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Dubrovnik Airport Galiot Conference, Split 8/9. MAY 2014. Author: Tomislav Macan, DBV Airport Chief Technical Officer.

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Presentation on theme: "Dubrovnik Airport Galiot Conference, Split 8/9. MAY 2014. Author: Tomislav Macan, DBV Airport Chief Technical Officer."— Presentation transcript:

1 Dubrovnik Airport Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

2 Maintenance function  All actions necessary for retaining an item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification  Increase availability of a system  Keep system’s equipment in working order Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

3 Question?  Why do we need maintenance?  What are the costs of doing maintenance?  What are the costs of not doing maintenance?  What are the benefits of maintenance?  How can maintenance increase profitability of company? Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

4 Purpose of Maintenance  Attempt to maximize performance of production equipment efficiently and regularly  Prevent breakdown or failures  Minimize production loss from failures  Increase reliability of the operating systems Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

5 Principle Objectives in Maintenance  To achieve product quality and customer satisfaction through adjusted and serviced equipment  Maximize useful life of equipment  Keep equipment safe and prevent safety hazards  Minimize frequency and severity of interruptions  Maximize production capacity – through high utilization of facility Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

6 Maintenance Objectives  Must be consistent with the goals of production (cost, quality, delivery, safety)  Must be comprehensive and include specific responsibilities Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

7 Maintenance Costs  Cost to replace or repair  Losses of output  Delayed shipment  Scrap and rework Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

8 Maintenance types  Three types of maintenance  Breakdown maintenance – emergency or priority repairs on failed equipment  Preventive (scheduled) maintenance – routine inspection and servicing to keep facilities in good repair  Predictive (Condition-based) maintenance Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

9 Corrective or Breakdown Maintenance  Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed and can not perform its normal function anymore  Quite justified in small factories where: Down times are non-critical and repair costs are less than other type of maintenance Financial justification for scheduling are not felt Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

10 Disadvantages of Corrective Maintenance  Breakdown generally occurs inappropriate times leading to poor and hurried maintenance  Excessive delay in production & reduces output  Faster plant deterioration  Increases chances of accidents and less safety for both workers and machines  More spoilt materials  Direct loss of profit  Can not be employed for equipments regulated by statutory provisions e.g. cranes, lift and hoists etc Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

11 Preventive Maintenance (PM)  Principle – “Prevention is better than cure”  Procedure - Stitch-in-time  It locates weak spots of machinery and equipments provides them periodic/scheduled inspections and minor repairs to reduce the danger of unanticipated breakdowns Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

12 Implementing Preventive Maintenance  Need to know when a system requires service or is likely to fail  High initial failure rates are known as infant mortality  Once a product settles in, MTBF generally follows a normal distribution  Good reporting and record keeping can aid the decision on when preventive maintenance should be performed Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

13 Candidates for Preventive Maintenance Mean Time Between Failure (MTBF) Frequency of Failure Good candidates have more normal distribution with low variability Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

14 Advantages of PM  Advantages: Reduces break down and thereby down time Lass odd-time repair and reduces over time of crews Greater safety of workers Lower maintenance and repair costs Less stand-by equipments and spare parts Better product quality and fewer reworks and scraps Increases plant life Increases chances to get production incentive bonus Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

15 Predictive (Condition-based) Maintenance  In predictive maintenance, machinery conditions are periodically monitored and this enables the maintenance crews to take timely actions, such as machine adjustment, repair or overhaul  It makes use of human sense and other sensitive instruments, such as audio gauge, vibration analyzer, amplitude meter, pressure, temperature and resistance strain gauges etc. Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

16 Predictive Maintenance (Contd.)  Unusual sounds coming out of a rotating equipment predicts a trouble  An excessively hot electric cable predicts a trouble  Simple hand touch can point out many unusual equipment conditions and thus predicts a trouble Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

17 Computerized Maintenance System Output Reports Inventory and purchasing reports Equipment parts list Equipment history reports Cost analysis (Actual vs. standard) Work orders –Preventive maintenance –Scheduled downtime –Emergency maintenance Data entry –Work requests –Purchase requests –Time reporting –Contract work Data Files Personnel data with skills, wages, etc. Equipment file with parts list Maintenance and work order schedule Inventory of spare parts Repair history file Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

