Maintenance Management
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Maintenance and Reliability
Outline ¨ The Strategic Importance of Maintenance and Reliability ¨ Reliability ¨ Improving Individual Components ¨ Providing Redundancy
Outline - continued ¨ Maintenance ¨ Implementing Preventive Maintenance ¨ Increasing Repair Capability ¨ Total Productive Maintenance ¨ Techniques for Establishing Maintenance Policies
Learning Objectives ¨ Explain the benefits of maintenance ¨ Distinguish preventive from breakdown maintenance ¨ Explain the importance of employee involvement in maintenance ¨ Use expected value analysis to solve maintenance problems
NASA ¨ Maintenance of space shuttles ¨ Columbia: ¨ ¨ ¨
86,000,000 miles on odometer 3 engines each the size of a VW expected to make 77 more launches
¨ Maintenance requires ¨ ¨ ¨
600 computer generated maintenance jobs 3-month turnaround More than 100 people 17-5
©
1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J. 07458
Maintenance Management ¨ All activities involved in keeping a system’s equipment working ¨ Objective: Maintain system capability & minimize costs
© 1995 Corel Corp.
The Strategic Importance of Maintenance and Reliability ¨ Failure has far reaching effects on a firm’s ¨ ¨ ¨ ¨ ¨ ¨ ¨
operation reputation profitability customers product employees profits
Maintenance Performance Employee Involvement
Maintenance Procedures
Maintenance Performance
© 1995 Corel Corp.
© 1995 Corel Corp.
Employee Involvement ¨ ¨ ¨ ¨
© 1995 Corel Corp.
Information sharing Skill training Reward system Power sharing
Maintenance Procedures ¨ ¨ ¨ ¨
Clean and lubricate Monitor and adjust Minor repair Computerized records
Maintenance Procedures
© 1995 Corel Corp.
Maintenance Benefits Reduced inventory
Improved capacity
Lower operating costs
Maintenance
Continuous improvement
Faster, more dependable throughput
Higher productivity
Improved quality
Tactics for Reliability and Maintenance ¨ Reliability Tactics ¨ improving individual components ¨ providing redundancy ¨ Maintenance Tactics ¨ implementing preventive maintenance ¨ increasing repair capabilities
Fig 17.2
Transparency Masters to accompany Operations Management, 5E (Heizer & Render)
17-13
©
1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J. 07458
Reliability of Components in Series
R = R1 * R2 * R3 * ...
Evaluating Maintenance ¨ Reliability ¨
Probability that an item will function for a given time
¨ Mean time between failures (MTBF) ¨
Average time between failures of a repairable item
¨ Failure rate ¨
Reciprocal of MTBF
Failure Rate (%)
FR(%) =
Number of failures Number of units tested
* 100%
Lifetime Failure Rates “normal” failure
Failure rate
Infant mortality and improper use failure
Lifetime
Wearout failure
Mean Time Between Failures
MTBF
=
1 FR(N)
Failures Per Operating Hour
FR(n) =
Number of Failures Operating Time
Providing Redundancy
Probability of first component + working
Probability of second component * working
Probability of needing second component
= P(R)
Maintenance Decisions ¨ 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
Types of Maintenance Preventive ¨ Routine inspection & servicing ¨ Prevents failures ¨ Bases for doing ¨ Time: Every day ¨ Usage: Every 300
pieces ¨ Inspection: Control chart deviations
Breakdown ¨ Non-routine inspection & servicing ¨ Remedial ¨ Basis for doing ¨ Equipment failure
Mean Time Between Failure and Preventive Maintenance Candidate for preventive maintenance will have distribution with low variability Frequency of failure
Mean Time Between Failure
Organizing the Maintenance Function ¨ 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
Operator-Ownership Approach ¨ 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
Maintenance Costs Cost
st o C e c n a n e t n i a M l a Tot ost C PM
Breakdown Cost Optimal
Maintenance Commitment
Contract for Preventive Maintenance ¨ 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
Features of 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
Total Productive Maintenance ¨ 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
Other Techniques for Establishing Maintenance 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
ASSIGNMENT ¨ Problem 1: ¨ California Instruments, Inc., produces 3,000 computer chips per day. Three hundred are tested for a period of 500 operating hours. During the test, six failed: two after 50 hours, two at 100 hours, one at 300 hours, and one at 400 hours. ¨ Find FR(%) and FR(N). ¨ Problem 2: ¨ If 300 of these chips are used in building a mainframe computer, how many failures of the computer can be expected per month?
ASSIGNMENT ¨ Problem 3: ¨ Find the reliability of this system: 0.92
0.95
0.90
0.98
0.90
ASSIGNMENT ¨ Problem 4: ¨ Given the probabilities below, calculate the expected breakdown cost. ¨ Number of Break downs 0 1 2 3
Daily Frequency 3 2 2 3
¨ Assume a cost of $10 per breakdown.
