Equipment 2011 IOE ME

8/7/2019 Equipment 2011 IOE ME

http://slidepdf.com/reader/full/equipment-2011-ioe-me 1/10

CONSTRUCTION EQUIPMENT

ANDTHEIR MAINTENANCE MANAGEMENT

.Shah

B.Sc. Mechanical Engineering (India) MS Manufacturing Engineering & Management (UK )

Institute of Engineering, Lalitpur

January, 2011

January 31, 2011 1

Equipment and their MaintenanceManagement

• Major construction Equipment used inConstruction Industries

• Equipment utilization in the Department ofoa s

• Fleet Management

• Maintenance & Operation System

• Source of Data

January 31, 2011 2Er. Satya Narayan Shah

Generally, we use the Equipmentwhen a job requires -

1. SPEED

2. QUALITY

3. ECONOMY

4. EMERGENCY/DISASTER

MANAGEMENTJanuary 31, 2011 3Er. Satya Narayan Shah

Pneumatic/Hydraulic Tools◦ Air Compressors

◦ Rock Drill/Jack Hammer/Other Drills

◦ Concrete Breaker

◦ Asphalt Cutter

◦ Impact Wrenches/Nail Driver

◦ Grinder

◦ Concrete Vibrator

◦ Back Fill Tamper

◦ Circular saw/ Chain Saw

◦ Road Broom


Aggregate Producer Rock Crushers, Screen, and Conveyors Central Mix Plant, (Batch Plant/Continuous

Mix Plant)

Bitumen Decanter, Bitumen Heater Bitumen Distributor Portable Mix Plant Pavers Rotary Sweeper Aggregate Spreader Concrete Mixers/Concrete Batch Plant Concrete Vibrator


Earth Moving Equipment◦ Dozers (Track/Wheel)

◦ Loader/Shovel (Track/Wheel)

◦ Excavators (Track/Wheel)/ )◦ Scrapers

◦ Grader

◦ Milling Machine

◦ Hauler (Off highway haulers, TippingTrucks, Mini Dumpers)




Compaction Equipment◦

Sheep Foot Rollers/TampingRollers

◦ Steel Wheel Static Rollerteel Wheel Static Roller

◦ Steel Wheel Vibrating Roller

◦ Pneumatic roller

◦ Plate Compactor/Rammer


Ancillary Equipment Water Distributor

Rotary Tiller Mixer Portable Electric Generator

Welding Generator

Pile Driver

Water Pump

Boring Rig

Crane/ Fork Lift

Flat Bed Truck

Low Bed Transporter


EQUIPMENT STATUS in DOR

ACTIVE EQUIPMENT: 487AVERAGE AGE (approx): 16.4 YRS.MORE THAN 25 YEARS OLD: 79 (16.22 %)21-25 YEARS OLD: 27(5.54%)16-20 YEARS OLD: 149(30.60%)

- .6-10 YEARS OLD: 82(16.84%)Up to 5 YEARS OLD: 40 (8.21%)MORE THAN 15 YEARS OLD: 255 (52.36%)Economic service life is taken as 15 yearsRAINY SEASON DEPLOYMENT: 100

(Equipment only)9January 31, 2011 Er. Satya Narayan Shah

LIST OF MAJOR EQUIPMENTType of Equipment Total No Average Age

Dozer Wheel 8 22

Dozer Track 21 15.3

Excavator 12 6.8

Motor Grader 21 19.2

.

Loader Backhoe 9 17.6

Roller 3 Wheel 52 19.9

Roller Pneumatic 14 18.2

Truck Tipper 95 20.2

10

2- equipment owned by Baitadi-Darchula Road Project, 26 - equipment

owned by Banepa-Sindhuli-Bardibas Project, 2 Tractors owned by Surkhet- Jumla-Road Project and 8 equipment owned by MTC which are not used by DOR’s day to day activities.January 31, 2011 Er. Satya Narayan Shah

% SHARE OF EQUIPMENT BYAGE

16.22

5.54

16.84

8.21

MORE THAN 25 YEARS OLD:

21‐25 YEARS OLD:

‐

11

30.60 22.59

11‐15YEARS OLD:

6‐15 YEARS OLD:

Up to 5 YEARS OLD:

January 31, 2011 Er. Satya Narayan Shah

EQUIPMENT AGEDISTRIBUTION

79

149

110

82

80

100

120

140

160

12

27

40

0

20

40

60

MORE THAN 25 YEARS

OLD:

