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8/10/2019 Maintenance and Reliability in OM
1/22
University of the Southern
Caribbean
Operations Management
Maintenance and Reliability
Presented by Group 2
8/10/2019 Maintenance and Reliability in OM
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Purpose
Identify
Reliability functions or
activities
Role of maintenance in
reliability
Concepts for managing
reliability
Outline Introduction
Reliability functions
Role of maintenance
Approaches to
reliability management
Summary
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It is not the strongest, nor the mostintelligent that survives. It is the one that is
the most adaptable to change.
Reliability and maintenance are tools in themanufacturing survival tool kit!
- Al Poling
IntroductionSurvival in a Global Market
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Nolan and Heap define Inherent Reliability as:
"the level of reliability achieved with an effective
maintenance program. This level is established by the design
of each item and the manufacturing processes that
produced it. "
Reliability functions
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Key functional players
Design and development engineers
Production and quality assurance
personnel Test and evaluation personnel
Supply chain and item managers Sustaining (in-service) engineers
Field and warehouse maintainers
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Reliability Tactics
Improving individual components
Providing redundancy
Reduced single point of failure Enhances operational Quality
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Reliability The Big Picture
Meaningful definition:
TechnologyDevelopment
Production &Deployment
Operations & Support
Reliabil i ty Function s
System Development& Demonstration
ConceptRefinement
Reliability by the book=R(t)=1
et
MTBF
Reliability by the book=R(t)=1
et
MTBF
1
et
MTBFe
tMTBF
tMTBF
OverallEquipment
Effectiveness=
AvailabilityX
Performance
RateQuality
RateX
In other words, we tie $ directly
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Empowerment Reliability ScorecardAsset ManagementPrevention
Education/Training Design for Reliability RAM Modeling OEE
Performance Mgmt.
Multi-skilling
Operator Driven Reliability
TeamworkRoles & Responsibilities
Org. Structure
Vision & Mission
People
Mgmt. of Change
Contractor Mgmt.
T/A or S/D Mgmt.
Materials Mgmt.Standardization
Failure Investigation
Mtce. Work Mgmt.
Process
Reliability Centered Mtce.
Risk Based Inspection
Life Cycle Costing
CMMS/Data Mgmt.PdM/Cond. Monitoring
Basic PM
Critical Equipment Ranking
Tools/Methods
Customer
Training Hrs/Emp.
Learning & Growth
PM ComplianceInternal Business Process
Mtce $ as % RAV
Financial
Measurement
Total Plant Reliability
Best Practice Working Partially Working Not Working/Absent
Rel iab i l i ty Cons ul t ing benchmarks cus tomers to ident ify strengths,
recogn ize imp rovement opportu ni t ies and del iver act ion able roadmap
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Overall System Reliability
In The Fault Tree Analysis Guide a system is defined as:
"A composite of equipment, skills, and techniques capable of
performing or supporting an operational role, or both. A
complete system includes all equipment, related facilities,
material, software, services, and personnel required for its
operation and support to the degree that it can be
considered self-sufficient in its intended operational
environment."
l f
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Role of maintenance inreliability
Primary Roles Prevent
Support the updating of maintenance processes
Conduct preventive and predictive maintenance
Communicate with operators and engineers
Restore Diagnose failure
Take appropriate action on deficient items
Quality Assurance for maintenance
Report
Failure ID & categorization
Record failure and maintenance data Initiate deficiency reports/warranty actions
Requires
Trained and skilled maintainers
Interface with engineering & supply
Restore ReportPrevent
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Role of maintenance
Prevent failures
Restore Report
PREVENT
Support the updating of maintenance processes and schedules Support engineers as they periodically update maintenanceprocesses and schedules based on RCM analysis
Work with engineers, as requested, to assess impact ofoperational changes or environmental influences
Conduct Preventive and Predictive Maintenance
Maintain the embedded health management capabilities
Conduct PM and PdM tasks as planned to reduce total maintenance
Communicate with operators and engineers
Establish dialogue with operators and engineers to eliminatefailures
Ensure operators and engineers understand the current reliabilitystate
Support process updatesPM and Pd.M.Communicate with Ops &
Eng.
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Role of maintenance
Restore failed items Diagnose failure
Locate & isolate failed items
Skilled maintainers use approved troubleshooting equipment andprocedures
Take appropriate action on deficient items
Skilled maintainers use approved maintenance equipment, materials andprocedures
Reduce repeat failures (Is item under warranty? Is it a bad actor?)
