Power Point Operation Management Heizer Chapter 17

8/9/2019 Power Point Operation Management Heizer Chapter 17

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17 - 1© 2014 Pearson Education, Inc.

Maintenance andReliability

PowerPoint presentation to accompany

Heizer and Render

Operations Management, Eleventh EditionPrinciples of Operations Management, Ninth Edition

PowerPoint slides by Jeff Heyl

dditional content from !erry "oo#

1717

© 2014 Pearson Education, Inc.


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O$tline

► !lobal "ompany Profile%Orlando Utilities Commission

► The trate!ic Im"ortance o#

$aintenance and %elia&ilit'► %elia&ilit'

► $aintenance

► Total Producti(e $aintenance


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17 - )© 2014 Pearson Education, Inc.

&earning Ob'ectives

(hen yo$ complete this chapter yo$sho$ld be able to%

)* +escribe ho* to im"ro(e s'stemrelia&ilit'

* +etermine s'stem relia&ilit'

-* +etermine mean time &et*een #ailure

+$T

.* +isting$ish &et*een "re(enti(e and&rea/do*n maintenance


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(hen yo$ complete this chapter yo$sho$ld be able to%

&earning Ob'ectives

/* +escribe ho* to im"ro(emaintenance

0* "ompare "re(enti(e and &rea/do*nmaintenance costs

1* +efine autonomous maintenance


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Orlando 2tilities "ommission

► $aintenance o# "o*er !eneratin! "lants

► E(er' 'ear each "lant is ta/en o##-line #or 1-) *ee/s maintenance

► E(er' three 'ears each "lant is ta/en o##-line #or - *ee/s #or com"lete o(erhauland tur&ine ins"ection

► Each o(erhaul has 1,00 tas/s andre3uires 72,000 la&or hours

► OUC "er#orms o(er 12,000 maintenancetas/s each 'ear



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Orlando 2tilities "ommission

► E(er' da' a "lant is do*n costs OUC110,000

► Une5"ected outa!es cost &et*een)0,000 and 00,000 "er da'

► Pre(enti(e maintenance disco(ered acrac/ed rotor &lade *hich could ha(e

destro'ed a 27 million "iece o# e3ui"ment



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3trategic 4mportance of

Maintenance and Reliability

▶ailure has #ar reachin! e##ects on a#irm6s

▶O"eration

▶%e"utation

▶Pro#ita&ilit'

▶

Customer satis#action▶%educin! idle time

▶Protectin! in(estment in "lant ande3ui"ment


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▶$aintenance is all acti(ities in(ol(ed in/ee"in! a s'stem6s e3ui"ment in*or/in! order

▶%elia&ilit' is the "ro&a&ilit' that amachine *ill #unction "ro"erl' #or as"eci#ied time


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4mportant 5actics

▶%elia&ilit'

1. Im"ro(in! indi(idual com"onents

2. Pro(idin! redundanc'

▶$aintenance

1. Im"lementin! or im"ro(in! "re(enti(emaintenance

2. Increasin! re"air ca"a&ilit' or s"eed


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Maintenance Management

Employee 4nvolvement

Partnerin! *ith maintenance"ersonnel

/ill trainin!

%e*ard s'stemEm"lo'ee em"o*erment


Proced$resClean and lu&ricate$onitor and ad8ust$a/e minor re"air 9ee" com"uteri:ed records

Res$lts

%educed in(entor'Im"ro(ed 3ualit'Im"ro(ed ca"acit'%e"utation #or 3ualit'Continuous im"ro(ement

%educed (aria&ilit'

i!ure 17.1


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Reliability

▶'stem relia&ilit'

▶Im"ro(in! indi(idual com"onents

R s ; R1 5 R2 5 R) 5 < 5 Rn

*here R1 ; relia&ilit' o# com"onent 1

R2 ; relia&ilit' o# com"onent 2

and so on


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17 - 1)© 2014 Pearson Education, Inc.

Overall 3ystem Reliability

% e l i a & i l i t ' o # t h e s ' s t e m +

" e r c e n t .

