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Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved.

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Page 1: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

Maintenance

McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved.

Page 2: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

You should be able to:1. Explain the importance of maintenance in production

systems2. Describe the range of maintenance activities3. Discuss preventive maintenance and the key issues

associated with it4. Explain breakdown maintenance and name the key

issues associated with it5. State how the Pareto phenomenon pertains to

maintenance decisions

14S-2Student Slides

Page 3: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

MaintenanceAll activities that maintain facilities and

equipment in good working order so that a system can perform as intended

Maintenance activity categories:Buildings and groundsEquipment maintenance

14S-3Student Slides

Page 4: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

The goal of maintenance is to keep the production system in good working order at minimal cost

Reasons for wanting to keep equipment and machines in good operating condition:1. Avoid production or service disruptions2. Not add to production or service costs3. Maintain high quality4. Avoid missed delivery dates

14S-4Student Slides

Page 5: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

Reactive:Breakdown maintenance

Dealing with breakdowns or problems when they occur

Proactive:Preventive maintenance

Reducing breakdowns through a program of lubrication, adjustment, cleaning, inspection, and replacement of worn parts

14S-5Student Slides

Page 6: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

The goal of preventive maintenance is to reduce the incidence of breakdown or failures in the plant or equipment to avoid the associated costs Loss of output Idle workers Schedule disruption Injuries Damage to other equipment, products, or facilities Repairs

Inventories of spare parts Repair tools and equipment Repair specialists

14S-6Student Slides

Page 7: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

It is periodicIt can be scheduled according to the availability

of maintenance personnel and to avoid interference with operating schedules

Maintenance is scheduled using some combination of1. The result of planned inspections that reveal a need

for maintenance2. According to the calendar (passage of time)3. After a predetermined number of operating hours

14S-7Student Slides

Page 8: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

The goal is to strike a balance between the cost of preventive maintenance and the cost of breakdown

The amount of preventive maintenance, therefore, is a function of the expected frequency of breakdown, the cost of breakdown, and the cost of preventive maintenance

Student Slides14S-8

Page 9: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

The frequency of breakdown of a machine per month is $1,000 and the cost of preventive maintenance is $1,250 per month. If preventive maintenance is performed, the probability of a machine breakdown is negligible. Should the manager use preventive maintenance, or would it be cheaper to repair the machine when it breaks down?

Number of breakdowns 0 1 2 3

Frequency of occurrences .20 .30 .40 .10

Student Slides14S-9

Page 10: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

4.1)10(.3)40(.2)30(.1)20(.0breakdowns of

number Expected

Number of breakdowns 0 1 2 3

Frequency of occurrences .20 .30 .40 .10

$150

$1,250 - )1.4($1,000

emaintenancpreventive ofCost

breakdownofcost Expected

emaintenanc preventiveofbenefit Expected

14S-10Student Slides

Page 11: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

Suppose the average time before breakdown is normally distributed with a mean of 3 weeks and a standard deviation of .60 weeks. If breakdown cost average $1,000 and preventive maintenance costs $250, what is the optimal maintenance interval?

Find the number of standard deviations from the mean represented by an area under the normal curve of .25

Using the standard normal table, it is -0.67Use this value to determine the maintenance interval

25.000,1$

250$

costBreakdown

cost Preventive

weeks2.598)(-.67)(.603deviation) (standard Mean z

14S-11Student Slides

Page 12: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

Predictive maintenance An attempt to determine when best to perform

preventive maintenance activitiesIdeally, preventive maintenance will be performed

just prior to a breakdown or failure because this will result in the longest possible use of facilities or equipment without a breakdown

Total productive maintenance JIT approach where workers perform preventive

maintenance on the machines they operate

14S-12Student Slides

Page 13: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

Maintenance problems are sometimes designed into products:Poor designDesigner have accorded other aspects of

design greater importanceCostAppearance is more important than maintenance

activities

Student Slides14S-13

Page 14: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

Approaches to dealing with breakdowns:Use of standby or backup equipmentInventories of spare parts are maintainedUse operators who are able to perform at

least minor repairs on the equipment they operate

Have repair people who are well trained and readily available to diagnose and correct problems

14S-14Student Slides

Page 15: Maintenance McGraw-Hill/Irwin Copyright © 2012 by The McGraw-Hill Companies, Inc. All rights reserved

When breakdowns become frequent and/or costly:What is the cost of replacement compared to

continued maintenance?Issues:

Predicting breakdownsTechnological changeSystem disruptionsTraining employees on the use of new equipmentForecast of future demand

14S-15Student Slides


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© The McGraw-Hill Companies, Inc., 2002 McGraw-Hill/Irwin

McGraw-Hill/Irwin ©2005 The McGraw-Hill Companies, All rights reserved McGraw-Hill/Irwin

Irwin/McGraw Hill The McGraw-Hill Companies, Inc., 2000 · Slides by Matthew Will Chapter 2 Irwin/McGraw Hill ©The McGraw-Hill Companies, Inc., 2000. Irwin/McGraw Hill ... " Tools

McGraw-Hill/Irwin Copyright © 2008, The McGraw-Hill Companies, Inc. All rights reserved.McGraw-Hill/Irwin Copyright © 2008 The McGraw-Hill Companies, Inc

Relevant Costs for Decision Making - NELY BACHSIN BLOG · PDF fileChapter Thirteen . McGraw-Hill/Irwin ... McGraw-Hill/Irwin Copyright © 2008, ... McGraw-Hill/Irwin Copyright © 2008,

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#14-1 McGraw-Hill/Irwin © 2005 The McGraw-Hill Companies, Inc., All Rights Reserved. McGraw-Hill/Irwin © 2005 The McGraw-Hill Companies, Inc., All Rights

Chapter 10 · Irwin/McGraw-Hill © The McGraw-Hill Companies, Inc., 2001 $ Irwin/McGraw-Hill © The McGraw-Hill Companies, Inc.,

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Chapter Ten LocalMarketing in Emerging Markets Irwin/McGraw-Hill ©The McGraw-Hill Companies,, Inc., 2000 Irwin/McGraw-Hill ©The McGraw-Hill Companies,,

Local Marketing in Mature Markets Chapter Eight. Irwin/McGraw-Hill ©The McGraw-Hill Companies,, Inc., 2000 Irwin/McGraw-Hill ©The McGraw-Hill Companies,,

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