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Prepared by: Shatina Saad @ FPP OPM 53311-1
Operations Operations ManagementManagement
Maintenance and ReliabilityMaintenance and ReliabilityChapter 11Chapter 11
Prepared by: Shatina Saad @ FPP OPM 53311-2
OutlineOutline THE STRATEGIC IMPORTANCE OF
MAINTENANCE AND RELIABILITY RELIABILITY
Improving Individual Components Providing Redundancy
MAINTENANCE Implementing Preventive Maintenance Increasing Repair Capability
TOTAL PRODUCTIVE MAINTENANCE TECHNIQUES FOR ESTABLISHING
MAINTENANCE POLICIES
Prepared by: Shatina Saad @ FPP OPM 53311-3
Learning ObjectivesLearning ObjectivesWhen you complete this chapter, you should be able to :
Identify or Define: Maintenance Mean time between failures Redundancy Preventive maintenance Breakdown maintenance Infant mortality
Describe or Explain: How to measure system reliability How to improve maintenance How to evaluate maintenance performance
Prepared by: Shatina Saad @ FPP OPM 53311-4
All activities involved in keeping a system’s equipment working
Objective: Maintain system capability & minimize total costs
© 1995 Corel Corp.
Maintenance ManagementMaintenance Management
Prepared by: Shatina Saad @ FPP OPM 53311-5
The Strategic Importance of The Strategic Importance of Maintenance and ReliabilityMaintenance and Reliability
Failure has far reaching effects on a firm’s operation reputation profitability customers product employees profits
Prepared by: Shatina Saad @ FPP OPM 53311-6
Maintenance Procedures
Employee Involvement
Maintenance PerformanceMaintenance Performance
© 1995 Corel Corp.
© 1995 Corel Corp.
Maintenance PerformanceMaintenance Performance
Prepared by: Shatina Saad @ FPP OPM 53311-7
Good Maintenance & Reliability Good Maintenance & Reliability StrategyStrategy
Requires: Employee involvement Maintenance and reliability procedures
To yield: Reduced inventory Improved quality Improved capacity Reputation for quality Continuous improvement
Prepared by: Shatina Saad @ FPP OPM 53311-8
Employee InvolvementEmployee Involvement
Information sharing Skill training Reward system Power sharing
© 1995 Corel Corp.
Prepared by: Shatina Saad @ FPP OPM 53311-9
Maintenance & Reliability Maintenance & Reliability ProceduresProcedures
Clean and lubricate Monitor and adjust Minor repair Computerized
records
Maintenance Procedures
© 1995 Corel Corp.
Prepared by: Shatina Saad @ FPP OPM 53311-10
Lower operating
costs
Continuous improvement
Faster, more dependable throughput
Higher productivity
Improved quality
Improved capacity
Reduced inventory
Maintenance
Maintenance BenefitsMaintenance Benefits
Prepared by: Shatina Saad @ FPP OPM 53311-11
Tactics forTactics for Reliability and Maintenance Reliability and Maintenance
Reliability Tactics improving individual components providing redundancy
Maintenance Tactics implementing preventive maintenance increasing repair capabilities
Prepared by: Shatina Saad @ FPP OPM 53311-12
System Reliability -System Reliability - Components in Series Components in Series
Average Reliability of all Components (Percent)
Relia
bility
of t
he S
yste
m (P
erce
nt)
100
80
60
40
20
0
100 99 98 97 96
n=1
n=10
n=50
n=100
n=200
n=300n=400
Prepared by: Shatina Saad @ FPP OPM 53311-13
Reliability Probability that an item will function for a
given time Reliability of Components in Series
R = R1 * R2 * R3 * ... Mean time between failures (MTBF)
Average time between failures of a repairable item
MTBF = 1 / Failure Rate (N) Failure rate
Reciprocal of MTBF
Evaluating MaintenanceEvaluating Maintenance
Prepared by: Shatina Saad @ FPP OPM 53311-14
Failure Rate Failure Rate
Number of failuresFR (%) = * 100% Number of units tested
FR (N) = Number of Failures
Number of unit-hours of operating time
Prepared by: Shatina Saad @ FPP OPM 53311-15
Lifetime Failure RatesLifetime Failure Rates
Infantmortality
andimproper use
failure
“normal” failure Wearoutfailure
Failurerate
Lifetime
Prepared by: Shatina Saad @ FPP OPM 53311-16
Providing RedundancyProviding Redundancy
Probability of first
component working
Probability of second component working
+
Probability of needing second component
* = P(R)
Prepared by: Shatina Saad @ FPP OPM 53311-17
How much preventive & breakdown maintenance