=(era!e relia&ilit' o# each com"onent +"ercent

> > > > > > > > >

100 7

100 ?

0 ?

0 ?

40 ?

20 ?

0 ?

n ; 1 0

n ; 1

n ; 0 n ; 1 0 0 n ; 2 0 0 n ; ) 0 0

n ; 4 0 0

i!ure 17.2


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Rs

R)

.

R2

.0

Reliability E6ample

R1

.0

%elia&ilit' o# the "rocess is

R s ; R1 5 R2 5 R) = .0 5 .0 5 . ; .71) or 71.)@


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Prod$ct 7ail$re Rate 87R9

asic unit o# measure #or relia&ilit'

%+@ ; 5 100@Aum&er o# #ailures

Aum&er o# units tested

%+ N ;Aum&er o# #ailures

Aum&er o# unit-hours o# o"eratin! time

$ean time &et*een #ailures

$T ;1

%+ N


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7ail$re Rate E6ample

20 air conditionin! units #or use in the internationals"ace station o"erated #or 1,000 hoursOne #ailed a#ter 200 hours and one a#ter 00 hours

%+@ ; +100@ ; 10@220

%+ N ; ; .00010 #ailureBunit hr 2

20,000 - 1,200

$T ; ; ,4)4 hrs1

.00010


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7ail$re Rate E6ample

20 air conditionin! units #or use in the internationals"ace station o"erated #or 1,000 hoursOne #ailed a#ter 200 hours and one a#ter 00 hours

%+@ ; +100@ ; 10@220

%+ N ; ; .00010 #ailureBunit hr 2

20,000 - 1,200

$T ; ; ,4)4 hrs1

.00010

ailure rate "er tri"

% ; %+ N +24 hrs+ da'sBtri"

% ; +.00010+24+

% ; .01) #ailureBtri"


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Providing Red$ndancy

Pro(ide &ac/u" com"onents toincrease relia&ilit'

5Pro&a&ilit' o##irstcom"onent

*or/in!

Pro&a&ilit' o#needin!second

com"onent

Pro&a&ilit'o# secondcom"onent

*or/in!

RS ;

+. +. 5 +1 - .

; . .1 ; .

;


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Red$ndancy E6ample

= redundant "rocess is installed to su""ort theearlier e5am"le *here R

s ; .71)

R1

0.0

0.0

R2

0.0

0.0

R)

0.

RS

; D. .+1 - . 5 D. .+1 - . 5 .

; D. +.+.1 5 D. +.+.2 5 .

; . 5 . 5 . ; .4

%elia&ilit' hasincreased #rom

.71) to .4


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Parallel Red$ndancy

Increased relia&ilit'throu!h "arallelredundanc'

R1

0.

0.

R4

0.7

R2

0.7

R)

%elia&ilit' #orthe middle "ath

; R2 5 R) ; .7 5 .7 ; .0

Pro&a&ilit' o# failure #or all ) "aths

; +1 ? 0. 5 +1 ? .0 5 +1 ? 0.; +.0 5 +.044 5 +.0 ; .00012

%elia&ilit' o# ne* desi!n ; 1 ? .00012 ; .


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Maintenance

▶T*o t'"es o# maintenance

▶Preventive maintenance ? routineins"ection and ser(icin! to /ee" #acilities

in !ood re"air ▶:rea#down maintenance ? emer!enc'

or "riorit' re"airs on #ailed e3ui"ment


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4mplementing Preventive

Maintenance

▶Aeed to /no* *hen a s'stem re3uiresser(ice or is li/el' to #ail

▶Fi!h initial #ailure rates are /no*n asinfant mortality

▶Once a "roduct settles in, $T !enerall'#ollo*s a normal distri&ution

▶Good re"ortin! and record /ee"in! can aidthe decision on *hen "re(enti(emaintenance should &e "er#ormed


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"omp$terized Maintenance

3ystem

i!ure 17.)

O$tp$t Reports

In(entor' and"urchasin! re"orts

E3ui"ment"arts list

E3ui"menthistor' re"orts

Cost anal'sis+=ctual (s. standard

Hor/ orders

+ata 7iles

Personnel data*ith s/ills,

*a!es, etc.

