A

SYNOPSIS ON

“ANALYSIS AND OPTIMIZATION OF MAINTANANCE

MANAGEMENT OF INSTRUMENTS AT M/S. ASHAPURA

VOLCLAY LTD.”

SUBMITTED BY

NAME :

ENROLLMENT NO :

Submitted in partial fulfillment of the requirements for qualifying

MBA (OPERATION)

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ANALYSIS AND OPTIMIZATION OF MAINTANANCE

MANAGEMENT OF INSTRUMENTS AT M/S.

ASHAPURA VOLCLAY LTD

Under Supervision of :

Submitted By:

Name :

Programme Code : MBA (OPERATION)

Enrollment No. :

Name of the Study Centre : Study Centre Code :

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TABLE OF CONTENTS

S. NO. CONTENTS PAGE NO.

1. Title of the project……………………………………………….…....9

2. Introduction to topic…………………………………………….…..10

3. Rationale of study…………………………………………………...13

4. Objective of the study……………………………………………….13

5. Research Methodology………………………………………….…..14

6. Expected Contribution from Study……………………….………..15

7. Limitation……………………………………………………….…...17

8. Chapterisation…………………………………………………….…18

9. References ………………………………………...………………..19

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2. INTRODUCTION

Maintenance Management is an orderly and systematic approach to planning, organizing,

monitoring and evaluating maintenance activities and their costs. A good maintenance

management system coupled with knowledgeable and capable maintenance staff can

prevent breakdown problems and environmental damage; yield longer asset life with

fewer breakdowns; and result in lower operating costs and a higher quality of

instruments.

Importance

Maintenance management is crucial to companies because proper maintenance makes

workers aware of the resources with which they have to work. When workers are aware

of the cost and nature of their maintenance resources, they are less likely to be wasteful

with those resources. They also are more aware of how their resources and maintenance

work impacts the environment. A good maintenance management system makes work

more efficient and increases the quality of visitor experiences.

Interrelationship

Maintenance management is interrelated with other forms of management in a business.

For example, it is connected to financial management, since a maintenance management

system determines how maintenance resources, which have a cost, are allocated and used

up. Business owners and operators cannot develop or adjust their maintenance

management systems without also addressing other management systems within the

company.

Requirements

To develop a proper maintenance management system, a company first has to evaluate

its current maintenance practices to determine what maintenance tasks and resources are

used and necessary. Ideally, the maintenance management system should be able to

record maintenance tasks and inventory/resources, provide feedback to the facilities

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operations manager for analysis, and support the needs of the company and its customers.

Computerized maintenance management software programs often can meet these

requirements and greatly reduce the amount of work necessary compared to manual

systems.

The word “Operation” is usually linked with “Maintenance”. To put these terms in

context, Operation is the performance of work or services and the provision of materials

and energy to ensure the day-to-day proper functioning of an asset, e.g., the work

activities, associated chemicals and electricity to run a water treatment plant. As such, it

has a direct but simple impact on the cost of operating an asset. Maintenance is the work

performed on an asset such as a road, building, utility or piece of equipment to preserve it

in as near to its original condition as is practical and to realize its normal life expectancy.

This Technical Information Document, as its name implies, concentrates on maintenance

management systems only. In general, maintenance can be classified into the following

categories:

(a) Routine - ongoing maintenance activities such as cleaning instruments and regular

calibration checking, which are required because of continuing use of the facilities.

(b) Preventive - periodic adjustment, lubrication and inspection of mechanical or other

equipment to ensure continuing working condition; and

(d) Emergency - unexpected breakdowns of assets or equipment. These are unpredictable

or reactive type of maintenance and are more difficult to schedule than the above three

categories.

COMPANY PROFILE

Established in 1960, Ashapura Group is India’s largest muti-mineral solutions provider.

The flagship company Ashapura Minechem Ltd. is listed on India’s premier exchanges.

