Dubrovnik Airport
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Maintenance Costs
Cost to replace or repair
 Losses of output
 Delayed shipment
 Scrap and rework

Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Preventive Maintenance (PM)
– “Prevention is better than cure”
 Procedure - Stitch-in-time
 It
 Principle
 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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Candidates for Preventive
Maintenance
Frequency of Failure
Good candidates
have more normal
distribution with low
variability
Mean Time Between Failure (MTBF)
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Computerized Maintenance System
Data Files
Output Reports
Equipment file
with parts list
Inventory and
purchasing reports
Equipment
parts list
Maintenance
and work order
schedule
Equipment
history reports
Repair
history file
Inventory of
spare parts
Personnel data
with skills,
wages, etc.
Data entry
– Work requests
– Purchase
requests
– Time reporting
– Contract work
Cost analysis
(Actual vs. standard)
Work orders
– Preventive
maintenance
– Scheduled
downtime
– Emergency
maintenance
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Maintenance Costs –
traditional view
Total
costs
Costs
Preventive
maintenance
costs
Breakdown
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Maintenance Costs –
Full cost view
Costs
Total
costs
Full cost of
breakdowns
Preventive
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
How Maintenance is Performed
Operator
Maintenance
department
Manufacturer’s
field service
Depot service
(return equipment)
Competence is higher as we
move to the right
Preventive
maintenance costs less and
is faster the more we move to the left
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Categorization of facilities,
equipment and systems
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Aerodromski priručnik
poglavlje 4.7.
INTERNI PRIRUČNIK ZA ODRŽAVANJE
1.
2.
3.
4.
5.
6.
7.
8.
OPREMA ZA PRIHVAT I OTPREMU
ZRAKOPLOVA I PUTNIKA
VOZILA IZVAN PLATFORME
ELEKTRO OPREMA
ELEKTRONIČKA OPREMA
STROJARSKA OPREMA
OBJEKTI I INFRASTRUKTURA
RTG UREĐAJI
INFORMATIKA
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
GALIOT Device structure
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Galiot Device structure layers

Categories: 96
(GSE 19)

Devices: 600
(GSE 300)

Procedures: 400
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
GALIOT Departments
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Implementation
Year of admin.
% of admin. in 2013.
GSE equipment
2003.
100
Public vehicles
2003.
100
Electro eq.
2005.
100
Electronics
2009.
50
Mechanic eq.
2009.
50
Infrastructure
2005.
90
Security eq.
2006.
100
IT
2010.
50
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
GALIOT History at DBV Airport







2003. - Maintenance of GSE equipment
2004. – UKMP, Accident report, NOTAM, RIFF,
Update with lighting equip.
2005. – update with electrical equip. and
infrastrucutre
2006. – reporting, messaging, alarm, scheduling,
update with security equip.
2008. – Emergency module
2009. – update with Airport manual (incl. electronic
and mechanic equip.). Iphone application for
Emergency module
2010.-2013. full integration of Galiot based at Airport
Manual including new module structure.
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
GALIOT Maintenance 2014.
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Izbornik 1
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Izbornik 2
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Report – GSE Maintenance
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Report – Lighting Maintenance
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Report – GSE repair
Galiot Conference, Split 8/9. MAY 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
Statistics and Audits
2013.
GSE
equipment
(aprox. 120
selfpropelled
+ 200 towed
units)
Preventive
Repairs
maintenance
Upgrade
and new
Outsourcing
517 (without
weekly
overhaul by
operators)
18
8
580
AUDITS by Airlines, Agency and others Authorities:
 Total 15-20 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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
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 2014.
Author: Tomislav Macan, DBV Airport Chief Technical Officer
THANK YOU
Tomislav Macan, DBV Airport Chief Technical Officer
tomislav.macan@airport-dubrovnik.hr