E3ui"ment #ile*ith "arts list

$aintenanceand *or/ order

schedule

In(entor' o#s"are "arts

%e"airhistor' #ile


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Maintenance "osts

i!ure 17.4 +a

Totalcosts

rea/do*nmaintenancecosts

C o s t

s

$aintenance commitment

5raditional ;iew

Pre(enti(emaintenance

costs

O"timal "oint +lo*estcost maintenance "olic'


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Maintenance "osts

i!ure 17.4 +&

C o s t s

$aintenance commitment

7$ll "ost ;iew

O"timal "oint +lo*estcost maintenance "olic'

Totalcosts

ull cost o#&rea/do*ns

Pre(enti(emaintenancecosts


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Maintenance "ost E6ample

▶hould the #irm contract #or maintenanceon their "rinters

N2M:ER O7

:RE


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1. Com"ute the e5"ected num&er o# &rea/do*ns

N2M:ER O7:RE

0 2B20 ; .1 2 B20 ; .)1 B20 ; .4 ) 4B20 ; .2

K Aum&er o#&rea/do*ns

E5"ected num&er

o# &rea/do*ns

Corres"ondin!

#re3uenc'

; 5

; +0+.1 +1+.4 +2+.) +)+.2

; 0 .4 . .

; 1. &rea/do*ns B month


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2. Com"ute the e5"ected &rea/do*n cost "ermonth *ith no "re(enti(e maintenance

E5"ected&rea/do*n cost

E5"ected num&ero# &rea/do*ns

Cost "er&rea/do*n

; 5

; +1.+)00

; 40 "er month


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17 - )0© 2014 Pearson Education, Inc.


). Com"ute the cost o# "re(enti(e maintenance

Pre(enti(e

maintenance cost

Cost o# e5"ected&rea/do*ns i#

ser(ice contractsi!ned

Cost o#

ser(icecontract

;

; +1 &rea/do*n B month+)00 10 B month

; 40 B month

Fire the ser(ice #irmL it is less e5"ensi(e


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4ncreasing Repair "apabilities

1. Hell-trained "ersonnel

2. =de3uate resources

). =&ilit' to esta&lish re"air "lan and

"riorities4. =&ilit' and authorit' to do material

"lannin!

. =&ilit' to identi#' the cause o#&rea/do*ns

. =&ilit' to desi!n *a's to e5tend $T


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i!ure 17.

O"erator +autonomousmaintenance

$aintenancede"artment

$anu#acturer6s#ield ser(ice

Me"ot ser(ice+return e3ui"ment

Increasin! O"erator O*nershi" Increasin! Com"le5it'

Pre(enti(emaintenance costs less andis #aster the more *e mo(e to the le#t

Com"etence is hi!her as *emo(e to the ri!ht


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17 - ))© 2014 Pearson Education, Inc.

$tonomo$s Maintenance

▶Em"lo'ees acce"t res"onsi&ilit' #or

▶O&ser(e

▶Chec/

▶ =d8ust

▶Clean

▶Aoti#'

▶Predict #ailures, "re(ent &rea/do*ns,"rolon! e3ui"ment li#e


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5otal Prod$ctive Maintenance

85PM9

▶Mesi!nin! machines that are relia&le,eas' to o"erate, and eas' to maintain

▶Em"hasi:in! total cost o# o*nershi"*hen "urchasin! machines, so thatser(ice and maintenance are includedin the cost


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5otal Prod$ctive Maintenance

85PM9

▶Me(elo"in! "re(enti(e maintenance"lans that utili:e the &est "ractices o#o"erators, maintenance de"artments,

and de"ot ser(ice▶Trainin! #or autonomous maintenance

so o"erators maintain their o*n

machines and "artner *ithmaintenance "ersonnel


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More on Maintenance ?

