operations mainteance

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McGraw-Hill/Irwin Copyright © 2007 by The McGraw-Hill Companies, Inc !ll

15S15S

Maintenance


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15S-2

Learning ObjectivesLearning Objectives

Explain the importance of maintenance inproduction sstems

!escribe the range of maintenance activities

!iscuss preventative maintenance and the"e issues associated #ith it

!iscuss brea"do#n maintenance and the

"e issues associated #ith it State ho# the $areto phenomenon pertains

to maintenance decisions


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&ntroduction&ntroduction

Maintenance 'll activities that maintain facilities and

e(uipment in good #or"ing order so

that a sstem can perform as intended )#o basic categories

*uilding and grounds

E(uipment maintenance


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15S-+

,oal of Maintenance,oal of Maintenance

)o "eep production sstems in good #or"ingorder at minimal cost

easons for maintenance

)o avoid production or service disruptions )o not add production or service costs

)o maintain high (ualit

)o avoid missed deliver dates


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eactive vs $roactiveeactive vs $roactive

eactive Maintenance. *rea"do#n maintenance

eactive approach/ dealing #ith brea"do#ns or

problems #hen the occur $roactive Maintenance.

$reventive maintenance

$roactive approach/ reducing brea"do#nsthrough a program of lubrication0 adjustment0cleaning0 inspection0 and replacement of #ornparts


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easons for "eeping e(uipment running 'void production disruptions

ot add to production costs

Maintain high (ualit

'void missed deliver dates

Maintenance easonsMaintenance easons


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$roduction capacit is reduced Orders are delaed

o production Overhead continues

4ost per unit increases

ualit issues $roduct ma be damaged

Safet issues &njur to emploees

&njur to customers

*rea"do#n 4onse(uences*rea"do#n 4onse(uences


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)otal Maintenance 4ost)otal Maintenance 4ost

Breakdown and

repair cost

Optimum Amount of

preventive maintenance

C o s t

Total Cost

Preventive

maintenance cost

)able 15S71


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Preventive maintenance. goal is toreduce the incidence of brea"do#ns orfailures in the plant or e(uipment to

avoid the associated costs $reventive maintenance is periodic

esult of planned inspections

'ccording to calendar

'fter predetermined number of hours

$reventive Maintenance$reventive Maintenance


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:re(uenc of brea"do#n

&f the average cost of a brea"do#n is

;109990 and the cost of preventativemaintenance is ;10259 per month0 should#e use preventive maintenance<

Example S-1Example S-1

Number of breakdowns 0 1 2 3

Frequency of occurrence .20 .0 .!0 ."0


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umber of *rea"do#ns

:re(uenc of Occurrence

Expected number of *rea"do#ns

91

2%

7297%9

7+9719

1799

97%9

7697%9

17+9

Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400

Preventive maintenance = $1250Preventive maintenance = $1250

PM res!ts in savin"s o# $150 per monthPM res!ts in savin"s o# $150 per month

Example S-1 SolutionExample S-1 Solution


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$redictive Maintenance$redictive Maintenance

$redictive maintenance

'n attempt to determine #hen best toperform preventive maintenance activities

)otal productive maintenance

=&) approach #here #or"ers performpreventive maintenance on the machinesthe operate


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*rea"do#n $rograms*rea"do#n $rograms

Standb or bac"up e(uipment that canbe (uic"l pressed into service

&nventories of spare parts that can be

installed as needed Operators #ho are able to perform minor

repairs

epair people #ho are #ell trained andreadil available to diagnose and correctproblems #ith e(uipment


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eplacementeplacement

)rade-off decisions 4ost of replacement vs cost of continued

maintenance

e# e(uipment #ith ne# features vsmaintenance

&nstallation of ne# e(uipment ma causedisruptions

)raining costs of emploees on ne# e(uipment :orecasts for demand on e(uipment ma re(uire

ne# e(uipment capacit

>hen is it time for replacement

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