TOPIC:

IMPROVING MAINTENANCE

Things you need to learn:

Differences between preventive and
breakdown maintenance
How to improve maintenance
Definition of autonomous maintenance

TYPES OF MAINTENANCE:
PREVENTIVE MAINTENAINCE
BREAKDOWN MAINTENAINCE

PREVENTIVE MAINTENANCE:
- involves routine inspection, servicing &
keeping facilities in good repair to prevent
failure

BREAKDOWN MAINTENANCE:
- involves reparation of machines that
failed

IMPLEMENTING PREVENTIVE
MAINTENANCE
1. Determine when preventive maintenance is economical
2. Maintaining equipment history
3. Choose the best maintenance policy

Assume that BSA 3-7, an accounting firm, uses high speed printers in report preparations. The
computerized approach however, has a problem. Over the past 20 months, the printers have
broken down at the rate of:
Number of breakdowns

Months

4
20 TOTAL

Each breakdown, BSA 3-7 estimates that it loses average of 300 in production time and repair
service (Policy 1). One alternative is to purchase a service contract for preventive maintenance.
But, though it contracts for preventive maintenance, there will be still breakdowns averaging 1 per
month. The price for this service is 200 per month (Policy 2).

In order to choose between 2 policies, follow these 4 steps:

1. Compute the expected number of breakdowns if the company continues as
is. (Policy 1)
Breakdowns

Frequency

2/20 = 10%

8/20 = 40%

6/20 = 30%

4/20 = 20%

Expected number of breakdowns = (corresponding frequency) X corresponding number of breakdowns)

= (10% x 0) + (40% x 1) + (30% x 2) + (20% x 3)
= 1.6 breakdowns per month

2. Compute for expected breakdown cost of Policy 1.

Expected breakdown cost = Expected number of breakdowns/month x Cost per breakdown
= 1.6 x 300
= 480/month

3. Compute for expected preventive cost (Policy 2).

Expected preventive cost = Cost of expected breakdown/month for Policy 2 + Cost of Service
Contract
= (1 x 300) + 200
= 500/month

4. Compare the two policies.

P500month > P480/month
DECISION: Policy 1

INCREASING REPAIR
CAPABILITIES

well-trained personnels
adequate resources
establish a repair paln and priority
material planning
identify the cause of breakdowns

design ways to improve MTBF

AUTONOMUS MAINTENANCE
MAINTENANCE
- an approach that an operator partners
with a maintenance personnel
to observe, check, adjust, clean
and notify