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MS-57 JULY DECEMBER 2016 SOLVED ASSIGNMENT
- 1. Solved Assignment July Dec 2016 MS-57 (Sample Copy) Course Code MS - 57 Course Title Total Quality Management Assignment Code MS-57/TMA/SEM - II/2016 Assignment Coverage All Blocks To buy MBA assignments please use below link https://www.payumoney.com/store/#/buy/kian-publication For other Information please click on below link http://ignousolvedassignmentsmba.blogspot.in/ KIAN PUBLICATION Whatsapp- 9580039150 ignousolvedassignmentsmba@gmail.com kianpublication1@gmail.com ignou4you@gmail.com
- 2. 1. What is reliability centred maintenance? What are the important steps involved in implementing it in any plant? Reliability-Centred Maintenance (RCM) is the process of determining the most effective maintenance approach. The RCM philosophy employs Preventive Maintenance (PM), ---------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------------------function of the facility, with the required reliability and availability at the lowest cost. RCM requires that maintenance decisions be based on maintenance requirements supported by sound technical and economic justification. The primary RCM principles are: 1. RCM is Function Oriented – It seeks to ------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------functional reliability, but increases life cycle cost in terms of procurement and operating costs. 2. RCM is System Focused – It is ---------------------------------------------------------------------------- component function. 3. RCM is Reliability Centered – It treats failure statistics ------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------occur in each given operating age bracket). 4. RCM Acknowledges Design Limitations – Its objective is to maintain ------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------that a difference often exists between the perceived design life and the intrinsic or actual design life, and addresses this through the Age Exploration (AE) process. 5. RCM is driven by Safety and Economics – Safety must be -------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------------------------- becomes the criterion.
- 3. 6. RCM ------------------------------------------------------ Condition – Therefore, failure ----------------------------------------------------- --------------------------------------------------------------- of acceptable quality (operation continues). 7. RCM --------------------------------------------- Screen Maintenance Tasks – This --------------------------------------------------------- ----------------------------------------------------------------------------------------------. See Figure 1. 8. RCM Tasks ---------------------- – The tasks must address the ------------------------------------------------------ characteristics. 9. RCM ---------------- Be Effective – The ----------------------------------------------------------------------- and be cost effective. 10. RCM is a Living System – It gathers ---------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------Proactive Maintenance element of the RCM program. There are several different -------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------- that are recommended, summarized in the following 7 steps. Step 1: Selection of equipment for RCM analysis The first step is to ----------------------------------------------------------------------------------------------------- selected should be critical, in terms of its effect on operations, its previous costs of repair and previous costs of preventative maintenance. Step 2: Define the ------------------------------------------------------- that contain the selected equipment The equipment belongs to a system that performs a crucial function. The system can be large or small, but the function of the system, and its inputs and outputs, should be known. For example, the ----------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------------------------at the other end. In this case, the electric motor supplying the mechanical energy would be considered as part of a different system. Step 3: Define ------------------------------------------------- can fail (failure modes) In step 3 the objective is to list all of the ways that the function of the system can fail. For example, the ------------------------------- ------------------------------------------------------------------------------------------------- transport the goods quickly enough. Step 4: Identify the ----------------------------------------------- modes With the help of operators, experienced ---------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------------------conveyor could include a lack of lubrication on the rollers, a failure of a bearing, or a loosened belt. Step 5: Assess the effects of failure In this step the effects of each ------------------------------------------------------------------------------------------------------------------------ ----------------------------------------------- and other equipment. Criticality of each of these failure modes can also be considered. There are various recommended techniques that are used to give this step a systematic approach. These include: 1. Failure, ---------------------------------------------------- (FMEA) 2. Failure, --------------------------------------------- criticality analysis 3. Hazard -------------------------------------------- studies (HAZOPS) 4. Fault ------------------------------------------- (FTA) 5. Risk-------------------------------------- (RBI) The most important failure modes will be determined -------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------for further analysis. Importantly, the failure modes that are retained include only those that have a real probability of occurring under realistic operating conditions.
