THE MECHANIC NEXT DOOR
Maintenance, repair and overhaul (MRO) has become a buzzword the world over as the cost of equipment both in defence domain as well as in civil domain is rising to astronomical levels. The expertise required for MRO support is primary centred into the hands of OEMs and therefore, it is they who are establishing various MRO hubs both in the defence domain as well as in the civil domain specially where aeroplanes and ships are concerned. The model has been evolving on regular basis from 100 percent sourced from the OEM to incorporation of local experts, of course, after upskilling them appropriately.
It is obvious that interest of OEMs will be limited to this support to their own supplied equipment. This support remains active when the supply lines and business interests are continuing, however, reduces when business expansion is not intended to be continued for multiple reasons. New norms of MRO are also emerging nowadays where such setups are being established by other than those from the OEMs. The newly structured hubs address the requirement of multiple OEMs and have necessary tie ups with them for skilling and spare support. The trend of such MRO hubs coming in those countries is growing where the user base is higher including the future potential of expansion besides availability of the expertise. India is already on its way to become aviation and ship MRO hub as a country as initial baby steps have been taken which need to be expanded both in terms of size and scope.
Normally when we use the term ‘MRO’, it gives a mental sense of higher end equipment both in the defence services as well as in the civil. However, MRO is needed in every equipment right from a bicycle to a hypersonic missile. Large number of equipments of ‘so called low cost’ and of common use despite being in large numbers are still to be associated with this term MRO in a routine way and that is the great challenge.
This thought is about the mechanic next door who repairs punctures, changes tyres, changes batteries and such services which don’t require specialised equipment and infrastructure. A roadside place invariably of the government one, and some electric connection is all that he has but has developed reasonable skill sets to address the MRO needs of all those who are local to the place and also passer by and need this support in distress. This mechanic next door also provides at least ‘MR’ part of MRO and his empowerment will enable establishment of quality chains of MRO in the country. Basic MRO needs and how can that be fulfilled, will be examined in the succeeding paragraphs.
Maintenance
When any equipment is introduced for use and bought by the user, invariably it comes with some warranty and/or guarantee. These two terms are often confused. Guarantee relates to the performance standards of the sold equipment which is assured to the user/buyer. As against this, warranty relates to the commitment of manufacturer/seller to repair and replace the defective product up to a specified period. It is not necessary that the entire equipment has a common warranty period. It’s separate parts may have warranty for separate durations and there may be certain exclusions.
The equipment may be categorised in different forms, but two categorisations are important one those which come duly assembled and are ready to use whereas the other ones are those which require installation. Normally all the equipment are accompanied with brochures giving reasonable details to extend this support but there are certain equipment which are installed free or with some nominal charge from 5he manufacturers accredited staff. Normally, such services should be utilised but at times we attempt to do it ourselves or take the assistance of the mechanic next door. Mechanic next door is contacted when the installation support is either time critical or cost effective. Though there is no statistical data to indicate that the services provided by these local mechanics are any less superior but with growing trend of branding and economic well being, the comfort is more when an accredited mechanic provides the support. This is resulting in increasing usage of aggregators like ‘Urban Company’ to an unbelievable levels.
It will be therefore prudent that some kind of quality accreditation is given to these individuals. This certification can be from OEM/suppliers . Alternately once these people are on the rolls of some trusted brands/service provider then the quality assurance is given by the company even if the individuals providing the service are not individually accredited. If we have the vision of having MRO networks in the country and abroad, upskilling and accreditation establishment will also need to be given due attention including expansion. This will ensure availability of trained manpower in this ever expanding field.
Repair
While effective preventive as well as planned maintenance will reduce the scope of repairs substantially but repairs will still be needed. Repairs should not be seen only from the immediate fault removal perspective but an institutional mechanism should exist to study the reasons necessitating repair. Recurring faults in a particular component should be followed by design change as well as qualitative improvement in the components failing repetitively.
It is therefore important that we not only identify suitable tools and their specifications but methods of repair domain also being available so that any repairer needing this support can access the nominated websites to do the needful. MRO Forum can either lead this initiative or can extend this support with link based model.
It is also equally important that the mechanic next door is also co-opted in the national network. Focus of central and state governments to provide free mobiles, cheap data and internet inroads provide the requisite wherewithal to develop this connectivity. It should be made mandatory for all to be part of this network nationally and some basic data related to their skill sets can also be captured to create a usable database. This approach will reduce the idling time of these maintainers and more power to them as well as the users.
For repair to be carried out, there is no need for the repairer to always come home or the repairable equipment to be taken to the mechanics. A model currently in vogue by Urban Company could be followed with appropriate modification. Since all the repairers will be available ‘online’ due to the proposed model, video consultation can be provided for trivial repair needs. At times, wrong pressing of switch at user end can also create problem viz AC throwing hot air in place of cool air. All this as well as other trivial rectifications can be done by the user. It becomes most cost effective in terms of time as well as finances.
Next stage is wherein the mechanic comes home and repairs the product. It addresses basic faults including replacement of minor items being carried by the mechanic. The visit charges are adjusted towards the bill if the same is needed.
Last stage relates to the replacement of major assembly for which assessed cost is intimated and repair is either carried out at user location or at the repairer end in the nominated location.
Once we empower the mechanic next door, all such facilities can be easily provided. To make it more potent, a new mechanism may be needed to be instituted where a fixed resource/spare/tool is maintained at user end, little upgraded resource within the society complex, mohalla or the village and higher end wherewithal with the repairer duly networked with transparent asset visibility.
Overhaul
This is the most advanced activity and is largely understood by the majority. Though this is most complex, resource intensive and critical portion, this also requires major re-set. India has huge potential for this capacity and can be the world leader. Baby steps have already started. This activity has to be made time efficient. Our current model in the defence forces is also not as efficient as it should be. A detailed study indicating pitfalls needs to be undertaken to fix the problems. The overhaul should be also linked to upgrades as well rather than getting the new equipment at the exorbitant cost.
End Lessons
India has huge HR which requires to be upskilled and accredited. All such resources need to be networked with national mandate and being part of national data base. Focus must be on preventive maintenance as well as predictive maintenance to reduce repair and overhaul needs. Time based MRO should be shifted to functional parameter model with quantifiable parameters. The MRO must factor design as well as upgrades to exploit the full potential. A quality upgrade can save replacement of the equipment and thus can be huge cost saver.
Crafting of MRO with automation, IoT and other technological developments like AI, blockchain, 3 D printing etc can bring in unparalleled surge in the equipment availability with drastic reduction in the costs. It may appear childish to some of the readers but a dedicated cell under PMO can transform the nation and address the problem of unemployment. It can also help other nations with this soft power. Defence veterans and industry leaders can take the lead.
Sanjay Pande
My compliments to Gen Ashok sir for this intelligible article on MRO giving the insight ,end lessons and way ahead.
MRO has now being practiced in almost all major industries and various IoT platforms are already existing globally, the benefits of which is now already established.
With the aim of taking on challenges of any equipment from “Womb to Tomb” without being dependent on other external agencies or country is need of the hour. Which precisely ATMANIRBHAR BHARAT is looking towards. Required potential of technically skilled human resource is already there with Defense. With equipment specific accreditations by OEMs for few sophisticated systems, to this tech skilled manpower ,concept of MRO can be very well be implemented for Defense systems also, and in the bargain we me reduce the Brain drain of our trained and skilled manpower.
For this, as rightly brought out by the author, WILL to do has to be generated at the highest level, and if implemented it will pay rich dividend in terms of saving national revenue and increase in operational availability of equipment at all time.