2. MAINTENANCE-EFFECTS
■ Right type of maintenance policy-required else may lead to either over
maintenance or under maintenance
■ Equipment Life-depends on nature and maintenance function
implemented in industry. Good maintenance policy increase life of
equipment
■ Maintenance-relates to targets and reliability of equipment
■ Proper selection of skilled, semi-skilled and unskilled labour should be
with proper division of responsibilities.
3. PRODUCTIVITY, QUALITY,
RELIABILITY AND MAINTAINABILITY(PQRM)
■ PQRM- important aspects for profitability of any industry
■ Each one has different role and affect performance of others
■ Productivity:
Measure of economic efficiency which shows how effectively
economic outputs are converted into outputs
Measurement-by comparing amount of goods and services produced
with the inputs which were used for production
Labor productivity-ratio of output of goods and services to labor
hours devoted to the production of that output
Productivity-shows changes from period to period in amount of
goods and services produced per hour
4. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
Productivity-reflect joint effects of many influences, like capital
investment, level of output, utilization of capacity, energy and
materials.,managerial skill etc
■ Maintenance Productivity:
Mostly a group activity-hence difficult to define
Productivity to be measure for whole dept. or a fixed group who
always remain together when on work or individual maintenance
worker basis
Different industries attempt their own metrics to indiciate change in
maintenance productivity
5. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
Parameters for that are:
Downtime due to failure-highest expenses
Downtime due to maintenance itself
Cost of manpower
Spare parts, stock expenses
Tools, instruments, room, transport, soft for maintenance
Equipment condition-very sophisticated parameter
These matrices-converted in rupees and a base value is worked out
■ Maintainbaility-key factor for maintenance productivity
6. PRODUCTIVITY, QUALITY, RELIABILITY AND
MAINTAINABILITY(PQRM) Ctd.
■ Quality:
It is the ongoing process of building and sustaining relationships by
assessing, anticipating and fulfilling stated and implied needs.
In industries-it is the extent to which products, services, processes
and inter-relationships are free from defects, constraints and items
which do not add value for customers and commodity conforms to
standards applied to said commodity by mechanical or other
standards.
Quality can be static or dynamic
Static-keeps in the industry
Dynamic-to excel or win it
7. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Quality Circle(QC) in Maintenance:
– Emplies development and use of skills, capabilities and creativity of
people through cumulative process of education, work experience
and participation etc to solve their problems.
– Quality Circle-consist of small group of employees doing similar
work, who meet regularly on regular basis for analysing and solving
work related problems
– QC-capturing creative and innovative power that lies within work
force
– Provide self-motivation and happiness in improving environment
without any compulsion or monitory benefits
8. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Objectives of QC-change in attitude, self development, development of
team spirit and improved organizational culture etc.
■ Quality maintenance-help managers and other concerned persons to
develop , formulate and use quality indicators for maintenance
management/functions
■ Quality aspect in maintenance function is beneficial in following ways:
– Gain insight into how maintenance function can be made more
reliable, more cost effective and more efficient
– Compare maintenance information systems with other good systems
of your industry or other industries
– Align your maintenance program with you TQM initiatives
9. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Monitor processing techniques
■ Keep control check with replacement and life cycle cost
■ Use of QAMM(Quality Assured Maintenance Management)
■ Total Quality Preventive Maintenance Programmes which prology life,
improve equipment safety and reliability , reduce cost of major repairs
and minimize inconvenience of equipment downtime etc.
10. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Reliability:
– Focuses in ability of a product to perform its intended function.
– It can be defined as the probability that an item will continue to perform its
intended function without failure for a specified period of time under stated
conditions
– Product could be an electronic or mechanical product, component
hardware, a software product etc.
– Reliability Engineering is the application of reliability concept in
engineering or industries and in more concerned with basic reliability.
– It covers all aspects of product’s life-from its conception, subsequent design
and production process as well as through practical use lifetime
11. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Reliability is important for
– Reputation of the company/industry
– Customer Satisfaction
– Warranty Costs
– Repeat Business
– Cost Analysis
– Customer Requirments
– Competitive Advantage
12. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Difference between Reliability and Quality
Reliability Quality
Concerned with performance of a
product over its entire life time
Concerned with performance of a
product at one point in time
Assures components,equipments etc
function without failure for desired
periods during whole deisgn life
Quality control is a single, albeit vital,
link in total reliability process
Quality control assures conformance to
specifications and incoming parts and
components meet specifications.
13. PRODUCTIVITY, QUALITY, RELIABILITY
AND MAINTAINABILITY(PQRM) Ctd.
■ Maintainability:
– Ease with which a system or component can be modified to correct
faults, improve performance or other attributes or adapt to a
changed environment
– Defined as ease in time and resources of retaining equipment in or
restoring it to a specified operational condition.
– Also be defined as measures taken during design, development and
installation of a manufactured product that reduce required
maintenance, man-hours , tools , logistic costs
– Important aspect of any system’s lifecycle.