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Maintenance Management
MEM575
Learning Objectives
Understand Maintenance, reliability and its
enhancements
Able to differentiate Types of maintenance;
Preventive, Breakdown, others
Understand Total Productive Maintenance
Maintenance and Reliability
The objective of maintenance and
reliability is to maintain the
capability of the system while
controlling costs
Maintenance is all activities involved
in keeping a system’s equipment in
working order
Reliability is the probability that a
machine will function properly for a
specified time
3
Important Tactics
Reliability
1. Improving individual components
2. Providing redundancy (backup)
Maintenance
1. Implementing or improving
preventive maintenance
2. Increasing repair capability or speed
4
Maintenance
Breakdown maintenance
Reactive/Corrective approach; dealing with
breakdowns or problems when they occur
Preventive maintenance
Proactive approach; reducing breakdowns
through a program of lubrication, adjustment,
cleaning, inspection, and replacement of worn
parts
5
Maintenance
Predictive maintenance
An attempt to determine when best to
perform preventive maintenance activities
Total productive maintenance
JIT approach where workers perform
preventive maintenance on the machines they
operate
6
Costs Occur When Breakdown
Costs due to machine downtime
Probable loss of sales to customer
Costs due to idle direct or indirect labour
Costs due to delays in other processes that may
depends for material supply on the machine that is
down
Increased scrap costs
Repair costs
Costs due to customer dissatisfaction from possible
delays in deliveries
7
Breakdown Programs
Standby or backup equipment that can be
quickly pressed into service
Inventories of spare parts that can be installed
as needed
Operators who are able to perform minor
repairs
Repair people who are well trained and readily
available to diagnose and correct the problems
using proper equipment.
8
Elements of Preventive Maintenance
9
Maintenance Cost Example
Should the firm contract for maintenance on their
printers if the cost of hiring the maintenance
services monthly is RM 150?
Number of Number of Months That
Breakdowns Breakdowns Occurred
0 2
1 8
2 6
3 4
Total: 20
Average cost of breakdown = RM300/breakdown
Routine servicing cost = RM300/service
10
Maintenance Cost Example
Expected number
of breakdowns = ∑ Number of
breakdowns x
Corresponding
frequency
= (1.6)($300)
= $480 per month
12
Maintenance Cost Example
Number of breakdowns 0 1 2 3
Frequency of occurrence .20 .30 .40 .10
14
Number of Frequency of Expected number of
Breakdowns Occurrence Breakdowns
0 .20 0
1 .30 .30
2 .40 .80
3 .10 .30
1.00 1.40
Total Cost
Cost
Preventive
maintenance cost
Breakdown and
repair cost
Optimum Amount of
preventive maintenance
16
Economics of Maintenance
For highly complex automated machines with
expensive parts & highly skilled labour, preventive
maintenance is advisable.
Preventive maintenance can be done when time
machines are idle or low production time
If the cost of shutting down the machine is high, it
would be better to wait until breakdown
17
Total Productive Maintenance (TPM)
Direct employee involvement
– a sense of ownership and they would care more of the
machine that they involved with, organize appropriate
operation & maintenance training
Proper documentation
– Organized, computerized and easy access database of
maintenance problems, solutions and schedule by
employees e.g. expert system which assist in
troubleshooting various machine
Utilize machines that are reliable, easy to operate,
and easy to maintain
18
Autonomous Maintenance
▶ Employees accept responsibility for
▶ Observe
▶ Check
▶ Adjust
▶ Clean
▶ Notify
▶ Predict failures, prevent breakdowns,
prolong equipment life
Total Productive Maintenance (TPM)
80 –
60 –
40 –
20 –
0 |– | | | | | | | |
100 99 98 97 96
Average reliability of all components (percent)
22
Reliability Calculation’s Example
R1 R2 R3
23
Redundancy Example
A redundant process (backup) is installed to
support the earlier example where Rs = .713
The reliability of the system could be improved by having machines
in parallel, but expensive.
R1 R2 R3
Reliability has
0.90 0.80 Backup increased from
.713 to .94
Simulation
By using past data of breakdowns and
random number, good tool to decide
in replacing parts that have not yet
failed
25
Computerized Maintenance
System
Data Files Output Reports
Equipment file
with parts list Inventory and
purchasing reports
Maintenance Equipment
parts list
and work order
schedule
Equipment
Repair history reports
history file
Cost analysis
Data entry (Actual vs. standard)
– Work requests
– Purchase
Inventory of requests
spare parts – Time reporting
– Contract work
Work orders
– Preventive
maintenance
– Scheduled
Personnel data downtime
with skills, – Emergency
wages, etc. maintenance Figure 17.3
26
Establishing Maintenance Policies
Simulation
Computer analysis of complex
situations
Model maintenance programs before
they are implemented
Physical models can also be used
Expert systems
Computers help users identify
problems and select course of action
27
Maintenance Policies – (Example)
Critical component is replace before it breaks down through
the Preventive Maintenance Program
Establish a repair facility and have an adequate maintenance
crew to reduce down time
Use parallel paths of production (for critical stages) so that
breakdowns will not paralyze the entire production
Design critical components in more reliable manner
Establish storage/buffer between stages of production line
Use standby machinery when a particular machine breaks
down
28
Let’s Recap
Understand Maintenance, reliability and its
enhancements
Able to differentiate Types of maintenance;
Preventive, Breakdown, others
Understand Total Productive Maintenance