Author: Mr Narashiman Jagannathan
INTRODUCTION
1. Maintenance, Repair and Overhaul (MRO) of any equipment is a unique rebuild process after a designated period based on exploitation. MRO is applied mostly on equipment for affordability as replacement involves high costs every other decade. The aim is to restore equipment capability to that of a new current generation or new equipment. By overhauling, the equipment is planned to be retained for four to six decades, and rebuilding offers a cost-effective option to the state.
2. The basic documents required to establish the MRO facility are identified and discussed in subsequent paras.
3. Contract Documents between Customer (who is holding the equipment) and service provider (who is establishing MRO facility to Customer).
- Protocol between customer and service provider. This may be said as proposal of scope of work for creation of production facilities in a systematic and calculated manner.
- Technical and commercial offer from service provider. Service provider conceives the ideas and methods for arranging various resources after studying the scope of work.
- Final contract document after mutual agreement of customer and service provider.
4. Detailed project report (DPR). This will include
- Bldg layout with marking of facilities (overall and function wise(like for engine, gearbox, electrical and electronics assy etc.,))
- Identification of Main MRO dept and support MRO process function wise( major assy like engine, gearbox, Electrical and Electronic assy)
- Requirement of manpower function wise
- Requirement of machineries and test equipment function wise
- Infrastructure requirement like work table, cupboards, racks etc.,
5. MRO flow process layout and process documents in detail are required for major assembly stages. Normally Transfer of Technology (ToT) for MRO will be provided from designer of Original equipment (OEM). Otherwise the service provider shall explore and establish these documents in line with OEM based on his expertise.
6. Spares Management. This is based on Manufacture recommended list of spares (MRLS) and expertise of service provider. In MRO process, the component is assessed after stripping and segregated based on limits given by designer or by expertise of service provider
- as reusable if it is within the permissible limit
- for reclamation (by rebuild or regeneration) if the spare is within the reclaimable limit (above discard limit and below permissible limit)
- Parts are discarded beyond this limit. New parts are fitted against this discarded items
7. The List of spares required for MRO is derived after identification of source of supply of spares
- to be procured
- Locally manufactured (Manufacture of spares (MOS))
- Trade item (standard items manufactured by local factories )
- Import from OEM
- to be reclaimed.
8. Regeneration Process books required for individual sparesin the event of reclamation. This will include details of material building process and manufacturing process to bring back to specified shape.
9. Manufacturing process documents for spares. This include manufacturing drawings, details of manufacturing processes (like machining, heat treatment, protective coating etc and QA plan).
10. QA plan and procedures for
- receipt inspection
- MRO stage inspection
- Final inspection and trials
- Calibration of measuring and testing equipment
- Material testing and analysis procedure
11. List of Machinery and Test equipment. This will include
- Special purpose machine/ tools(SMT), test equipment (STE)
- General purpose machinery, Material handling equipment, measuring and test equipment
- Special purpose test facilities (like trial tracks, gradient testing, dip testing etc.,
