Maintenance Management
All activities involved in keeping a system’s equipment working
Objective: Maintain system capability & minimize total costs
Failure has far reaching effects on a firm’s
operation
reputation
profitability
customers
product
employees
profits
Maintenance Performance
Employee Involvement
Information sharing
Skill training
Reward system
Power sharing
Maintenance ProceduresClean and lubricate
Monitor and adjust
Minor repair
Computerized records
Good Maintenance & Reliability Strategy
To yield:
reduced inventory
improved quality
improved capacity
reputation for quality
continuous improvement
Maintenance Tactics
implementing preventive maintenance
Routine inspection & servicing
Prevents failures
Bases for doing
Time: Every day
Usage: Every 300 pieces
Inspection: Control chart deviations
increasing repair capabilities
Non-routine inspection & servicing
Remedial
Basis for doing
Equipment failure
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
How much preventive & breakdown maintenance
Who performs maintenance
Centralized, decentralized, operator etc.
Contract or in-house
Centralized maintenance department
Does all maintenance (PM & breakdown)
Decentralized maintenance department
Useful if different equipment used in different areas of company
Contract maintenanceCompute 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
Used if little equipment or expertise
Operator ownership approach
When to replace or repair
How much to replace
Individual or group replacement
Evaluating Maintenance
Mean time between failures (MTBF)
Average time between failures of a repairable item
Failure rate
Reciprocal of MTBF
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 backupHandles non-routine problems
Provides maintenance training
Has plant-wide responsibilities
Objective: Maintain system capability & minimize total costs
Failure has far reaching effects on a firm’s
operation
reputation
profitability
customers
product
employees
profits
Maintenance Performance
Employee Involvement
Information sharing
Skill training
Reward system
Power sharing
Maintenance ProceduresClean and lubricate
Monitor and adjust
Minor repair
Computerized records
Good Maintenance & Reliability Strategy
To yield:
reduced inventory
improved quality
improved capacity
reputation for quality
continuous improvement
Maintenance Tactics
implementing preventive maintenance
Routine inspection & servicing
Prevents failures
Bases for doing
Time: Every day
Usage: Every 300 pieces
Inspection: Control chart deviations
increasing repair capabilities
Non-routine inspection & servicing
Remedial
Basis for doing
Equipment failure
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
How much preventive & breakdown maintenance
Who performs maintenance
Centralized, decentralized, operator etc.
Contract or in-house
Centralized maintenance department
Does all maintenance (PM & breakdown)
Decentralized maintenance department
Useful if different equipment used in different areas of company
Contract maintenanceCompute 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
Used if little equipment or expertise
Operator ownership approach
When to replace or repair
How much to replace
Individual or group replacement
Evaluating Maintenance
Mean time between failures (MTBF)
Average time between failures of a repairable item
Failure rate
Reciprocal of MTBF
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 backupHandles non-routine problems
Provides maintenance training
Has plant-wide responsibilities
