Prevents and detects potential failures Avoids disruptions Types routine

Prevents and detects potential failures avoids

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Prevents and detects potential failures ¨ Avoids disruptions ¨ Types: routine & inspection Non-routine inspection & servicing (repairs, replacement of parts, overhaul) Remedial and emergency basis Production process is interrupted TYPES OF MAINTENANCE
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MEAN TIME BETWEEN FAILURE AND PREVENTIVE MAINTENANCE Frequency of failure Mean Time Between Failure Candidate for preventive maintenance will have distribution with low variability
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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 THE MAINTENANCE FUNCTION
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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 APPROACH
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COMPUTERIZED MAINTENANCE SYSTEM Output Reports Inventory and purchasing reports Equipme nt parts list Equipment history reports Cost analysis (Actual vs. standard) Work orders Data Files Personnel data with skills, wages, etc. Equipment file with parts list Maintenance and work order schedule Inventory of spare parts Repair history file
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MAINTENANCE COSTS The traditional view attempted to balance preventive and breakdown maintenance costs Typically this approach failed to consider the full costs of a breakdown Inventory Employee morale Schedule unreliability
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Maintenance Commitment Cost Breakdown Cost Optimal MAINTENANCE COSTS TRADITIONAL VIEW
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MAINTENANCE COSTS FULL COST VIEW Maintenance Commitment Cost Optimal Total costs Full cost of breakdowns Preventive maintenance costs
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INCREASING REPAIR CAPABILITIES 1. Well-trained personnel 2. Adequate resources 3. Ability to establish repair plan and priorities 4. Ability and authority to do material planning 5. Ability to identify the cause of breakdowns 6. Ability to design ways to extend MTBF
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INCREASING REPAIR CAPABILITIES Figure 17.5 Operator (autonom ous maintena nce) Maintena nce departme nt Manufactur er’s field service Depot service (return equipment) Increasing Operator Ownership Increasing Complexity Preventive maintenance costs less and is faster the more we move to the left Competence is higher as we move to the right
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