- 4. Step 6: Select a ---------------------------------------- each failure mode At this step, the most ----------------------------------------------------------------------------------------------------------- maintenance tactic that is selected must be technically and economically feasible. Condition-based maintenance is ------------------------------------------------------------------------ the onset of the failure mode. Time or usage-based preventative maintenance is selected when ----------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------- risk of failure using this method. For failure modes that do --------------------------------------------------------------------------------------------------------- options, then a redesign of the system to eliminate or modify the failure mode should be considered. Failure modes that were not --------------------------------------------------------------------------------------------------------------- candidates for a run-to-failure maintenance schedule. Step 7: Implement -------------------------------------------------------------- tactic selected Importantly, the RCM methodology will only ----------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------reviewed and renewed as additional information is found. 2. What is the importance of maintenance budgeting? Give the advantage of Zero Based Budget. Maintenance budgeting- A budget is a detailed plan of operations for some -------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------and other expenses. It is prepared to bring efficiency and economy in the maintenance activities. Since the importance of the maintenance costs lies in their influence on production costs, the budgets must therefore portray them in production terms, and must result from ------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------- the information, prepares the budget statement and issues the periodic returns and statistics relating to actual performance against forecasted performance. Maintenance costing and budgeting is a planning and ---------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------- discussion between the maintenance management, the production management and the financial control. Importance- The central importance of budgeting to the formulation of maintenance strategy, is stressed and it is explained, by reference to real case examples, that the maintenance budget should be -------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------units and, finally, it is explained that, all too often, maintenance budgeting is
- 5. rarely as rational as described, senior management seeing maintenance only as a cost and ignoring the linkage between maintenance expenditure and production output. The need for a maintenance budget arises from the ------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------needs, e.g. operating pattern and availability) and in turn generates the maintenance workload. Most large process plants use some form of strategic ----------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------replacement of capital equipment (which I find surprising). Budgeting has two primary functions: planning and control. ------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------------control of a budget benefit a company in many ways, including: ENHANCING MANAGERIAL PERSPECTIVE- In ---------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------company's ability to respond to them, forces managers to synthesize the external economic environment with their internal goals and objectives. FLAGGING POTENTIAL PROBLEMS- Because the -------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------, managers can revise their immediate plans to change a product mix, revamp an advertising campaign, or borrow money to cover cash shortfalls. COORDINATING ACTIVITIES- Preparation ---------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------- demonstrates to managers the inter-connectedness of their activities.
- 6. EVALUATING PERFORMANCE- Budgets --------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------- a consistent pattern of inefficiency. REFINING THE HISTORICAL VIEW- The importance ---------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------. The need for a flexible and relevant historical perspective warrants its vigilant revision and expansion as conditions and experience warrant. Since the importance of the maintenance costs lies in their influence on production costs, the budgets must therefore portray them in production terms, and must result from discussions ---------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------information, prepares the budget statement and issues the periodic returns and statistics relating to actual performance against forecasted performance. Zero Based Budget- Zero Base Budgeting is the latest technique of budgeting. ----------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------to develop standard costs. Where it is difficult to compare the resources allocation with the output, ZBB is more appropriate in controlling. ADVANTAGES OF ZERO BASE BUDGETING- ZBB is a revolutionary concept. The benefits are as under: 1. ---------------------------- of Funds: Funds are scarce. Priority ---------------------------------------------- on cost-benefit analysis. 2. Systematic Evaluation: Manager has --------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------for the ongoing projects is made, if there is justification to continue, further. In other words, there is no difference between the new projects and ongoing projects from the view-point of allocation of funds. 3. Links Budgets with Goals of Enterprise: Those ----------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------of the enterprise would be developed.
