Chap014s Maintenance
Transcript of Chap014s Maintenance
-
7/28/2019 Chap014s Maintenance
1/12
14s-1 Maintenance
William J. Stevenson
Operations Management
8th edition
-
7/28/2019 Chap014s Maintenance
2/12
14s-2 Maintenance
CHAPTER
14s
Maintenance
McGraw-Hill/Irwin
Operations Management, Eighth Edition, by William J. StevensonCopyright 2005 by The McGraw-Hill Companies, Inc. All rights reserved.
-
7/28/2019 Chap014s Maintenance
3/12
14s-3 Maintenance
Introduction
Maintenance All activities that maintain facilities and equipment in
good working order so that a system can perform as
intended
Breakdown maintenance
Reactive approach; dealing with breakdowns or
problems when they occur
Preventive maintenance Proactive approach; reducing breakdowns through a
program of lubrication, adjustment, cleaning,
inspection, and replacement of worn parts
-
7/28/2019 Chap014s Maintenance
4/12
14s-4 Maintenance
Reasons for keeping equipment running Avoid production disruptions
Not add to production costs
Maintain high quality Avoid missed delivery dates
Maintenance Reasons
-
7/28/2019 Chap014s Maintenance
5/12
14s-5 Maintenance
Production capacity is reduced Orders are delayed
No production
Overhead continues
Cost per unit increases
Quality issues
Product may be damaged
Safety issues
Injury to employees
Injury to customers
Breakdown Consequences
-
7/28/2019 Chap014s Maintenance
6/12
14s-6 Maintenance
Total Maintenance Cost
Breakdown and
repair cost
Optimum Amount of
preventive maintenance
Cost
Total Cost
Preventive
maintenance cost
Table 14S.1
-
7/28/2019 Chap014s Maintenance
7/12
14s-7 Maintenance
Preventive maintenance: goal is to reducethe incidence of breakdowns or failures in
the plant or equipment to avoid the
associated costs Preventive maintenance is periodic
Result of planned inspections
According to calendar
After predetermined number of hours
Preventive Maintenance
-
7/28/2019 Chap014s Maintenance
8/12
14s-8 Maintenance
Frequency of breakdown
If the average cost of a breakdown is $1,000,
and the cost of preventative maintenance is
$1,250 per month, should we use preventive
maintenance?
Example S-1
Number of breakdowns 0 1 2 3
Frequency of occurrence .20 .30 .40 .10
-
7/28/2019 Chap014s Maintenance
9/12
14s-9 Maintenance
Number ofBreakdowns Frequency ofOccurrence Expected number ofBreakdowns
0
1
2
3
.20
.30
.40
.10
1.00
0
.30
.80
.30
1.40
Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400Preventive maintenance = $1250PM results in savings of $150 per month
Example S-1 Solution
-
7/28/2019 Chap014s Maintenance
10/12
14s-10 Maintenance
Predictive Maintenance Predictive maintenance
An attempt to determine when best to perform
preventive maintenance activities
Total productive maintenance
JIT approach where workers perform
preventive maintenance on the machines they
operate
1 11
-
7/28/2019 Chap014s Maintenance
11/12
14s-11 Maintenance
Breakdown Programs Standby or backup equipment that can be
quickly pressed into service
Inventories of spare parts that can be installed
as needed Operators who are able to perform minor
repairs
Repair people who are well trained andreadily available to diagnose and correct
problems with equipment
14 12 M i
-
7/28/2019 Chap014s Maintenance
12/12
14s-12 Maintenance
Replacement
Trade-off decisions Cost of replacement vs cost of continued
maintenance
New equipment with new features vs
maintenance
Installation of new equipment may causedisruptions
Training costs of employees on new equipment Forecasts for demand on equipment may require
new equipment capacity
When is it time for replacement?