18 Maintenance Costs  The traditional view attempted to balance preventive and breakdown maintenance costs  Typically this approach failed to consider the true total cost of breakdowns  Inventory  Employee morale  Schedule unreliability Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

19 Maintenance Costs – traditional view Total costs Breakdown maintenance costs Costs Maintenance commitment Preventive maintenance costs Optimal point (lowest cost maintenance policy) Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

20 Maintenance Costs – Full cost view Costs Maintenance commitment Optimal point (lowest cost maintenance policy) Total costs Full cost of breakdowns Preventive maintenance costs Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

21 How Maintenance is Performed Operator Maintenance department Manufacturer’s field service Depot service (return equipment) Preventive maintenance costs less and is faster the more we move to the left Competence is higher as we move to the right Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

22 Total Productive Maintenance (TPM)  Designing machines that are reliable, easy to operate, and easy to maintain  Emphasizing total cost of ownership when purchasing machines, so that service and maintenance are included in the cost  Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot service  Training workers to operate and maintain their own machines Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

23 Categorization of facilities, equipment and systems Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

24 DUBROVNIK AIRPORT MAINTENANCE CONCEPT Documents :  Zakon o zračnom prometu 69/09 (čl. 79)  Pravilnik o aerodromima NN 64/12  Pravilnik o održavanju i pregledanju aerodroma te mjerama potrebnim za njegovu sigurnu uporabu, NN 65/05  ICAO Annexes and Airport service manuals (Annex 9) Brochures and practices:  Strategic Approach to Facilities Life Cycle Management  Product technical sheets  “Best practice” the result is Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

25 Aerodromski priručnik poglavlje 4.7. INTERNI PRIRUČNIK ZA ODRŽAVANJE 1. OPREMA ZA PRIHVAT I OTPREMU ZRAKOPLOVA I PUTNIKA 2. VOZILA IZVAN PLATFORME 3. ELEKTRO OPREMA 4. ELEKTRONIČKA OPREMA 5. STROJARSKA OPREMA 6. OBJEKTI I INFRASTRUKTURA 7. RTG UREĐAJI 8. INFORMATIKA Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

26 GALIOT Device structure Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

27 Galiot Device structure layers  Categories: 96 (GSE 19)  Devices: 600 (GSE 300)  Procedures: 400 Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

28 GALIOT Departments Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

29 Implementation Year of admin.% of admin. in GSE equipment Public vehicles Electro eq Electronics Mechanic eq Infrastructure Security eq IT Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

30 GALIOT History at DBV Airport  Maintenance of GSE equipment  – UKMP, Accident report, NOTAM, RIFF, Update with lighting equip.  – update with electrical equip. and infrastrucutre  – reporting, messaging, alarm, scheduling, update with security equip.  – Emergency module  – update with Airport manual (incl. electronic and mechanic equip.). Iphone application for Emergency module  full integration of Galiot based at Airport Manual including new module structure. Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

31 GALIOT Maintenance Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

32 Izbornik 1 Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

33 Izbornik 2 Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

34 Report – GSE Maintenance Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

35 Report – Lighting Maintenance Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

36 Report – GSE repair Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

37 Statistics and Audits Preventive maintenance RepairsUpgrade and new Outsourcing GSE equipment (aprox. 120 selfpropelled towed units) 517 (without weekly overhaul by operators)  AUDITS by Airlines, Agency and others Authorities:  Total yearly checking procedured and SLA  of which 3-5 checking in detail GSE maintenance  and 2-3 checking in detail operational surfaces, pavements, strips, lighting, signage and markings. Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

38 GALIOT – Maintenance conclusion  easy planning and control  automatic counting and scheduling  self-made procedures  easy administration  useful reports and notifications  important warnings by levels  history Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

39 GALIOT – Maintenance module  THANKS TO MER SYSTEMS for development of the module according to best practice and custom made by DBV Airport inside National and EU regulatory frame & keep it up to date. Galiot Conference, Split 8/9. MAY Author: Tomislav Macan, DBV Airport Chief Technical Officer

40 THANK YOU Tomislav Macan, DBV Airport Chief Technical Officer


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