- 7. 4. Zero Base Approach: Zero is taken as the base, ------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------is on analysis and decision-making 5. Optimum use of Resources: As cost------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------, resources are used to the optimum advantage of the organization. 6. No Incremental Approach: Normally, budgets ------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------with Zero-Base Budgeting. Manager has to justify their activities and the funds requested. 7. Most Appropriate for Non-Manufacturing Areas: Zero------------------------------------------------------------------------------------ ---------------------------------------------------------------- is not, directly, related with the final output of the organization. Within the business world, ZBB can be applied to research and development, data processing, quality control, marketing and transportation, legal staff and personnel office. Example: A separate training department may ------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------types of training to staff, outside the firm, may be more ideally suitable, while reducing the costs to the enterprise. 3. A remote control unit has 25 components in series. Each component has a reliability of 0.999. What is the reliability of the remote control unit? If it is desired to have a reliability of 0.996 for 3000 hours of operation, what should be the failure rate of each component? Assume that the time to failure for each component is exponentially distributed. ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------
- 8. ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- 4. Define hazard rate the discuss the three periods or regions of the life cycle of a unit or device as illustrated by the ‘bath-tub’ curve. The hazard rate is defined for ------------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- change and the units that have already failed play no further role since only the survivor’s count. The failure rate (or hazard rate) is denoted by h(t) and is calculated from h(t)=f(t)1−F(t----------------------------------------------------------------------------------------------------------------------------) failure rate. The failure rate is sometimes called a "conditional failure --------------------------------------------------------------------------------------- ------------------------------------------ population survivors) converts the expression into a conditional rate, given survival past time t. Since h(t) is also equal to the negative -------------------------------------------------------------------- the useful identity: be the Cumulative Hazard Function, -------------------------------------------------------------------- follow from these formulas are: It is also sometimes useful to define an average --------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------- that can be used as a specification or target for the population failure rate over that interval. If T1 is 0, it is dropped from the expression. Thus, for example, AFR----------------------- --------------------------------------------------------------------------------- over the first 40,000 hours of operation. The formulas -------------------------------------------- are:
- 9. Three periods or regions of --------------------------------------------------------------------- ‘bath-tub’ curve- After years of research examining the failure data of many types of components and devices, several modes of failure have come to light. This is illustrated by ------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------- against time, which denotes the life cycle of the component or device. From the figure, it is seen that the life cycle of a unit or device can be sub-divided into three distinct periods’ or regions. These three regions of the life cycle are as follows: 1. Early failure, or initial failure, or running in failure, or infant mortality region : When a batch of new items just produced or ----------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------during the initial failure period, this period is also known as the debugging or burn-in period. 2. Incidental or random failure region: After the initial failures, --------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------------------stress or part strengths meeting up to them as deterministic functions of time. 3. Wear-out failure region: As time passes, the units ----------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------and generally are in the form of physico-chemical or metallurgical degradation. This region is called the wear-out failure region and in this period the hazard rate increases.
- 10. In the early failure region, both h(t) and f(t) decrease --------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------------------------------the figure, we call discern the shapes of the failure distributions in the three regions of the life cycle of a unit or device. These shapes have led to early authors on reliability to propose the use ----------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------is that of constant hazard in the random variable region. Before we close our discussion on ------------------------------------------------------------------------------------------------ in the three regions of the bath-tub curve. The factors contributing to the early failures are as follows: i) design ----------------------------------------------------, ii) ----------------------------------------------------- defects, iii) -------------------------------------- defects, iv) commissioning ---------------------------------, and v) Operating defects. Moreover the design and manufacturing defects -------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------. The main contributors of wear-out failures are as follows: i) overload, ii) looseness, ----------------------------------------------- iii) Metallurgical ------------------------------------------. Conclusion- With respect to both human and electromechanical failures, the shape of the hazard function over the lifetime appears to take on a shape somewhat like a bathtub. We are of the opinion that the bathtub curves for electrical and mechanical devices are different and further more each has been changed since attention to quality became a strategic issue in America. Prior to the quality movement, a --------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------hazard rate begins to increase. We feel that today’s plots of h(t) vs. t are not like the traditional bathtub shapes. A few arguments for the demise of the “bathtub” curve will now be pre- sented. The initial portion, called the “burn-in” period for electronic devices and the period of early failures ------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------------------------------------, nurturing of suppliers, supplier evaluation and certification and with attention to eliminating and removing the root causes of defects in manufacturing, quality has vastly improved. There is very little poor quality to improve upon and hence few reasons to expect a downward slope to the curve.