▶ = sim"le redundanc' #ormula

▶

Pro&lems *ith &rea/do*n and "re(enti(emaintenance

▶Predicti(e maintenance

▶Predicti(e maintenance tools

▶$aintenance strate!' im"lementation

▶E##ecti(e relia&ilit'

Supplemental Material


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Providing Red$ndancy ?

n lternate 7orm$la▶ The relia&ilit' o# one "um" ;

The "ro&a&ilit' o# one "um" not #ailin! ; 0.

P +#ailin! ; 1- P +not #ailin! ; 1 - 0. ; .2

P +#ailure o# &oth "um"s ;

P +#ailure "um" N1 5 P +#ailure "um" N2

P +#ailure o# &oth "um"s ; 0.2 5 0.2 ; .04

P +at least one "um" *or/in! ;

1.0 - .04 ; .

►

I# there are t*o "um"s *ith the same"ro&a&ilit' o# not #ailin!


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Problems (ith :rea#down

Maintenance

▶%un it till it &rea/s

▶$i!ht &e o/ #or lo* criticalit' e3ui"mentor redundant s'stems

▶Could &e disastrous #or mission-critical"lant machiner' or e3ui"ment

▶Aot "ermissi&le #or s'stems that could

im"eril li#e or lim& +li/e aircra#t


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Problems (ith Preventive

Maintenance

▶i5 it *hether or not it is &ro/en

▶cheduled re"lacement or ad8ustment o#"artsBe3ui"ment *ith a *ell-esta&lished

ser(ice li#e

▶T'"ical e5am"le ? "lant relam"in!

▶ometimes misa""lied

▶%e"lacin! old &ut still !ood &earin!s

▶O(er-ti!htenin! electrical lu!s in s*itch!ear


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nother Maintenance 3trategy

▶Predictive maintenance ? Usin! ad(ancedtechnolo!' to monitor e3ui"ment and "redict#ailures

▶Usin! technolo!' to detect and "redict imminente3ui"ment #ailure

▶Qisual ins"ection andBor scheduled measurements o#(i&ration, tem"erature, oil and *ater 3ualit'

▶$easurements are com"ared to a health' &aseline▶E3ui"ment that is trendin! to*ards #ailure can &e

scheduled #or re"air


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Predictive Maintenance 5ools

▶Qi&ration anal'sis

▶In#rared Thermo!ra"h'

▶Oil and Hater =nal'sis

▶Other ToolsJ

▶Ultrasonic testin!

▶Ri3uid Penetrant M'e testin!

▶hoc/ Pulse $easurement +P$


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Predictive Maintenance

;ibration nalysis

▶Usin! sensiti(e transducers and instrumentsto detect and anal':e (i&ration

▶ T'"icall' used on e5"ensi(e, mission-critical

e3ui"ment?lar!e tur&ines, motors, en!ines or!ear&o5es

▶o"histicated #re3uenc' +T anal'sis can"in"oint the e5act mo(in! "art that is *orn or

de#ecti(e▶Can utili:e a monitorin! ser(ice


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Predictive Maintenance 4nfrared

84R9 5hermography

▶Usin! I% cameras to loo/ #or tem"erature hots"ots on e3ui"ment

▶ T'"icall' used to chec/ electrical e3ui"ment

#or *irin! "ro&lems or "oorBloose connections▶Can also &e used to loo/ #or cold +*et s"ots

*hen ins"ectin! roo#s #or lea/s

▶Fi!h 3ualit' I% cameras are e5"ensi(e ? most"a' #or I% thermo!ra"h' ser(ices


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Oil and (ater nalysis

▶ Ta/in! oil sam"les #rom lar!e !ear&o5es,com"ressors or tur&ines #or chemical and"article anal'sis

▶Particle si:e can indicate a&normal *ear

▶ Ta/in! coolin! *ater sam"les #or anal'sis ?can detect e5cessi(e rust, acidit', ormicro&iolo!ical #oulin!