21‐25 Y E AR S O LD : 1 6‐20 Y EA RS O L D: 1 1‐1 5Y EA RS O LD : 6‐15 Y EA RS O L D: U p to 5 YEARSOLD:

January 31, 2011 Er. Satya Narayan Shah



DEPARTMENT OF ROADSOrganization

DIRECTOR

GENERAL

DDGPlanin &Desi n

DDG

Maintenance

DDGForeign

DDGMechanical

PDADB Directorate s

Cooperation

PMEU

RSSDU

GEU

BRIDGE

CENTRAL

L AB

GENERAL

DRU

Multi

Lateral

Bi-lateral Equipment

Maintenance

DEVELOPMENT

CONTRACT

MANAGEMENT

Administration

Procurement

and

Training

Accounts


DoR Organization (Mechanical)

14

ORGANISATION MECHANICAL

Mechanical Branch:Equipment Maintenance and Management SectionEquipment Procurement and Training Section

Heavy Equipment Division (HED) : 6 Locations

Itahari, Hetauda, Kathmandu, Butwal, Nepalgunj, Godawari

Mechanical Office (MO) : 9 LocationsBirtamod, Lahan, Janakpur, Bharatpur, Kathmandu, Pokhara, Dang, Surkhet, Budar(2 MOs at Phidim and Butwal not opened)

Mechanical Training Centre (MTC), Lalitpur 15January 31, 2011 Er. Satya Narayan Shah 16Janu ar y 31, 2011 Er. Sat ya Nar ayan Shah

MANPOWER

Engineers (Diff. Level) 47

Mechanics (Diff. Level) 477

Operators (Diff. Level) 228

Sanctioned Posts: 1038 Posts

Drivers (Diff. Level) 89

Administrative Staff

(Diff Level)

90

Peon 50

Guard & Sweeper 57

Total 1038


MECHANICAL BRANCH & ITS ANCILLARIES

To provide support services to the construction and maintenance of Highways and other constructions.

Other Government Agencies

Contractors

During Emergency Disaster Management

18Janu ar y 31, 2011 Er. Sat ya Nar ayan Shah



MAIN RESPONSIBILITY

EQUIPMENT MANAGEMENT REPAIR & MAINTENANCE OF EQUIPMENT.

SUPPORT DIVISION

ROAD

OFFICES

AND

PROJECTS

FOR OPERATION OF EQUIPMENT

PROCUREMENT OF EQUIPMENT PROJECT REQUEST

SUPPORT DOR & OTHER CONSTRUCTION INDUSTRIES THROUGH PROVIDING TRAININGS TO THE MANPOWER

RENTING EQUIPMENT

19J anuar y 31, 2011 Er. Satya Nar ayan Shah

Activities of Mechanical BranchMajor activities of Mechanical Branch are as follows:

Monitoring of Heavy Equipment Divisions, Mechanical

Offices

and

Mechanical

Training

Centre.

Budgeting and Program formulation.

Equipment procurement.

Spare parts procurement from the manufacturer.

Monitoring of auction of equipment & vehicles.

Advise equipment and vehicle allocation.

Support DOR in policy formulation process.


Activities of Heavy Equipment Divisions and

Mechanical Offices

Major activities of HEDs and MOs are as follows:

Repair and maintain equipment owned by the HEDs/MOs.

Repair and maintain vehicles owned by the Civil Divisions.

Avail equipment to the Civil Divisions as per the directions of the Regional Directorate.

Support and monitor Mechanical Offices (not applicable to MO)

Support DoR projects.

Give equipment on hire without affecting the departmental work and administer Revolving Fund from the hire revenue. Keep store inventory record of asset owned by the HEDs/MOs


Activities of Heavy Equipment Divisions and

Mechanical Offices‐ contd…….

Maintain and report necessary records of financial expenditure as per the financial regulation.

Maintain and report repair, maintenance and operation records of equipments and vehicles as per the directives of the Mechanical Branch.

Advise Re ional Directorate Division Road Offices and Road , Projects related to equipment and vehicles.

Plan necessary spare parts requirements and send requisition to department for procurement of spare parts from the manufacturer, if necessary.

Auction economically not repairable, obsolete and scrap asset.


Activities of Mechanical Training Centre Develop and provide trainings in operation of the

construction equipment to DoR employees.

