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INDUSTRIAL MAINTENANCE Elevating maintenance to Maintenance 4.0

Jan 24, 2020

The maintenance world is evolving just like any other industry. New process and techniques are constantly being developed, tested and implemented to gain best efficiency rate with the highest ROI. The Economic Times recently hosted the third edition of the World Class Maintenance Summit to delve on the topics of integration of maintenance with digitisation and smart factory and impact of this revolution over manpower distribution. EM was the media partner for the summit.A report reflecting on the event…

To bring out the latest trends and topics involving maintenance upgradation, the Economic Times recently organised the World Class Maintenance Summit in Mumbai, India. The symposium fostered discussions and closed room workshops for maintenance, operations and technical heads across sectors to ensure the industry achieves operational excellence and, enables them to build plants of the future.

Moving from cost to cost-effective

The day one of the summit commenced with a special address on ‘Impact of Industry 4.0 in manufacturing industry’ by Capt BVJK Sharma, Director-Ports, Adani Group. Elaborating on the industry progression, and technologies like Predictive Maintenance, Big Data, reliable centred maintenance, etc, aiding in achieving optimum productivity, Sharma mentioned, “Through reliability centred maintenance, one can ensure efficient & cost-effective maintenance task.”

Following this, a panel discussion was held on ‘Breaking down maintenance: Preventive vs corrective’. The moderator, Shekhar Jitkar, Publisher & Chief Editor, EM, set off the conversation with a comment on the need for change through digitalisation and the necessity to understand the challenges and approach one should adopt; on this, Sudhir Bhujbal, Head of Facilities Management, Environment Health & Safety, Maintenance, Bosch Electric Drives, commented, “In the last two and a half decades, maintenance has moved from reactive to proactive and from a function to an integral process.” Adding on to this, Ramchandra Pandian, Vice President – Engineering & Maintenance, Pidilite Industries, cited, “It is important to asses if changes are happening across industries or are there any exceptions. Depending on the process and criticality of the industry, one needs to adopt the technologies needed.” Answering a question on if there are any advantageous strategies in proactive maintenance, Vishal Mittal, Chief Maintenance Manager, Indian Oil Corporation, mentioned, “Unless and until there is support from the top management, one will be unable to implement proactive maintenance.” Commenting on Indian industry’s beliefs in corrective maintenance more than preventive or predictive, Robin Goel, Operations Professional, Driving Reliability & Productivity through People & Technology, Danone India, remarked, “You can have a system installed in the plant but you need human resource who knows how to utilise it. That’s why, there needs to be a culture shift.” Opining on the need of smart tech, Sanjay Pokal, Head-Engineering, BASF India, stated, “Today’s world is changing; so, today, you have to go with FME & RCM to ensure asset is available when needed to perform.”

Integrating maintenance with digitalisation

Following this, C J Iyer, Executive Director, BPCL, spoke on ‘Industry 4.0 – Experiences for improved maintenance’. Illustrating on smart manufacturing and its pillars, need for asset management and for maintenance being a top drive, he accentuated, “The key thing is not technology or excellence, but it is marrying the two.” Further, K G Shenoy, Sr Vice President, Mahindra & Mahindra (M&M), elaborated on ‘Industry 4.0 further complicate or simplify plant maintenance’. With reference to M&M using reliability centred maintenance, he emphasised, “No digital initiative will help one if their base is not strong.” Next, to talk about the next step for breakthrough on data and asset management, IoT pumping predictive maintenance and dynamic condition monitoring, V Bino George, Head of Business Consulting – Infor India, spoke on ‘Maintenance 4.0’.

Subsequently, Shripad Ranade, Leadership Coach and Management Consultant, ikigai Discoveries, moderated a panel discussion on ‘How we can improve our maintenance practices by using predictive maintenance’. Giving perspective on the industry’s journey to adopt predictive maintenance, Nitin Tilak, GM CMS, Tata Motors, commented, “All industries are now making a shift from corrective maintenance to predictive maintenance.” To this, Prasanth NV, Assistant General Manager, Plant Maintenance, TVS Motors, added, “Proactive maintenance is eliminating breakdown. With the right data collection, maintenance can be cost effective.” Giving a picture on how pharmaceutical factories are benefiting from predictive maintenance, Dr Bikash Kumar Nayak, Plant Head, Aurobindo Pharma, explained, “By default, generation of data with the help of machine helps us take corrective action and prevent breakdowns.” Offering a holistic standpoint on maintenance, Prabhakaran P V, Head – Product Management, Fluke Technologies, emphasised, “We need to understand the criticality of the load & device, and plan accordingly to maintain it.” Commenting on improving automatic analytic data, Firdous Ansari, Vice President, Ambuja Cements, remarked, “One can improve automatic analytic data by accurate current data and historic data.”