QA/PA for maintenance processes and materials Ensure maintainers use qualified materials and processes
Establish a Quality Assurance program for maintenance
Analyze quality escapes and no fault found events for trends andcorrective actions
Prevent Report
RESTORE
Diagnose failureAppropriate action on item
Maintenance QA/PA
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Approaches to reliabilitymanagement
h f E h
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Techniques for EnhancingMaintenance Simulation: evaluates the impact of various policies Expert systems: mimic human logic and helps isolate various plant
faults
Automated sensors: warn about failing machine
Expert systems
Computers help users identify problems and select course of action
Automated sensors
Warn when production machinery is about to fail or is becomingdamaged
The goals are to avoid failures and perform preventive maintenancebefore machines are damaged
2011 Pearson Education, Inc. publishing asPrentice Hall
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Computerized MaintenanceSystemFlexibility
Planning
Reporting
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Autonomous Maintenance Emphasis on employee empowerment
Employees predict failures, prevent breakdowns,and prolong equipment life
Total Productive Maintenance (TPM)Combines the concepts of:
Total Quality Management (TQM)
Preventive Maintenance concepts Designing machines that are reliable, easy to operate, and easy to
maintain
Emphasizing total cost of ownership when purchasing machines
Utilizing the best practices of operators, maintenance departments anddepot service
Training for autonomous maintenance, in partnership with maintenancepersonnel 2011 Pearson Education,
Inc. publishing as PrenticeHall
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2011 Pearson
Education, Inc.publishing as Prentice
Maintenance StrategyComparison
MaintenanceStrategy Advantages Disadvantages
Resources/TechnologyRequired
ApplicationExample
Breakdown No priorworkrequired
Disruption ofproduction,injury or death
May needlabor/partsat odd
hours
Office copier
Preventive Work canbescheduled
Labor cost,may replacehealthycomponents
Need toobtainlabor/partsfor repairs
Plantrelamping,Machinelubrication
Predictive Impendingfailures canbe detected& workscheduled
Labor costs,costs fordetectionequipment andservices
Vibration, IRanalysisequipmentorpurchasedservices
Vibrationand oilanalysis of alargegearbox
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18
Costs
Total Cost
Lost Revenue
MaintenanceCost
100%Mechanical Availability
Profit Optimization
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19
Path to First Quartile
High Mechanical Availabilityand Low Cost
LowMechanical Availabilityand High Cost
98
1 1.4 >10
Maintenance Cost, % (US $/PRV)
MechanicalA
vailability,
%
Not SustainableEffectiveness
Efficiency and Cost
Industry Leaders
Facility
Sustainable
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Summary
Reliability functions involve numerous activities across various functionalareas.
As the first observer of failures maintenance plays a key role -prevent,restore, and report
Focus on design improvements
Practice preventive maintenance
Give employees ownership of their equipment
Build and maintain systems that drive out variability and inspire customersatisfaction
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Kececioglu D. (2003) -Maintainability, Availability, and Operational Readiness Engineering Handbook.DE Stech
Publications, Inc, Electronic books
Hayes, T. (1997), The Learning Organization: fashionable fad or path to progress?www.globasearchbusiness.com
Gallimore K. F. and Penlesky, R.J. (1988) A framework for developing
maintenance strategies, Production and Inventory Management Journal, First Quarter, pp.16 -21.
LBNL 2005. Planning and Reporting for Operations & Maintenance in Federal Energy Saving Performance Contracts.
Lawrence Berkeley National Laboratory, Berkeley, California. Available at: http://ateam.lbl.gov/mv/.
Heizer, J., & Render, B. (2014). Maitenance and Reliability -Chapter 17 PowerPoint presentation. Retrieved from
https://ttuscmy.sharepoint.com/personal/ramellas_usc_edu_tt/_layouts/15/guestaccess.aspx?guestaccesstoken=
%2bfnjUOIuVrxiFSuSESugxgNcoozS9bwjSkGFWb7jjTs%3d&docid=038e4aa394a3846b0b05cc9486e596cf4
Industrial Energy Efficient Training/Dupont Sustainable Solutions. Retrieved from
https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3
O&M Best Practices Guide, Release 3.0, Chap 5: Types of maintenance Program. Retrieved from
http://www1.eere.energy.gov/femp/pdfs/om_5.pdf
References
http://www.globasearchbusiness.com/https://ttuscmy.sharepoint.com/personal/ramellas_usc_edu_tt/_layouts/15/guestaccess.aspx?guestaccesstoken=%2bfnjUOIuVrxiFSuSESugxgNcoozS9bwjSkGFWb7jjTs%3d&docid=038e4aa394a3846b0b05cc9486e596cf4https://ttuscmy.sharepoint.com/personal/ramellas_usc_edu_tt/_layouts/15/guestaccess.aspx?guestaccesstoken=%2bfnjUOIuVrxiFSuSESugxgNcoozS9bwjSkGFWb7jjTs%3d&docid=038e4aa394a3846b0b05cc9486e596cf4https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3https://ttuscmy.sharepoint.com/personal/ramellas_usc_edu_tt/_layouts/15/guestaccess.aspx?guestaccesstoken=%2bfnjUOIuVrxiFSuSESugxgNcoozS9bwjSkGFWb7jjTs%3d&docid=038e4aa394a3846b0b05cc9486e596cf4https://ttuscmy.sharepoint.com/personal/ramellas_usc_edu_tt/_layouts/15/guestaccess.aspx?guestaccesstoken=%2bfnjUOIuVrxiFSuSESugxgNcoozS9bwjSkGFWb7jjTs%3d&docid=038e4aa394a3846b0b05cc9486e596cf4http://www.globasearchbusiness.com/8/10/2019 Maintenance and Reliability in OM
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Group Members RolesTeam Leader Adrian Cabralis,
To Liaise with the members as to the status of the work within the team
To ensure that required resources are in the correct place at the right time
To schedule task and ensure that one task is not holding up others tasks and to re-schedule resources to tasks wherenecessary
To communicate with other memebers of the team
Design/Scribe Onika Blandin:
Structural; give shape and voice to the work.
Proofreading look at the syntax (spelling, punctuation and grammatical side of the work)
Checks for sense, clarity, grammatical and mechanical accuracy, and conformance,
focus on the structure and flow of the work as a whole.
Research of the body
Beckles, Kurnisha Sherwana
Bishop, Raynelle Renysce To provide applicable and relevant, input.
Browne, Kenwin Leon To communicate with other members of the team
Charles, La Tricia Christien
Onika Blandin
Adrian Cabralis,
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