- 11. Many manufacturers of consumer products, with substantial electronic circuitry, e.g., appliances, are now foregoing the “burn-in” period. That is , no “burn-in”. The reason for “burn-in” (high temperatures, and sometimes vibration) is to allow substandard components (e.g., bad capacitor and faulty processes, -------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------------------------components or processes. This is somewhat analogous to the cessation of polio immunizations in the United States, with the belief that it is more likely that the polio shot will cause the disease than prevent it since it is now so rare in the U.S. population. Since the exponential distribution, as will be shown in a ----------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------of the hazard function relate to its facility and stability when there is censoring of some of the data and when there are several modes of failure present in the failure process. 5. How can be questionnaire for ‘Maintenance Audit’ prepared? What is the main difference of audition result areas compared to auditing management processes? It has been observed that one third of all ------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------------------------------------------maintenance can result in unnecessary maintenance activity and downtime and in excessive spares usage, whilst being ineffective in preventing breakdown. Performing a periodic maintenance audit is essential in maintaining a profitable business. A maintenance audit answers the following questions: How effective is your current planned maintenance program? What areas are working? What areas could be improved? The objective of this performance maintenance audit program is to demonstrate a process of identifying specific business functions associated with a company’s core business services and or products and identify a series of questions related to service deliverables to establish a performance benchmark ----------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------and improve your processes – a ‘process optimization' process. The following audit process can be adapted for any business type, simply identify the functional areas and then establish the performance questions. The auditors prepare a detailed questionnaire on the various issues of concern in maintenance management and circulate in advance to the company management personnel. -------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------------------questionnaire are compiled and conclusions are arrived at as to the selected areas and management personnel to be concentrated upon during the next steps. The organizational performance of maintenance ----------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------, service response time, meantime to repair, and breakdown analysis reporting.
- 12. The review process is designed to evaluate the effectiveness of an existing maintenance management program. By assessing each of the key elements, one can obtain an overview of program effectiveness. This overview provides: A program ------------------------------------------------- rating Identification -------------------------------------- improvement A ----------------------------------------------------------- productivity gains The overall review process, together with a ----------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------is a concern of senior management or where staff is unavailable to complete part or all of the audit process. As a general rule, the better the maintenance --------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------management program. These components are further subdivided into key elements. The five basic components. Alternative groupings and factors can be developed for special applications. For example, a ------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------own unique conditions. However, variations on the forms, processes, and procedures should only be undertaken after becoming familiar with the audit process, after several iterations. The maintenance management audit process described in this article is designed to identify the tasks of a facilities organization seeking to improve effectiveness and efficiency. -------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------------------merit the most intensive investigation. Either way, the audit process defines checklists of facilities maintenance management performance and provides measures of effectiveness, setting up a baseline for future comparisons. Implementing condition based maintenance involves measurement or monitoring of appropriate physical variables or signatures of the machine using instrumentation and interpreting the signatures to indicate if maintenance of the machine is called for or not.. Listing and Identification of Plant Machines Listing and numbering of all -------------------------------------------------------------------------------------------------------------------------- -------------------- locate all machines within the plant, identify them in the maintenance program and retrieve data. Selection of Critical Machines Critical machines are those whose failure may ---------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------history records are not available the knowledge and experience of maintenance and operation personnel will be of great help in identifying the critical machines. The performance of a plant unit is a useful measure of its condition, for prognosis and need for maintenance action. The variety of units and their ---------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------- the innovation of condition monitoring engineers.
