Maintenance and Reliability

10
Decisions
Weeks 10 (Chapter 17)

Operations Management, Sustainability and Supply Chain Management,

Global Edition, Eleventh Edition, PEARSON
Jay Heizer and Barry Rander © 2014 Pearson Education
 Textbook for Used

Operations Management, Sustainability and

Supply Chain Management,
Global Edition, Eleventh Edition, PEARSON
Jay Heizer and Barry Rander (2014)
 Outline
► Global Company Profile:
Orlando Utilities Commission
► The Strategic Importance of
Maintenance and Reliability
► Reliability
► Maintenance
► Total Productive Maintenance
© 2014 Pearson Education
 10
OM
STRATEGY
DECISION
▶ Design of Goods and Services
▶ Managing Quality
▶ Process Strategy
▶ Location Strategy
▶ Layout Strategy
▶ Human Resources
▶ SCM
▶ Inventory Management
▶ Scheduling
▶ Maintenace 4
© 2014 Pearson Education
Global Company Profile
orlando UTILITIES COMMISSION © 2014 Pearson Education
 strategic importance of
Maintenance & reliability

Maintenace
The activities involved in keeping a system’s equipment in
working order

Reliability the probability that a machine part or

product will function properly for a specified time under stated conditions
© 2014 Pearson Education
 maintenance
management
Employee Involvement
 Partnering with maintenance
personnel
 Skill training Results
 Reward system
 Employee empowerment • Reduced inventory
• Improved quality
• Improved capacity
• Reputation for quality
Maintenance and Reliability • Continuous improvement
Procedures • Reduced variability
• Clean and lubricate
• Monitor and adjust
• Make minor repair
• Keep computerized records
© 2014 Pearson Education
 Reliability

 System Reliability

Rs = R1 x R 2 x R3 x … x Rn
where R1 = reliability of component 1
R2 = reliability of component 2

and so on
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 MTBF
Mean Time
Between
Failures

Number of failures
FR(%) = x 100%
Number of units tested

Number of failures
FR(N) =
Number of unit-hours of operating time

1
MTBF =
FR(N)
© 2014 Pearson Education
 Reliability
 Providing Redundancy
The use of backup components or parallel paths to raise reliability

Probability of Probability of Probability of

RS = first + second x needing
component component second
working working component

= (0,8) + (0,8) x (1 – 0,8)

= 0,96
© 2014 Pearson Education
 Maintenance

2 type of maintenace:
 Preventive maintenance
A plan that involves routine inspections, servicing and keeping facilities in
good repair to prevent failure.
 Breakdown maintenace
Remendial maintenace that occurs when equipment fails and must be
repaired on an emergency or priority basis.

Infant mortality
The failure rate early in the life of a product or process.

© 2014 Pearson Education

 traditional view of
Maintenance

Total
costs
Preventive
maintenance costs
Costs

Breakdown
maintenance costs

●
Optimal point (lowest
Maintenance commitment
cost maintenance policy)
 full cost view of
Maintenance

Total
costs

Full cost of
breakdowns
Costs

Preventive
maintenance costs

Maintenance commitment ●
Optimal point (lowest
cost maintenance policy)
 (TPM)
total productive
MAINTENANCE
Combines total quality management with a strategic view of
maintenance from process and equipment design to
preventive maintenance

 Designing machines that are reliable, easy to operate and easy to

maintain
 Emphasizing total cost of ownership when purchasing machines, so that
services and maintenance are included in the cost
 Developing preventive maintenance plans that utilize the best practices
of operators, maintenance departments and depot service
 Training for autonomous maintenance so operators maintain their own
machines and partner with maintenace personnel
© 2014 Pearson Education
 AR Y ?
SUM M

Thankyou
very
Operations Management, Sustainability and Supply Chain Management,
Global Edition, Eleventh Edition, PEARSON
Jay Heizer and Barry Rander (2014) © 2014 Pearson Education