Operations

Management
Maintenance and Reliability

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 Outline
 GLOBAL COMPANY PROFILE: NASA
 THE STRATEGIC IMPORTANCE OF
MAINTENANCE AND RELIABILITY
 RELIABILITY
 Improving Individual Components
 Providing Redundancy
 MAINTENANCE
 Implementing Preventive Maintenance
 Increasing Repair Capability
 TOTAL PRODUCTIVE MAINTENANCE
 TECHNIQUES FOR ESTABLISHING
MAINTENANCE POLICIES
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 Learning Objectives
When you complete this chapter, you should be
able to :
Identify or Define:
 Maintenance
 Mean time between failures
 Redundancy
 Preventive maintenance
 Breakdown maintenance
 Infant mortality

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 Learning Objectives - continued
When you complete this chapter, you should be
able to :
Describe or Explain:
 How to measure system reliability
 How to improve maintenance
 How to evaluate maintenance performance

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 NASA
 Maintenance of space shuttles
 Columbia:
 86,000,000 miles on odometer
 3 engines each the size of a VW
 expected to make dozens more launches

 Maintenance requires
 600 computer generated maintenance jobs
 3-month turnaround
 More than 100 people

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 Maintenance Management

 All activities involved in

keeping a system’s
equipment working
 Objective: Maintain system
capability & minimize total
costs

© 1995 Corel Corp.

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 The Strategic Importance of
Maintenance and Reliability
 Failure has far reaching effects on a firm’s
 operation
 reputation
 profitability
 customers
 product
 employees
 profits

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 Maintenance Performance
Employee Maintenance
Involvement Procedures

Maintenance © 1995
Corel
Corp.
Performance

© 1995 Corel Corp.

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 Good Maintenance & Reliability
Strategy
 Requires:
 Employee involvement
 Maintenance and reliability procedures

 To yield:
 Reduced inventory
 Improved quality
 Improved capacity
 Reputation for quality
 Continuous improvement

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 Employee Involvement

 Information sharing
 Skill training
 Reward system
 Power sharing

© 1995 Corel Corp.

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 Maintenance & Reliability
Procedures

 Clean and lubricate Maintenance

Procedures
 Monitor and adjust
 Minor repair
 Computerized records
© 1995
Corel
Corp.

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 Maintenance Benefits
Lower
operating Faster, more
Reduced
costs dependable
inventory
throughput

Improved Maintenance Higher

capacity productivity

Continuous Improved
improvement quality

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 Tactics for
Reliability and Maintenance
 Reliability Tactics
 improving individual components
 providing redundancy
 Maintenance Tactics
 implementing preventive maintenance
 increasing repair capabilities

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 System Reliability -
Components in Series
100
n=1
80
Reliability of the System (Percent)

60

40

20

100 99 98 97 96
Average Reliability of all Components (Percent)

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 Reliability of
Components in Series

R = R1 * R2 * R3 * ...

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 Evaluating Maintenance

 Reliability
 Probability that an item will function for a given time
 Mean time between failures (MTBF)
 Average time between failures of a repairable item
 Failure rate
 Reciprocal of MTBF

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 Failure Rate (%)

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

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 Lifetime Failure Rates
“normal” failure Wearout
failure

Failure
rate Infant
mortality
and
improper use
failure

Lifetime
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Failures Per Operating Hour

Number of Failures
FR(n) =
Operating Time

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Mean Time Between Failures

1
MTBF =
FR(N)

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 Providing Redundancy

Probability of Probability of Probability

first second of needing
component + component * second = P(R)
working working component

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 Maintenance Decisions
 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

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 Types of Maintenance
Preventive Breakdown
 Routine inspection &  Non-routine inspection
servicing & servicing
 Prevents failures  Remedial
 Bases for doing  Basis for doing
 Time: Every day  Equipment failure

 Usage: Every 300 pieces

 Inspection: Control chart
deviations

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Mean Time Between Failure and
Preventive Maintenance

Candidate for preventive

maintenance will have
distribution with low
variability
Frequency
of failure

Mean Time Between Failure

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 Organizing the
Maintenance Function
 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

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 Operator-Ownership Approach

 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

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A Computerized Maintenance System

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 Maintenance Costs
Traditional View
Cost

Optimal Maintenance
Commitment
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 Maintenance Costs
Full Cost View
Cost
Total costs

Full cost of
breakdowns
Preventive
maintenance costs

Optimal
Maintenance
Commitment
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 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

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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

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Operations Manager Must Determine
How Maintenance Will be Performed

Operator Maintenance Manufacturer’s Depot Service

Department field service (return equipment)
Competence is higher as we more
Preventive maintenance costs to the right
less and is faster as we move
to the left

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 Total Productive Maintenance
 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

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 A Key To Success

High utilization of facilities, tight scheduling, low

inventory and consistent quality demand reliability
- total preventive maintenance is the key to
reliability.

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 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

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