Develop and provide trainings in repair and maintenance of the construction equipment to DoR employees.

Develop and provide modular trainings and custom made trainings to other agencies and individuals and administer Revolving Fund from the training fees.

Keep store inventory record of asset owned by the MTC. Maintain and report necessary records of financial

expenditure as per the financial regulation.


FLEET MANAGEMENTFleet management is the function that oversees, coordinates and facilitates various Equipment related activities • TOTAL FLEET REQUIREMENT- COMPOSITION

• TOTAL FLEET AVAILABLE

• ASSET MANAGEMENT• REPORTS/INFORMATION GENERATION

• EQUIPMENT DEPLOYMENT

• EQUIPMENT RENTING

• EQUIPMENT MAINTENANCE

• DISPOSAL

• REPLACEMENT

• INSURANCE

• HEALTH, SAFETY & SECURITY 24Er. Satya Narayan Shah



BENEFITS OF FLEETMANAGEMENT

Optimize the Fleet Operations

•Improve equipment efficiency•Fact-based decision making

January 31, 2011 Er. Satya Narayan Shah 25

•Improve return on your assets•Secure extra revenue by billing correctlyand preventing under billing


Optimize the Use, Size & Maintenance

of Fleet•Reduce capital expenditures


• e uce cos s or ma n enance, repa r an

operations•Lower total cost of ownership•Extend asset life cycles and warranties•Proof adherence to agreed Service Level

Agreements


Increase Safety & Security•Provide access control to the fleet•Detect safety violations


practices•Formulate safety norms/standards andguidelines•Insurance policy

EQUIPMENT OPERATIONAL & MAINTENANCE

SYSTEM

• TO ENSURE THAT THE OPERATIONAL FLEET

REQUIREMENT IS OPERABLE AND MAINTAINABLE

WITHIN THE ALLOCATED BUDGET

IDENTIFICATION OF EQUIPMENT

EQUIPMENT MOVEMENT MONITORING

January 31, 2011Er. Satya Narayan Shah

EQUIPMENT MOVEMENT MONITORING

OPERATION RECORD KEEPING

MONITOR STATUS OF EQUIPMENT

• TO PROVIDE ALL INFORMATION AND ADVICE TO TOP

MANAGEMENT FOR THE PROCESS OF DECISION

MAKING

28

CLASSIFYING EQUIPMENT

Similar Design

Heavy Equipment – Graders, Trucks, Loaders

Light Equipment – Vans, Sedans, Pickups

Similar Use

12000 K i 20000


12000 Kg operating wt excavator vs. 20000

Kg operating wt excavator

Single cab pickup vs. Double cab pickup

Regular vs. Limited Use

Pile driver, mini duper, tipper trucks, inspection

vehicles

29

Life of Equipment• Service Life; which indicates the amount of time a

unit is capable of operating and rendering service.The service life often permits the use of equipmentwell beyond its economic life

• Technological Life; which represents the relative

newer models. The difference is represented byobsolesce factor in hire rate calculation.

• Economic Life; which is critical as it refers to bothtime and costs and generally refers to the timewhen maintenance costs exceed the units ability togenerate revenue, i.e. the unit is no longer costeffective to operate. 30



Departmental EquipmentIdentification

• It is necessary to have a system to identifyeach equipment as the Department

operates the largest fleet of equipment inthe country.

• The DoR has developed and introduced asystem to allot RD No to all theConstruction Equipment and InspectionVehicles.

• RD No. consists of Departmental Code (foreach type of equipment) and Equipment No.(allotted to every individual equipment) e.g..001-017January 31, 2011 31Er. Satya Narayan Shah

Coding System Of Construction EquipmentASPHALT PLANT 001

ASPHALT PLANT 001

ASPHALT PAVER 002

ASPHALT, MIXER 003

BROOM ROAD, TOWED 009

BORING RIG 011

CRANE MOBILE 021

CRANE MOBILE 021

CRUSHER STONE 022

CUTTER CONCRETE 024

DOZER WHEEL 030

DOZER, TRACK 031


Maintenance of EquipmentObjectives of MaintenanceEffective fleet management aims at reducing

and minimizing overall costs through maximumcost effective utilization of resources such asvehicles, fuel, spare parts, etc.

