Professional Documents
Culture Documents
Maintenance Management
Maintenance Management
1
Overview
Introduction
Repair Programs
Preventive Maintenance (PM) Programs
Machine Reliability
Trends in Maintenance
Maintenance Issues in Service Organizations
Wrap-Up: What World-Class Companies Do
2
Equipment Malfunctions
3
Maintenance Departments
4
Maintenance Activities
Repairs
Repair activities are reactive.
Breakdowns and malfunctions typically occur
when equipment is in use.
Standby machines and parts can speed repairs.
Preventive Maintenance (PM)
Regularly scheduled inspections are performed.
PM activities are performed before equipment
fails.
PM is usually performed during idle periods.
5
Tradeoff Between Repairs and PM
6
Tradeoff Between Repairs and PM
Minimum Total
Maintenance Cost
Total
Maintenance
Minimum
Costs
Level of Preventive
Preventive Maintenance
Maintenance Cost
Breakdown
and Repair
Cost
Degree of Preventive Maintenance
7
Maintenance Policies that Reduce
Frequency and Severity of Malfunctions
Reduces Reduces
Maintenance Policy Frequency Severity
Emphasize preventive maintenance X X
Provide extra machines X
Replace machine parts early X
Involve operators in maintenance X X
Overdesign machines X
Design machines for maintainability X
Enhance maint. dept.s capability X X
Increase spare parts supply X
Increase standby machines X
Increase in-process inventories X
8
Repair Programs
Objectives
Get equipment back into operation as quickly as
possible.
Control cost of repairs crews.
Control cost of the operation of repair shops.
Control the investment in replacement spare parts.
Control the investment in standby or backup
machines.
Perform the appropriate amount of repairs at each
malfunction.
9
Repair Crews and Standby Machines
10
How Speedy Should Repairs Be?
Cost ($)
Minimum
Total Cost
of Repairs Total Costs
of Repairs
Cost of Repair
Crews & Shops,
Spare Parts, and
Standby Machines
Cost of
Interruptions to
0 Production
Slow Speed of Making Repairs Fast
11
Breakdowns Trigger
Repairs and Corrective Actions
An equipment breakdown should trigger two actions:
Fast repair of the malfunction equipment
12
Extent of Repairs
13
Advantages of Letting Workers
Repair Their Own Machines
Greater variety may make job more satisfying
May be more sensitive to potential malfunctions
Increase flexibility
Can make minor repairs faster
Can avoid minor repairs by cleaning, lubricating,
adjusting and servicing machines
Operate machines more carefully
14
Reasons for a PM Program
15
PM and Operations Strategies
16
Automation and the Prominence of PM
17
Scheduling PM Activities
18
PM Database Requirements
19
Modern Approaches to PM
20
Decision Analysis in PM
21
Determining the Frequency of Performing PM
22
Expected Number of Breakdowns
n
Bn N( p n ) B(n 1) p1 B(n 2) p 2 ... B1p (n 1)
1
where:
Bn = expected number of breakdowns for each of the
PM policies
pn = probability that a breakdown will occur between
PM inspections when PM is performed every n
periods
N = number of machines in group
23
Example: PM Frequency
24
Example: PM Frequency
25
Example: PM Frequency
n
B n N( p n ) B(n 1) p1 B(n 2) p 2 ... B1p (n 1)
1
B1 = 4(0.2) = 0.800
B2 = 4(0.2 + 0.3) + 0.8(0.2) = 2.160
B3 = 4(0.2 + 0.3 + 0.5) + 2.16(0.2) + 0.8(0.3) = 4.672
26
Example: PM Frequency
Exp. Weekly
PM Exp. Number Exp. Weekly Total
Every Number of BDs Cost of Cost Weekly
n Wks. Of BDs per Wk. BDs of PM Cost
1 0.800 0.800 $6,400 $6,000 $12,400
2 2.160 1.080 8,640 3,000 11,640
3 4.672 1.557 12,456 2,000 14,456
The policy that minimizes total weekly cost is:
perform PM every 2 weeks.
27
Large-Scale PM Projects
28
Approaches to Improving
Machine Reliability
Overdesign - enhancing the machine design to avoid
a particular type of failure
Design simplification - reducing the number of
interacting parts in a machine
Redundant components - building backup
components right into the machine so that if one part
fails, its automatically substituted
29
Secondary Maintenance Responsibilities
30
Trends in Maintenance
31
Computer Assistance in Maintenance
32
Maintenance Issues in Service Organizations
33
Wrap-Up: World-Class Practice
34
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