Introduction and Course overview

by

S. O. Duffuaa
Module Outline

Role of Maintenance in a
Company
Production and
Maintenance Relationship
Maintenance as an input
output system.



Module Outline
Maintenance costs
Maintenance planning
Maintenance Strategic
Planning
Overview of the course

Role of Maintenance

Predictable Plant Capacity
Efficient Energy Use
Maintenance and Availability
Maintenance and Quality
Maintenance and Equipment Life Time
Maintenance and Energy Use
Maintenance and Economy
Organizations Objectives include:
Meet or exceed customer satisfaction
Maximizing profit
Meet deliveries
Meet set targets
Meet set safety standard
Zero product defect

Does Maintenance affect these goals?
Role of Maintenance
Maintenance is the backbone of all
successful enterprises and contributes
to:

Improve Product Quality
Reduce Costs
Meet Set Targets
Improve Utilization
Improve Equipment Performance

Figure 1: Dependency between production/Service and
maintenance.
Production/
Service

Quality

Maintenance
Equipment Condition
Demand for
Maintenance
Production
Capacity
Primary Input Primary Output
Product Quality
Maintenance Costs
1. DIRECT COSTS
Cost of Periodic Inspection
Service Cost
Repair Cost, Overhaul Cost

2. STAND-BY COSTS
Cost of Operating and Maintaining a
Standby Unit


Maintenance Costs.
3. LOST PRODUCTION COSTS :
Cost due to Equipment down time.

4. DEGRADATION COST
Cost occurring due to deterioration of the
life span of equipment due to no
maintenance or inadequate maintenance.
PLANNING ORGANIZING
Maintenance
Process
Maintenance Philosophy
Maintenance Load Forecasting
Maintenance Capacity
Maintenance Organization
Maintenance Scheduling
Job Design
Standards
Work Measurement
Project Management
MONITOR
FEEDBACK
CONTROL
Work control
Material control
Inventory control
Cost control
Managing for quality
INPUT OUTPUT
Operational
Machines
Equipment
&
Facilities
Labor
Equipment
Management
Spares
Variations in
Maintenance
Demand
* Scheduling
Maintenance Planning
activities
Planning activities generally include the
following :
1. Maintenance philosophy
2. Maintenance load forecasting
3. Maintenance capacity
4. Maintenance organization
5. Maintenance scheduling.


Maintenance Strategies
1. Breakdown Maintenance (Run To
Failure)
2. Fault Finding (FF)
3. Time directed Preventive
Maintenance(TD)
4. Condition Based Maintenance (CBD)
5. Design Modification (DM)
6. Replacement Instead of Maintenance
7. Planned Replacement (Car Fleet)
8. Opportunity Maintenance
Maintenance an Internal Part of an
Organization
Growing
Maintenance Expectations
Fix it when it broke
Higher plant availability
Longer equipment life
Lower costs
Higher plant availability and reliability
Greater safety
Better product quality
No damage to the environment
Longer equipment life
Greater cost effectiveness
1940 1950 1960 1970 1980 1990 2000
Production System, Maintenance
System & Operations System
Relationship
Availability Performance
Conceptual Presentation
Of Availability Performance
Maintenance Strategies
Strategic Planning in Maintenance
Vision
Mission
Objectives
Measures/ balanced scored card
Strategies
Implementation
Targets or goals
Action plans
Vision
Where you want to be
To be an Award winning department
at the international level.
Mission Why you exist?
Keep plant equipment and assets well
configured, safe to operate with the
maximum availability maintained with
minimum cost.
Objectives
What to pursue to achieve mission
and objectives.
Recruit and maintain the best
technical staff.
Adopt effective and proactive
maintenance strategies using latest
knowledge and technology.
Avail the needed spare parts at the
minimum cost.
Measures
MTBF for reliability

Availability

Costs

Employee learning

Utilization
Strategies
TPM

Intelligent maintenance.

Reliability Centered Maintenance
(RCM)
Course Overview
May15-18, 2005
Day 8:00- 12:00 12:00- 1:00 1:00-3:00
Sunday
May, 15

Overview of
Maintenance Strategies

Introduction to RCM


Monday
May, 16
RCM Methodology &
Tools


RCM Tools

Tuesday
May,17
RCM STEPS


RCM Steps with example
Wednesday
May,18
RCM Implementation
L
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n
c
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Case Study