Who performs maintenance Centralized, decentralized, operator etc. Contract or in-house
When to replace or repair How much to replace
Individual or group replacement
Maintenance DecisionsMaintenance Decisions
Prepared by: Shatina Saad @ FPP OPM 53311-18
Preventive Breakdown
Routine inspection & servicing
Prevents failures Bases for doing
Time: Every day Usage: Every 300 pieces Inspection: Control chart
deviations
Non-routine inspection & servicing
Remedial Basis for doing
Equipment failure
Types of MaintenanceTypes of Maintenance
Prepared by: Shatina Saad @ FPP OPM 53311-19
Mean Time Between Failure and Mean Time Between Failure and Preventive MaintenancePreventive Maintenance
Frequencyof failure
Mean Time Between Failure
Candidate for preventivemaintenance will have
distribution with lowvariability
Prepared by: Shatina Saad @ FPP OPM 53311-20
Centralized maintenance department Does all maintenance (PM & breakdown)
Decentralized maintenance department Useful if different equipment used in different
areas of company
Contract maintenance Used if little equipment or expertise
Operator ownership approach
Organizing theOrganizing the Maintenance Function Maintenance Function
Prepared by: Shatina Saad @ FPP OPM 53311-21
Operator does preventive maintenance Equipment condition is their responsibility Learns equipment better Increases worker’s pride Reduces repair time & PM costs
Maintenance department is backup Handles non-routine problems Provides maintenance training Has plant-wide responsibilities
Operator-Ownership ApproachOperator-Ownership Approach
Prepared by: Shatina Saad @ FPP OPM 53311-22
A Computerized Maintenance SystemA Computerized Maintenance System
Prepared by: Shatina Saad @ FPP OPM 53311-23
Maintenance Commitment
Cost
Preventive Maintenance CostTotTotal Maintenance Cost
Breakdown Cost
Optimal
Maintenance CostsMaintenance CostsTraditional ViewTraditional View
Prepared by: Shatina Saad @ FPP OPM 53311-24
Maintenance CostsMaintenance CostsFull Cost ViewFull Cost View
Maintenance Commitment
Cost
Optimal
Total costs
Full cost of breakdowns
Preventive maintenance costs
Prepared by: Shatina Saad @ FPP OPM 53311-25
Contract for Preventive Contract for Preventive MaintenanceMaintenance
Compute the expected number of breakdowns without the service contract
Compute the expected breakdown cost per month with no preventive maintenance contract
Compute the cost of preventive maintenance
Compare the two options
Prepared by: Shatina Saad @ FPP OPM 53311-26
Increasing Repair Capabilities:Features Increasing Repair Capabilities:Features of A Good Maintenance Facilityof A Good Maintenance Facility
Well-trained personnel Adequate resources Ability to establish a repair plan and
priorities Ability and authority to do material
planning Ability to identify the cause of
breakdowns Ability to design ways to extend MTBF
Prepared by: Shatina Saad @ FPP OPM 53311-27
Operations Manager Must Determine Operations Manager Must Determine How Maintenance Will be PerformedHow Maintenance Will be Performed
Operator Maintenance Department
Manufacturer’s field service
Depot Service (return equipment)
Competence is higher as we more to the right
Preventive maintenance costs less and is faster as we move to the left
Prepared by: Shatina Saad @ FPP OPM 53311-28
Total Productive Maintenance Total Productive Maintenance (TPM)(TPM)
Additional requirements of: Designing machines that are reliable, easy to
operate and easy to maintain Emphasizing total cost of ownership when
purchasing machines, so that service and maintenance are included in the cost
Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot services
Training workers to operate and maintain their own machines
Prepared by: Shatina Saad @ FPP OPM 53311-29
A Key To SuccessA Key To Success High utilization of facilities, tight scheduling, low
inventory and consistent quality demand reliability - total preventive maintenance is the key to reliability.
Techniques for Establishing Techniques for Establishing Maintenance PoliciesMaintenance Policies
Simulation - enables one to evaluate the impact of various maintenance policies
Expert systems - can be used by staff to help diagnose faults in machinery and equipment