C11 maintenance
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C11 maintenance

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  • You might discuss the meaning of redundancy.
  • You might stress at this point that employee involvement is crucial.
  • Employee involvement, the key to maintenance? By this time, the student should be gaining the impression that employee involvement is the key to successful OM.
  • Examples demonstrating how each of the benefits is incurred would be worthwhile.
  • Ask students to identify some of the pros and cons of the various possibilities.
  • Is this an example of job enlargement or job enrichment?
  • You might discuss the meaning of redundancy.
  • Again, a multi-faceted approach!

C11 maintenance Presentation Transcript

  • 1. Operations Management Maintenance Management Chapter 11 OPM 533 11-
  • 2. Maintenance
    • The objective of maintenance is to maintain the capability of the system while controlling costs
      • Maintenance is all activities involved in keeping a system’s equipment in working order or operating condition
      • Maintenance is concerned with avoiding or minimizing downtime or to avoid undesirable results due to system failure.
  • 3. Concept of Maintenance
      • The most important function of maintenance is to provide system reliability that is to ensure that a specific machine continues to function for a specified period of time with minimum chances of breaking down and at minimum costs. This can be achieved through:
      • increasing repair capabilities or speeding the repair activities to minimizing interruption.
      • implementing preventive maintenance
    11-
  • 4. Strategic Importance of Maintenance
    • Maintenance can avoid work stoppage and ensure that the lost of production time and cost are minimized.
    • To keep the entire production system running smoothly with minimum interruption.
    • To avoid loss of sales and profits
    • Help reduce production cost such as idle labor cost and overtime cost
    11-
  • 5. Strategic Importance of Maintenance – cont.
    • To ensure that the entire workplace is a safe place to work for its employees.
    • To established a competitive edge and to enhance good customer service.
    • To ensure that the product meet the expected quality and specifications.
    • To reduce cost of breakdown and repairs.
    11-
  • 6. Good Maintenance Strategy
    • Requires:
      • Employee involvement
      • Maintenance and reliability procedures
    • To yield:
      • Reduced inventory
      • Improved quality
      • Improved capacity
      • Reputation for quality
      • Continuous improvement
    OPM 533 11-
  • 7. Employee Involvement
    • Information sharing
    • Skill training
    • Reward system
    • Power sharing
    OPM 533 11- © 1995 Corel Corp.
  • 8. Maintenance Benefits OPM 533 11- Lower operating costs Continuous improvement Faster, more dependable throughput Higher productivity Improved quality Improved capacity Reduced inventory Maintenance
  • 9. Maintenance
    • Two types of maintenance
    • Breakdown Maintenance
    • Preventive Maintenance
  • 10. Breakdown Maintenance
    • Involves performing maintenance activities after a machine breakdown or malfunction has occurred and then must be repaired on an emergency or priority basis.
    • Breakdown maintenance includes repairs, replacement of parts or even overhaul to ensure the machine is put back in operating condition.
    11-
  • 11. Preventive Maintenance
    • Involves performing maintenance activities before the equipment fails.
    • Objectives are :
    • i) To reduce frequency and severity of interruptions to production caused by machine malfunctions.
    • ii) To detect potential problems earlier and avoid the associate cost
    11-
  • 12. Preventive Maintenance – cont.
    • Preventive Maintenance activities includes regular inspection, machine adjustments, lubrication, cleaning and parts replacement
    • Two type of preventive maintenance
    • i) Routine maintenance
    • ii) Inspection
    11-
  • 13.
    • 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
    • Spare parts inventory and standby machines.
    Maintenance Decisions OPM 533 11-
  • 14. Spare Parts Inventory and Standby Machines
    • Firms must maintain a certain level of spare part inventory to ensure that the repairs can be done
    • Some companies invest in standby machines
    • Disadvantage of standby machines is the machine will be under utilized.
    11-
  • 15.
    • 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 OPM 533 11-
  • 16.
    • 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 OPM 533 11-
  • 17. 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
    OPM 533 11-
  • 18. Maintenance Cost Example Should the firm contract for maintenance on their printers? Average cost of breakdown = $300 Use service contract - cost RM150 per month and average breakdown is 1 per month. Number of Breakdowns Number of Months That Breakdowns Occurred 0 2 1 8 2 6 3 4 Total: 20
  • 19. Maintenance Cost Example
    • Compute the expected number of breakdowns
    = (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2) = 1.6 breakdowns per month Number of Breakdowns Frequency Number of Breakdowns Frequency 0 2/20 = .1 2 6/20 = .3 1 8/20 = .4 3 4/20 = .2 ∑ Number of breakdowns Expected number of breakdowns Corresponding frequency = x
  • 20. Maintenance Cost Example
    • Compute the expected breakdown cost per month with no preventive maintenance
    = (1.6)($300) = $480 per month Expected breakdown cost Expected number of breakdowns Cost per breakdown = x
  • 21. Maintenance Cost Example
    • Compute the cost of preventive maintenance
    = (1 breakdown/month)($300) + $150/month = $450 per month Hire the service firm; it is less expensive Preventive maintenance cost Cost of expected breakdowns if service contract signed Cost of service contract = +
  • 22. Tactics for Maintenance
    • Maintenance Tactics
      • implementing preventive maintenance
      • increasing repair capabilities
    OPM 533 11-
  • 23. Increasing Repair Capabilities: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
    OPM 533 11-
  • 24. Total Productive Maintenance (TPM)
    • 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
    OPM 533 11-
  • 25. OPM 533 11- 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