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Reliability
1. Improving individual components
2. Providing redundancy
Maintenance
1. Implementing or improving
preventive maintenance
2. Increasing repair capability or speed
R s = R 1 x R2 x R 3 x … x R n
80 – n=1
0
60 –
n=
40 – n 50
=
10
n 0
=
20 – 20
n= 0
n
=
30
0
40
0
| | | | | | | | |
0100
– 99 98 97 96
Figure 17.2
Average reliability of each component (percent)
© 2006 Prentice Hall, Inc. 17 – 5
Reliability Example
R1 R2 R3
Number of failures
FR(%) = x 100%
Number of units tested
Number of failures
FR(N) =
Number of unit-hours of operating time
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
– Time reporting
spare parts – Contract work
Work orders
– Preventive
maintenance
– Scheduled
Personnel data downtime
with skills, – Emergency
wages, etc. maintenance Figure 17.3
Preventive
maintenance
Costs
costs
Breakdown
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Total
costs
Full cost of
breakdowns
Costs
Preventive
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Full Cost View Figure 17.4 (b)
© 2006 Prentice Hall, Inc. 17 – 17
Maintenance Cost Example
Should the firm contract for maintenance
on their printers?
Number of Number of Months That
Breakdowns Breakdowns Occurred
0 2
1 8
2 6
3 4
Total: 20
Expected number
of breakdowns = ∑ Number of
breakdowns x
Corresponding
frequency
= (1.6)($300)
= $480 per month
= (1 breakdown/month)($300) + $150/month
= $450 per month
Competence is higher as we
move to the right
Preventive
maintenance costs less and
is faster the more we move to the left
Figure 17.5
© 2006 Prentice Hall, Inc. 17 – 23
Total Productive
Maintenance (TPM)
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 service
Training workers to operate and maintain their
own machines