Maintenance and Reliability in OM

8/10/2019 Maintenance and Reliability in OM

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University of the Southern

Caribbean

Operations Management

Maintenance and Reliability

Presented by Group 2


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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


8/22

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


17/22

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


20/22

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/


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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,

Documents

Maintenance and Reliability in OM