▶er(ices usuall' "ro(ided &' oil (endors and*ater treatment com"anies


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Other 5ools and 5echni@$es

▶Ultrasonic and d'e testin! ? used to #ind stresscrac/s in tu&es, tur&ine &lades and load&earin! structures

▶Ultrasonic *a(es sent throu!h metal▶ur#ace coated *ith red d'e, then cleaned o##, d'e

sho*s crac/s

▶hoc/-"ulse testin! ? a s"eciali:ed #orm o#(i&ration anal'sis used to detect #la*s in &all orroller &earin!s at hi!h #re3uenc' +)2/F:

Maintenance 3trateg


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Maintenance 3trategy

"omparison

M4N5ENN"E35R5E!> +;N5!E3 +43+;N5!E3

RE3O2R"E3A5E"HNO&O!>RE=24RE+

PP&4"54ONEBMP&E

rea/do*n Ao "rior *or/re3uired

Misru"tion o#"roduction, in8ur'

or death

$a' needla&orB"arts at

odd hours

O##ice co"ier

Pre(enti(e Hor/ can &escheduled

Ra&or cost, ma're"lace health'com"onents

Aeed to o&tainla&orB"arts

#or re"airs

Plantrelam"in!,machinelu&rication

Predicti(e Im"endin!

#ailures can&e detected S*or/scheduled

Ra&or costs, costs

#or detectione3ui"ment andser(ices

Qi&ration, I%

anal'sise3ui"ment or"urchasedser(ices

Qi&ration and

oil anal'sis o# alar!e !ear&o5


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Maintenance 3trategy

4mplementation

rea/do*n

Pre(enti(e

Predicti(e

1 2 ) 4 7 10ear

100@

0@

0@

40@

20@

0@

Percenta!e o# $aintenance Time &' trate!'

4 P di ti M i t


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4s Predictive Maintenance

"ost EffectiveC

▶ In most industries the a(era!e rate o# return is7J1 to )J1 #or each "redicti(e maintenancedollar s"ent

▶Qi&ration anal'sis, I% thermo!ra"h' andoilB*ater anal'sis are all economicall' "ro(entechnolo!ies

▶ The real sa(in!s is the a(oidance o#manu#acturin! do*ntime ? es"eciall' crucial inIT

P di ti M i t d


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Predictive Maintenance and

Effective Reliability

▶E##ecti(e %elia&ilit' +R eff is an e5tension o#%elia&ilit' that includes the "ro&a&ilit' o# #ailuretimes the "ro&a&ilit' o# not detectin! imminent

#ailure▶Fa(in! the a&ilit' to detect imminent #ailures

allo*s us to "lan maintenance #or thecom"onent in #ailure mode, thus a(oidin! the

cost o# an un"lanned &rea/do*n

R eff ; 1 ? +P +#ailure 5 P +not detectin! #ailure

H P di ti M i t


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How Predictive Maintenance

4mproves Effective Reliability

▶E5am"leJ a lar!e !ear&o5 *ith a relia&ilit' o# .0has (i&ration transducers installed #or (i&rationmonitorin!. The "ro&a&ilit' o# earl' detection o# a#ailure is .70. Hhat is the e##ecti(e relia&ilit' o#the !ear&o5

R eff ; 1 ? +P +#ailure 5 P +not detectin! #ailure

R eff ; 1 ? +.10 5 .)0 ; 1 - .0) ; .7

▶Qi&ration monitorin! has increased the e##ecti(erelia&ilit' #rom .0 to .7V


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Effective Reliability "aveats

▶Predicti(e maintenance onl' increasese##ecti(e relia&ilit' i#J

▶ou select the method that can detect the

most li/el' #ailure mode▶ou monitor #re3uentl' enou!h to ha(e hi!h

li/elihood o# detectin! a chan!e in com"onent&eha(ior &e#ore #ailure

▶Timel' action is ta/en to #i5 the issue and#orestall the #ailure +in other *ords 'ou don6ti!nore the *arnin!V


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1. Hell-trained "ersonnel

2. =de3uate resources

). Pro"er a""lication o# the threemaintenance strate!ies

4. Continual im"ro(ement to im"ro(ee3ui"mentBs'stem relia&ilit'


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Printed in the United tates o# =merica.

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Power Point Operation Management Heizer Chapter 17