this, follow good maintenance practices. installation, a good PM program, appropriate lubrication, and regular condition monitoring can reduce the motor repairs cost by half. Why replace a bearing, when just proper alignment can increase its life 10 times? Why replace a shaft or rotor-,when good bearing lubrication can ensure a long run We have several short training programmes to help improve electric motor life & efficiency. We conducted in Aug'10 the following trainings for NTPC - 1. Valve Actuators Maintenance & Calibration
- 2. Transformer & Accessories: Operation & Maint
- 3. Tribology- Bearing Maintenance & Lubrication
- 4. Vibration Monitoring & Analysis
- 5. Shaft Alignment Techniques
Get MaintoCare by email. Just send an .~mail to maintocare@gmail.com with namel Companyl Email MaintoCare will include features on maint. products, systems, techniques, facilities, aids and practical tips on how to do better maint. Contribution from maint experts are welcome like tipsl techniques I short articles MainTips: Tips to help you improve repair & maintenance DUST is Enemy nO.1 for maintenance Effect of Dustin lubricating oil and grease- machine damages are due to this reason. Lubrication forms a thin oil Film to separate surfaces in relative movement. Dust particles break this film. Surfaces rub on each other. Then, metal wear particles come out causing more damage, further increasing the surface roughness and the friction. Result - the machine gets damaged. Please ask all your maintenance managers, engineers and technicians about this and to observe how dust can enter into lubricating oil and AVOID it by all means. Effect of dust in electrical installations is even more serious. We will discuss it in coming issues of MaintoCare | |
Chief Engineer / Head Of Maintenance Vol. - 1 Issue - 2 Sept. 2010 special issue on Industrial Maintenance Expo-Delhi Mr K N Shenoy, Chairman, CII Institute of Quality recounted the role played by Institute in areas of training, and consultancy services in building the competency of Indian Industry. 3 lakh managers had benefited from the implementation of TPM, TQM, 6 Sigma, Lean etc. Maintenance losses, he noted, ranging 5 to 10 %, was far too above global benchmarks and needed urgent attention. Mr C. Banerjee, Dir.General CII, said that manufacturing was key to 20% GOP by 2025 in which such loss prevention would play important role. Importance of the Expo can be seen by the fact that companies are loosing 5-10 % of production thru m/c breakdowns due to poor maint. practices, besides causing hardships for the staff. High cost of maint. also adversely affects the bottom-lines. TPM Club India, CII, organized 1 day conference on 'Maint. Practices through TPM to achieve Zero Breakdowns'. TPM, a powerful Japanese mantra, is systematic way to drastically reduce costs and breakdowns. It is implemented worldwide and in 200 . Indian companies including PSUs. The Conf. had 12 eminent speakers with session on Management Solutions Valedictory Session of the IMEX 2010 Aug-5 Mr Arun Yadav, Minister of State for Heavy Industries & Public Enterprises, while expressing concern for inadequate maintenance, noted that country loses 3-4% of GDP due to corrosion amounting to Rs. 2 lakh crore per year which can and must be brought down drastically: Dr H P Kumar, CMD,NSIC strongly recommended to take this Expo to more centres in India and also to other countries so to access new technologies. Rare opportunity to know what was on show New Aids to Modern Plant Maintenance Oct. 11, 2010 ( Mon) New Delhi One day Summary/ Review program by the top maint. expert Mr SK Varshney Fee: Rs 8,500 Based on what was displayed & discussed at . following 4 recent national maintenance events: - 1. Ficci's 2 days Plant Maint Summit in May'10
- 2. CI/'s Industrial Maint Expo Aug 4 -6 (3 days)
- 3. CII / TPM club's Conference on 'Maint Practices thru TPM to achieve Zero Break Downs' Aug-4'10
- 4. AMTEX'10 Asian Machine Tools Expo Ju1'10 TopAsian Machine Show with over 1100 stalls Few companies have been requested to again display their popular products during this 1 day programme. DO NOT MISS.LIMITED SEATS .
The serious problems we face can not be solved at the same level of thinking we were at when we created them.Regular technical training is therefore necessary for all levels of the maintenance staff. | |
Tribology: Bearings / Lubrication & Vibration 15% discount to any additional participant from same company. Bearing is Heart of a machine. M/c stops when bearing stops 90% maint. staff are found to make errors in use of bearings This is the basic and our most popular training programme for any industry large or small. Every operation & maintenance man must know the type, application, proper selection, mounting , maint. & troubleshooting of bearing for long troublefree life. Lubricants – oil / grease are the food to bearings. All must know their proper grades / application. Basic knowledge of machine vibration is must today for doing the condition monitoring. | |
Systematic Preventive Maintenance - SPM Scientific Periodic & Preventive Maintenance Techniques Sept. 6-7, 2010 (mon-tue) 9.30 am to 5.30 pm Non residential. Course fee just Rs 3000. 15% discount to any additional participant from same company. An absolutely essential basic course for each & every mainte- nance man – mech./ elect. / civil / or utilities etc Will cover Proper steps, short cuts, tips, techniques on how to effectively plan & organize periodic & predictive maintenance with check lists, history-cards, condition monitoring and breakdown analysis. Proven ways to avoid machine problems Nomination: Please inform us at least 3 days in advance by your company email to our email: acadim@gmail.com Advance payment is to be by DD/ company Cheque ** Depending on low or high response the schedule/ venue may change How can you get MaintoCare free by email ? Just send an email to maintocare@gmail.com giving Name/ Age/ Designation/ Company/ Email Contribution from maint experts are welcome like tips/ techniques / short article- max 200 words Future issues of MaintoCare will include features on maint products, systems, techniques, facilities aids and pract tips | |
Mainto Care We feel happy to launch MaintoCare, on the occasion of national ‘Industrial Maintenance Expo-2010’ New Delhi The expo is the first ever national exhibition on industrial maintenance where 100 companies- including all top names are displaying their latest products. We will cover main features of this expo in our next issue. We will now focus our academy’s all maint. expertise under this banner. To begin with, here is our monthly newsletter. As the name suggests, we will bring to you useful topics of interest like news, views, tips, techniques, web links etc. on plant maintenance. As many know, our academy is in 7th year and is leading training provider in industrial operation & maint field, having done 355 training programmes - including 16 of 5 days each for overseas. We have a team of senior maint. experts with years of direct shop floor experience. MaintoCare is our beginning to have a more closer, 2 way communication with fellow maintenance professionals. | |
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