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MG 443 Lesson 6 Maintenance Strategies
MG 443 Lesson 6 Maintenance Strategies
MG 443 Lesson 6 Maintenance Strategies
Presented by:
Prof. E.A.M. Mjema
What is a strategy?
Strategyin a generic term refers to the
conception and the carrying out of a
general idea with the aim of reaching a
specific target.
Strategy can also be understood as the
enacting of the company's policy
through the company's management as
the basis of a long term planning
We think in order to act, to be
sure, but we also act in order
to think. We try things, and
those experiments that work
converge gradually into viable
patterns that become
strategies.
Maintenance Strategy – Cont.
A rule that fixes the time of doing a
maintenance action, the type of the
maintenance action, and a specific part
of a machine to be maintained.
A bulk of possible maintenance actions,
from a various possible conditions of a
piece of equipment to be maintained
and for a given period of time.
Maintenance strategies in this context will
therefore refer to:
the selection of type of maintenance from
the available options for planning and for
carrying out maintenance work,
the planning of the time for carrying out
of the maintenance work,
the planning of the required maintenance
personnel, and
the planning of the maintenance tools
Maintenance strategy planning is an
attempt to answer:
What to be done, with what kind of tools?
Which artefact - equipment, infrastructure,
to be worked on?
When to be done (either at what time or on
what occasion)?
Who is going to do it?
Where to carry out the work (in what place -
in the workshop, in-situ, etc.)?
How to carry out the work (self, contracts,
outsourcing, integration, etc.)?
RCM Design
-Out
Breakdown Maintenance
Is done when the equipment is at failure
state
Advantages:
initial low costs
no planning hassle
can be cost effective if failure can be tolerated
Disadvantages:
effect on the plant reliability
difficult to plan the ensuing maintenance work
- high logistic downtime
needs high spare parts inventory
Government regulations
Insurance need
Outsourcing - cont
Advantages
Flexibility
in procurement of specialists
Smaller overhead costs
Disadvantages
Dependence on external company
Quality of maintenance
Competitorscan collude with your
maintenance service provider
Integration of Maintenance
giving over of the maintenance tasks to
the production personnel as well as the
integration of the maintenance
personnel in the production
creation of the small maintenance
service centres – decentralized
maintenance departments
Integration - Cont
Advantages
M/C operators are given responsibility to
maintain “their” machines
Better utilization of maintenance personnel
Disadvantages
Qualityof maintenance could be
compromised
Profession ethics – some technical works
could only be done by registered engineer
or technician
Total Productive Maintenance - TPM
A major shift in maintenance – it becomes
everyone’s responsibility
It is resisted by both production and maintenance
personnel
Production employees do not have sufficient skill
and time to perform maintenance tasks
Maintenance department will be forced to "fix"
the problems that production employees create
Scepticism - An attempt to make production
employees do more work so the organization can
get by with fewer maintenance employees
TPM - cont
overcoming this resistance and bringing
about the necessary change in
organizational culture
break down the walls between the
production and maintenance
organizations
creating new work environments
allocate sufficient resources toward the
maintenance effort
training and adjusting reward systems
TPM - cont
Advantages
Maximizing Overall Equipment Effectiveness
Autonomous Maintenance by the operators
Maintenance is a responsibility of everyone
Disadvantages
Qualityof maintenance work
Professional ethics
Preventive
maintenance else
Breakdown maintenance
Failure
Is there
Interruption Production;
consequential damage;
NO
safety risk; or
BM
increased failure rate?
Yes
PM
Is No
CBM Possible and PM
Economic?
Yes
CBM