MS321-Manajemen Industri

& Proyek

 Explain

the importance of maintenance in

production systems
Describe the range of maintenance
activities
Discuss preventative maintenance and the
key issues associated with it
Discuss breakdown maintenance and the
key issues associated with it
15S-2

Maintenance

All activities that maintain facilities and

equipment in good working order so

that a system can perform as intended
Two

basic categories

Building and grounds

Equipment maintenance

15S-3

 To

keep production systems in good

working order at minimal cost
Reasons for maintenance
To avoid production or service disruptions
To not add production or service costs
To maintain high quality
To avoid missed delivery dates

15S-4

Reactive Maintenance:
Breakdown maintenance
Reactive approach; dealing with breakdowns or

problems when they occur

Proactive Maintenance:
Preventive maintenance
Proactive approach; reducing breakdowns through

a program of lubrication, adjustment, cleaning,

inspection, and replacement of worn parts
15S-5

 Reasons

for keeping equipment running

Avoid production disruptions

Not add to production costs

Maintain high quality

Avoid missed delivery dates

15S-6

 Production

capacity is reduced

Orders are delayed

No

production

Overhead continues
Cost per unit increases
Quality

issues

Product may be damaged

Safety

issues

Injury to employees
Injury to customers

15S-7

Table 15S.1

Cost

Total Cost

Preventive
maintenance cost

Breakdown and
repair cost
Optimum Amount of
preventive maintenance
15S-8

 Preventive

maintenance: goal is to
reduce the incidence of breakdowns or
failures in the plant or equipment to
avoid the associated costs

Preventive

maintenance is periodic

Result of planned inspections

According to calendar
After predetermined number of hours

15S-9

Frequency of breakdown
Number of breakdowns
Frequency of occurrence

0
1
2
3
.20 .30 .40 .10

If the average cost of a breakdown is

$1,000, and the cost of preventative
maintenance is $1,250 per month, should
we use preventive maintenance?

15S-10

Number of
Breakdowns
0
1
2
3

Frequency of
Occurrence
.20
.30
.40
.10
1.00

Expected number of
Breakdowns
0
.30
.80
.30
1.40

Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400

Preventive maintenance = $1250
PM results in savings of $150 per month

 Predictive

maintenance

An attempt to determine when best to perform

preventive maintenance activities

Total

productive maintenance

JIT (Just-In-Time) approach where workers

perform preventive maintenance on the

machines they operate

15S-12

 Standby

or backup equipment that can

be quickly pressed into service
Inventories of spare parts that can be
installed as needed
Operators who are able to perform minor
repairs
Repair people who are well trained and
readily available to diagnose and correct
problems with equipment
15S-13

 Trade-off

decisions

Cost of replacement vs cost of continued

maintenance
New equipment with new features vs
maintenance
Installation of new equipment may cause
disruptions
Training costs of employees on new equipment
Forecasts for demand on equipment may
require new equipment capacity

When

is it time for replacement?

15S-14

Pustaka : Operational Management, William J. Stevenson,

McGraw-Hill.