Strategising & maintaining reliability

This was followed by a dialogue on ‘How cyber security can create an opportunity for manufacturing industry’, involving Burgess Sam Cooper, Information and Cybersecurity Advisory Service Partner, Ernst & Young and Brijesh Singh, Inspector General of Police, Cyber, Government of Maharashtra, discussing the various imperatives and guidelines of cyber security. During the discussion, Singh emphasised, “Manufacturing sector is particularly more vulnerable because of all the IT setups it hosts. We need to build a competitive edge into process and product so that even people have the confidence.”

Next, there was an innovative un-conferencing session involving the audience discussing ‘Best shutdown & turnaround strategy for a plant’. The audience, that were divided into groups of three, discussed the various implications and ideal strategies one would implement during a shutdown. Following this was a fire side chat on the ‘Challenges and issues in adapting Industry 4.0 at plant level’ moderated by Sandeep Chatterjee, Associate Director, Deloitte India. Elaborating on data ownership, radical change and digital change, DS Ravindra Raju, President – Manufacturing, Deepak Fertilizers & Petrochemicals, emphasised, “A leader must handle the change happening within the organisation and ensure that no one feels threatened by the technology.” Adding on to this, Dhruv Jain, Group CoE (Smart Manufacturing & Industry 4.0), Aditya Birla Group, commented, “We need to involve people right from the start of the project. Prioritise areas while implementing technology.” Further, the trio also discussed the potential benefits of Industry 4.0 and it becoming an enabler. The first day culminated with Santanu Satapathy, Head – Engineering, JK Tyre & Industries, discussing ‘The future of reliability centred maintenance and how it is evolving’.

Formulate and redefine

The second day of the summit opened with a session reviewing the ‘Process preparations and HSE management during turnarounds’. Analysing the factors that trigger a plant shutdown, phases & execution of a shutdown and consequence management, Vinayak Marathe, Sr Vice President, Reliance Industries, mentioned, “To understand the best practises one needs to go, learn, adapt and implement.”

This was followed by a panel discussion on ‘How digitisation in maintenance is redefining safety in industry’. Moderator Chatterjee set off the discussion by questioning data and its importance, to which, Dr Ajay Srivastava, Sr General Manager, Operations, Sun Pharmaceutical Industries, remarked, “Data is the real money & real power right now.” Replying on digitalisation revolutionising the manufacturing industry, Koppoli Krupanand, Vice President, VPR Mining Infrastructure, commented, “Digitalisation is the way forward. It’ll be vital for industries to control, analyse and parameterise data.” Adding tidings on digitalisation in the auto industry, Gaurav Bhaskar, Maintenance, Mahindra & Mahindra, emphasised, “We need to start thinking of maintenance as a cost profit centre than an expense centre. Digitalisation not only shows us the problem but also offers us the solutions.” Noting on the adoption levels in the tyre industry, Satapathy, mentioned, “The tyre industry is also on the journey of digitalisation, and it is slowly taking control of the industry.” Adding on the benefits, Mathew Samuel, Head Integral Plant Maintenance Business, Siemens, remarked, “Due to digitalisation, there is manual safety as well as data integrity.”

Enabling the smart in maintenance

Thereafter, elaborating on ‘Smart asset maintenance: Digital technology and its impact on downtime’, Vijay Kumar Saboo, Head, Manufacturing & Supply Chain, Godrej & Boyce, mentioned, “Maintenance 4.0 is progressing to be a more exact science and we need to move towards it.” To explain digitalisation of the walk by inspection and how it works, Kaushal Mishra, Vice President – Manufacturing, Ambuja Cements, hosted a session on ‘How mobile is advancing manufacturing maintenance’. Following this, a special case study on ‘Using data analytics to improve operations and maintenance’ by Narendra Pasuparthy, CEO and Founder, Nandu’s Chicken. During this, he elaborated on the use of digitalisation in poultry farming. Next, Probal Ghosh, Chief – Mechanical, Tata Steel, spoke on ‘Using data and analytics to improve operations and maintenance’. He explicated on steel industry value chain, seamless integration that comes in with Industry 4.0, linkage between condition monitoring & predictive model and its needs. He mentioned, “Digital transformation is the key to create a successful ecosystem.”

Speaking on ‘Mechanised cleaning solutions for manufacturing industry segment’, Rajesh Wariar, DGM, IP Cleaning India, commented, “A technology is only as good as the training provided to use it.” Following this, the ‘Partner’s pitch session’, wherein, event partners – Infor, IP Cleaning India and Fluke Technologies pitched their products/technologies interpersonally to the audience. Lastly, bringing an end to the second day of the summit, Neeraj Kumar, Plant Maintenance Trainer, Maintenance Consultant, RCM Facilitator & Learner, conducted a workshop on ‘Asset strategy development and deployment’.

Embracing a digital upkeep

The Economic Times through the platform of the Plant Maintenance Summit delivered learnings, which will aid the organisations seeking solutions for issues faced right from planning to the final execution on ground through digitalising maintenance. This will in turn help leaders from the industry revolutionise the plant of the future.

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  • Partner’s pitch session, wherein, event partners – Infor, IP Cleaning India and Fluke Technologies pitched their products/technologies to the audience

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