Ashapura Minechem Ltd. is a part of the BSE Midcap & BSE 500 indices. The group has

mining & mineral processing facilities in Gujarat, Maharashtra, Karnataka, Kerala,

Andhra Pradesh and Orissa. Today Ashapura Group has attained global status with

projects in Belgium, Nigeria, Oman and Malaysia.

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Ashapura Group is one of the significant global players in bauxite and is amongst the

world’s top five Bentonite companies. Ashapura also dominates the value added

segments in the country for Bleaching Clay, Geosynthetic Clay Liners, Clay Catalysts,

Calcined Bauxite, etc.

Ashapura has advanced from being a single mineral company to a specialist in industrial

minerals. Bentonite, the multi-tasking mineral, continues to be a core product with

diverse applications in industries that range from agriculture to environment and foundry

to edible oils and cosmetics to medicine New applications for the industries presently

being catered as well as for new industries are developed every year through indigenous

and global research. The company’s diversification into bauxite was a major move and

today Ashapura is among the key players in Bauxite from India. Our strategy to expand

our mineral portfolio is paying rich dividends as we have added Kaolin, Attapulgite,

Barites, Feldspar and many other allied minerals to our product portfolio.

A new exciting area, with immense growth potential and limitless possibilities, opened

when the company decided to move into value added products. At present our major

value added products are Bleaching Clay, Clay Catalysts, Geosynthetic Clay Liners

(GCL), Calcined Bauxite and very soon it will be alumina.

All our products come with a promise of ‘no compromise on quality’.

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3. RATIONALE FOR STUDY

Maintenance Management is an orderly and systematic approach to planning, organizing,

monitoring and evaluating maintenance activities and their costs. A good maintenance

management system coupled with knowledgeable and capable maintenance staff can

prevent breakdown ,yield longer asset life with fewer breakdowns; and result in lower

operating costs and a higher quality of life. This research tries to find out the general

information and guidance on establishing Maintenance Management Systems for use in

M/s. Ashapura Volclay ltd. It describes a system framework from the initial step of

inventory gathering to preparing a community maintenance budget for asset maintenance

planning and monitoring.

4. OBJECTIVES OF THE STUDY

(1) To identifying the physical features of all assets which require maintenance.

(2) To identify maintenance activity and tasks, defining the type of maintenance task

(activity) to be performed on each asset and what work should be done under each

activity.

(3) To identify the frequency of the task - determining how often the activities should be

performed (frequency of service); this is important particularly in preventive type of

maintenance.

(4) To Estimate the time required to complete the task - indicating how long each task

should take to complete;

(5) To develop an annual work schedule - planning what time the maintenance work for

the entire year should take place;

(6) To Prepare and issue a work order - identifying what, when, where and by whom

maintenance work is to be done

(7) To Determine a Budget - determining the costs for all maintenance activities by

calculating labour hours, material, equipment, and contracting costs.

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5. RESEARCH METHODOLOGY

Research will be more of Explorative research and is the moral fiber of the project. In

order to bring about the objectives of the Project, it will be important to eloquent the

approach in which it is to be conducted, i.e. the research practice was to be carried out in a

certain framework. Purposes of the research are to rummage around for acquaintance.

Also research defines a systematic and organized search for applicable information on a

particular topic.

Interviews with the managers and engineers involved in the maintenance work will be

carried out and the final conclusion will be drawn out of it. Secondly, a questionnaire is to

be created for Evaluating the objectives and trends out of it.

The data was composed to attain aforementioned objectives. This data was collected as:-

Primary Data:

Primary data will be collected directly from the M/s. Ashapura Volclay ltd from the daily

maintenance register and the inventory records used in the daily maintenance in the

instruments workshops.

Secondary Data:

It consists of information that previously subsists somewhat in papers. A manuscript is a

very important trustworthy and priceless basis of information. Many researchers make use

of this fundamental source. Manuscript is nothing of this imperative source; but printed

evidence that contains important information about a problem or characteristic of learning.

It may be purchased material, journals; company profiles company annual reports, and

internal search etc. The composed data will be processed critically examined and

analyzed.