- 14. ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- At the end of your audit you should have a good idea of potential problem areas, where you can improve and where you are doing well. ------------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------- or semi-annual are also useful, a yearly audit can help smooth out performance fluctuations caused by seasonal changes. Examples of seasonal changes are equipment running at maximum load to ------------------------------------------------------------------------------------------------------------------------- maintenance spikes that can make it hard to compare performance against a prior quarter. 6. Write short notes on the following: a) Maintenance windows A maintenance window is a --------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------of defining standard maintenance windows is to allow clients of the service to prepare for possible disruption or changes. We encourage all services and systems to negotiate a maintenance window with their clients via an Service Level Agreement (SLA). For --------------------------------------------------------------------------- the ITS Service Managers. If a service does not have a ---------------------------------------------------------- equivalent) the following guidelines apply: Planned outages should be --------------------------------------------------------------------------------------------------- outside of this window should have explicit sign-off from the system steward or designated client representative. Planned outages and ------------------------------------------------------------------------------------------------------------------------ ----- grading week of the academic quarters, or during other significant campus events or key dates Production means ------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------- academic tasks and objectives. Windows for the whole plant ------------------------------------------------------------------------------- for the product. Windows for -------------------------------------------------------------------------------------- by production scheduling. Windows arising for the -------------------------------------------------------------------------------------------------------------------- ------------------ changes, catalyst changes, equipment cleaning etc.). These tend to have poor predictability. Windows for major sections of plant, or for units, that can be created by the use of standby or redundant plant, or inter stage storage. Windows arising for the -------------------------------------------------------------------------------------- safety work. Maintenance Windows are defined by collection, and when configured, can be set with an effective start date, start and end times, and a set recurrence pattern. ---------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------content outside of the maintenance window. b) Cost Absorption and Cost Apportionment
- 15. Cost Allocation: Cost Allocation means the ------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------------------------------, accumulating the costs that relate to the object of costing and choosing the method to identify those costs. Usually, the allocation of costs would be done based on machine-hours, direct-labor hours etc. Example: Say a ---------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------labor hours. The direct labor hours for Products A, B and C are 2000, 1000 and 3000 respectively. Solution: Total labor hours = 6000 Cost allocation: Overheads allocated for Product A = ----------------------------------------------- =$10,000 Overheads ---------------------------------------------------- B = 30000*1000/6000 = $5,000 Overheads allocated for Product C = 30000*3000/------------------------------------ Allocation of overheads is the process of ----------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------of that particular department. For example, the whole amount of repair and maintenance expenses for a machine is charged or allocated to that department where the machine has been installed. Cost Apportionment: Cost allocation is also referred to as Cost apportionment. Cost apportionment means the allotment of proportions of items of cost of cost centers or cost units. Distribution of an overhead cost to ------------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------------------------------------. Similarly, the amount of remuneration of the general manager should be distributed to the production, administration and marketing departments as the general manager is associated with all these departments. ------------------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------- c) Design and Maintainability In engineering, maintainability is the ease with which a product can be maintained in order to: isolate defects or their cause, correct defects or their cause, repair or replace faulty or -------------------------------------------------------------------------------------------------
- 16. -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------of interest in maintainability analysis is time-to-repair rather than time-to-failure. For example, if it is said that a particular ------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------the overall performance (availability, uptime, downtime, etc.) that will help you to make decisions about the design and/or operation of a repairable system. Maintainability is the parameter concerned with how the ------------------------------------------------------------------------------------------------ -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------requirement. This would take the form of sparing strategies, maintainer training, maintenance manuals, and identification of required support equipment. In some cases, maintainability involves a system of continuous improvement - learning from the past in order to improve the ability to maintain systems, or improve reliability of systems based on maintenance experience. d) Maintenance Audit A Maintenance Systems Audit (our organization calls it a “Maintenance Business Review” to emphasize business aspects of the maintenance function) can best be described as --------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------------------------involve individuals and their performance, though it does assess training and personnel development needs. Maintenance audit is applied to a service company. ---------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------means of decision rules the previous values are interconnected using different first and second level variables to establish the state of the maintenance activities by sections The development of a maintenance audit in a service --------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------------------------------expert system to create a maintenance audit. The maintenance audit developed can be applied in the context of a continuous improvement environment. The audit addresses seven Maintenance ------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------ maintenance aspects. The audit structure is as follows: ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------------------------------------------------------------------
- 17. Management: Management -------------------- Leadership Maintenance Policy Maintenance Improvement Program ----------------------------------------------- Quality Assurance Maintenance Review Program Health, --------------------- Management Spare -------------------------------: Spare Parts Procurements ------------------------ Management Personnel: Organizational Structure Workforce -------------------------- Participation Personnel Development Program Contractors ----------------------- ----------------- & Scheduling: Daily Planning Outage Planning Maintenance ------------------------------------: Operational -------------------------- Maintenance --------------------- Development Asset Lifecycle Management Plant & ---------------------- Monitoring Standard Procedures and Job Instructions Plant and ----------------------- Analysis Maintenance Management System Document Control System Repair Services The development of a maintenance audit in a service ----------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------system to create a maintenance audit. The maintenance audit developed can be applied in the context of a continuous improvement environment. KIAN PUBLICATION Whatsapp- 9580039150 ignousolvedassignmentsmba@gmail.com kianpublication1@gmail.com ignou4you@gmail.com