Outline ¨ The Strategic Importance of Maintenance and Reliability ¨ Reliability ¨ Improving Individual Components ¨ Providing Redundancy
Outline - continued ¨ Maintenance ¨ Implementing Preventive Maintenance ¨ Increasing Repair Capability ¨ Total Productive Maintenance ¨ Techniques for Establishing Maintenance Policies
Learning Objectives ¨ Explain the benefits of maintenance ¨ Distinguish preventive from breakdown maintenance ¨ Explain the importance of employee involvement in maintenance ¨ Use expected value analysis to solve maintenance problems
NASA ¨ Maintenance of space shuttles ¨ Columbia: ¨ ¨ ¨
86,000,000 miles on odometer 3 engines each the size of a VW expected to make 77 more launches
¨ Maintenance requires ¨ ¨ ¨
600 computer generated maintenance jobs 3-month turnaround More than 100 people 17-5
©
1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J. 07458
Maintenance Management ¨ All activities involved in keeping a system’s equipment working ¨ Objective: Maintain system capability & minimize costs
© 1995 Corel Corp.
The Strategic Importance of Maintenance and Reliability ¨ Failure has far reaching effects on a firm’s ¨ ¨ ¨ ¨ ¨ ¨ ¨
operation reputation profitability customers product employees profits
Maintenance Performance Employee Involvement
Maintenance Procedures
Maintenance Performance
© 1995 Corel Corp.
© 1995 Corel Corp.
Employee Involvement ¨ ¨ ¨ ¨
© 1995 Corel Corp.
Information sharing Skill training Reward system Power sharing
Maintenance Procedures ¨ ¨ ¨ ¨
Clean and lubricate Monitor and adjust Minor repair Computerized records
Maintenance Procedures
© 1995 Corel Corp.
Maintenance Benefits Reduced inventory
Improved capacity
Lower operating costs
Maintenance
Continuous improvement
Faster, more dependable throughput
Higher productivity
Improved quality
Tactics for Reliability and Maintenance ¨ Reliability Tactics ¨ improving individual components ¨ providing redundancy ¨ Maintenance Tactics ¨ implementing preventive maintenance ¨ increasing repair capabilities
Fig 17.2
Transparency Masters to accompany Operations Management, 5E (Heizer & Render)
17-13
©
1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J. 07458
Reliability of Components in Series
R = R1 * R2 * R3 * ...
Evaluating Maintenance ¨ Reliability ¨
Probability that an item will function for a given time
¨ Mean time between failures (MTBF) ¨
Average time between failures of a repairable item
¨ Failure rate ¨
Reciprocal of MTBF
Failure Rate (%)
FR(%) =
Number of failures Number of units tested
* 100%
Lifetime Failure Rates “normal” failure
Failure rate
Infant mortality and improper use failure
Lifetime
Wearout failure
Mean Time Between Failures
MTBF
=
1 FR(N)
Failures Per Operating Hour
FR(n) =
Number of Failures Operating Time
Providing Redundancy
Probability of first component + working
Probability of second component * working
Probability of needing second component
= P(R)
Maintenance Decisions ¨ 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
Types of Maintenance Preventive ¨ Routine inspection & servicing ¨ Prevents failures ¨ Bases for doing ¨ Time: Every day ¨ Usage: Every 300
pieces ¨ Inspection: Control chart deviations
Breakdown ¨ Non-routine inspection & servicing ¨ Remedial ¨ Basis for doing ¨ Equipment failure
Mean Time Between Failure and Preventive Maintenance Candidate for preventive maintenance will have distribution with low variability Frequency of failure
Mean Time Between Failure
Organizing the Maintenance Function ¨ 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
Operator-Ownership Approach ¨ 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
Maintenance Costs Cost
st o C e c n a n e t n i a M l a Tot ost C PM
Breakdown Cost Optimal
Maintenance Commitment
Contract for Preventive Maintenance ¨ 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
Features of 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
Total Productive Maintenance ¨ 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
Other Techniques for Establishing Maintenance 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
ASSIGNMENT ¨ Problem 1: ¨ California Instruments, Inc., produces 3,000 computer chips per day. Three hundred are tested for a period of 500 operating hours. During the test, six failed: two after 50 hours, two at 100 hours, one at 300 hours, and one at 400 hours. ¨ Find FR(%) and FR(N). ¨ Problem 2: ¨ If 300 of these chips are used in building a mainframe computer, how many failures of the computer can be expected per month?
ASSIGNMENT ¨ Problem 3: ¨ Find the reliability of this system: 0.92
0.95
0.90
0.98
0.90
ASSIGNMENT ¨ Problem 4: ¨ Given the probabilities below, calculate the expected breakdown cost. ¨ Number of Break downs 0 1 2 3
Daily Frequency 3 2 2 3
¨ Assume a cost of $10 per breakdown.
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