Sample Size The sample size in total included survey and interviews at M/s. Ashapura

Volclay ltd

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6. EXPECTED CONTRIBUTION FROM STUDY

Maintenance management is what its name implies -- the effective management of

workplace or industrial maintenance. It details procedures that define manpower

scheduling, equipment and tool control, quality control, reporting, cost control, inventory

control, training, loss prevention, inspection and work status. According to "Principles of

Controlled Maintenance Management," maintenance management applies management

principles of organization, inventory, continuous inspection, planning, scheduling and

management analysis to ensure that a system performs designated functions

economically, effectively and within the budget.

This study will help us to achieve the following goals as a contribution towards the

improvement of maintance management activities at M/s. Ashapura Volclay ltd .

1. One of the most significant advantages of maintenance management is the

management of control. Maintenance can be planned and serves a pre-active instead of a

reactive (be put to action after an event has come to pass). Management control ensures

timely schedules, well-defined job descriptions and the availability of standby equipment

in times of disaster.

2. Maintenance management reduces and even eliminates overtime by reducing the

chance of surprises. It ensures all loose ends are tied and enough contingency planning is

done to manage operations in case of undesirable circumstances and situations.

Management defines tasks and allocates resources effectively, ensuring that all objectives

are met in a timely and orderly.

3. Effective maintenance management improves output and ensures quality. It gives

a small amount of leeway to tolerances but within well established control limits.

Employee productivity improves, improving the overall productivity of individual and

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collective processes. Investing in maintenance management pays off for a company by

increasing its revenues.

4. A well established and documented maintenance management system provides

ample support to production managers, equipment operators, and other personnel and

users. An effective maintenance management program needs to be made public (and/or

published) for the benefit of everyone involved. End users can benefit from a better level

of support provided by maintenance management. It allows for reliable, on time, and

quality service.

5. Since maintenance management details the goals and objectives of departments

and employees, it make it easier for managers to spot errors and deviations from

established and desired outcomes.

6. Maintenance management ensures that labor, materials and equipment are well

utilized, which reduces waste of allocated resources. Utility costs are lowered and the

production of hazardous waste material is decreased with managed effort.

7. Maintenance management promotes safety and health. It ensures everyone

involved knows safety procedures in case of a minor or major disaster. A well-

implemented management program examines the risk of potential hazards and finds ways

of addressing them before they pose a risk. Regular housekeeping programs promote fire

prevention and safety measures.

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7. LIMITATIONS OF THE STUDY

The findings of the study are based on the information provided and data provided at

Banglore only. Efforts will be made to make the study as accurate as possible, 100%

accuracy cannot be claimed because of the following reasons: -

• The sample size to study is Limited to the M/s. Ashapura Volclay ltd,Bhuj Kutch.

• Sample to be drawn by Quota sampling, so the possibilities of sample error cannot

be ruled out. Some of the sampling and non-sampling errors may creep into the

study.

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8. CHAPTERISATION

Detailed/final project report will include the following chapters:

Introduction: Chapter –I

Objective and scope of study: Chapter –II

Methodology: Chapter –III

(Details of methodology used in studying and collecting the data

and issue will be described):

Descriptive work: Chapter –IV

Descriptive work on the topic, this chapter will include

analysis and interpretation of data tabulation and categorization;

Study report: Chapter –V

Study report of other researcher will be observed and analyzed.

Conclusion: Chapter –VI

Limitation Chapter –VII

Recommendation: Chapter –VIII

Bibliography: Chapter –IX

Appendix-1 Chapter –X

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9. REFRENCES

1. A review of overall models for maintenance management:David Sherwin, (Lund

University Institute of Technology, Sweden

2. Maintenance Policy and Procedures - 2nd Edition by Ivan Gothmale

3. Maintenance Policy and Procedures - 2nd Edition by harn joshep

4. www.plant-maintenance.com/maintenance_articles_rcm.shtml

5. www.vicfirth.com/education/percussion101-concertKeybo