• To reduce down time

• To lower overall maintenance costs

• To improve plant efficiency and performance

• To assure residual value

• To improve safety levels

• To reduce the demand for skilled maintenance staff.January 31, 2011 33Er. Satya Narayan Shah

Maintenance is: -• Replacing oils, which become contaminated with

particles and break down into constituents, one of whichis acid.

• Replacing filters, which become blocked with particlesreducing flow or allowing fluids directly into precisioncomponents by being by-passed.

• ,lubricating properties resulting in abnormal componentwear.

• Adjusting for normal wears in order to ensure maintainstandard performance.

• Adjusting, calibrating and setting in order to ensureeconomic operation.

• Enabling worn or damaged components to be replacedbefore serious and costly breakdown occur.

34

MAINTENANCE PLANNING

Manufacturer’s maintenance schedules

Staff and skill level

Spare parts stock level and lead times

Consumable stock level and local sources


Status and level of workshop tools/ capacity

Work priority

Field maintenance capability

Availability of fund/budget

35

MAINTENANCE SCHEDULING

Cycle scheduling- which is the

determination of work required on

equipment through unit inspections. This

method is used to identify work tasks


method is used to identify work taskswhich might be necessary in addition to

the standard periodic servicing tasks.

Calendar scheduling- which is the logging

of required activities on a calendar or

planning chart.36



MAINTENANCE CATEGORIES

Unscheduled maintenance- resulting fromaccidents, breakdown caused by unforeseencomponent or component failure, abuse of

equipment, operator negligence etc. Planned maintenance- refers to all the

planning of all maintenance works; reduces


p gthe need of unscheduled maintenance.

Preventive Maintenance/ MinorMaintenance

Major Repair

Overhaul

Reconditioning/Rehabilitation

37

Preventive Maintenance/ Minor Maintenance

Replacement of oils, filters, greases etc.

Specified intervals

Prevents the need of repairs – reduces

b kd


breakdowns.

Activities are-

Walk around check, operator’s report

Scheduled periodic servicing

Scheduled periodic inspection

38

Major Repair

Defects identified before complete failure of

the equipment

Repair against failure of a component/unit

Only the broken down parts are replaced


39

ver au•Returning a unit to an economic operational

condition

• Limited to broken-down component only

Reconditioning/Rehabilitation

Total overhauling of the equipment

Rebuilding to economic operational condition.

Returning the equipment as good as new

equipment.

It d t k ll th t f th


It undertakes all the components of the

equipment

Proper testing and calibration is required after

rehabilitation.

Special tools and workshop facilities are

required.40

LIFE EXTENSION THROUGH

OVERHAUL/RECONDITION

This option can be applied to two

situations when the economic life span

has been exceeded;


the equipment is required due to lack of

fund for replacement.

the equipment has specialized function

and low utilization.

41

FACTORS TO BE EVALUATED FOR OVERHAUL

CONSIDERATION

Replacement cost of comparable unit

Availability of spare parts

Workshop facilities


pThe Benefits- Reliability, Maintenance

Cost, Performance against Replacement.

Cost Estimation Vs. Budget

42



WORKSHOP DOCUMENTATION

Repair Requisition form

Job Record Card

Cost estimate form


Spare parts stock situation

Spare part order form

External repair form

43

REPORTS/INFORMATION

Inventory of Spare Parts

Annual Report on Equipment Utilization

Annual Equipment Status


q p

Annual Report on Activities of HEDs &

MOs

Recovery on Equipment

Profit Loss Analysis

44

EQUIPMENT OPERATIONSYSTEM

• Operational Control System

– Monthly Status Report

– Annual equipment Inventory

– ovemen on ro

– Equipment Operation Log Sheet

– Monthly Utilization Report

– Monthly Hire Report

– Theoretical Hire Report

– Vehicle log SheetJanuary 31, 2011 45Er. Satya Narayan Shah

SOURCE OF DATA

• Goods Requisition Forms

• Contract Document/Purchase Order• Invoice• Letter of Credit

• Store Entry Voucher• Repair Order• Job Card• Operation Logbook

• Equipment Hire BillJanuary 31, 2011 46Er. Satya Narayan Shah

January 31, 2011 47Er. Satya Narayan Shah January 31, 2011 48Er. Satya Narayan Shah










QuestionsPlease

??

?? ??


THANK YOU ALL


Contact: [email protected]@dor.gov.np

Documents

Equipment 2011 IOE ME