Chapter 5

Maintenance Resource
Requirements

© A.K.S. JARDINE
 Maintenance Optimization

Optimizing Equipment Maintenance and Replacement Decisions

Component Capital Equipment Inspection Resource

Replacement Replacement Procedures Requirements

Maintenance Management System (CMMS/EAM/ERP)

© A.K.S. JARDINE 2
Queueing Theory

© A.K.S. JARDINE
 Queueing Problem
Workshop

µ = 5.5 jobs / week 1

Arrivals 2 Departures

3
λ = 30 jobs / week
.
.
.
Wq
n

Ws

© A.K.S. JARDINE 4
 Solution continued:
• If n = 5, then capacity of workshop = 5 x 5.5
= 27.5 jobs / week
• However, demand = 30 jobs / week
• Therefore, at least 6 lathes are needed

n Ws [weeks] C(n) [$]

6 0.437 7755
7 0.237 4955
8 0.198 4570 Minimum
(n = 8)
9 0.189 4635
10 0.185 4775
11 0.183 4945
12 0.182 5130
© A.K.S. JARDINE 5
 Solution continued:
Wqµ
To obtain Ws we use the chart of Wq µ versus n:

ρ = 0.91 When n = 6:
ρ (traffic intensity) = λ = 30
1.4 . nµ (6)(5.5)
∴ ρ = 0.91

∴ 1.4 = Wq µ (from chart)

∴ Wq = 1.4 / µ = 1.4 / 5.5 = 0.255

∴ W s = Wq + 1 / µ
6
n = 0.255 + 1 / 5.5
(# of servers) = 0.437 week
NOTE: ρ is a measure of the average busyness of the system
© A.K.S. JARDINE 6
 Solution continued:
• Similarly, we can obtain Ws for n = 7, 8, …, 12
• When n = 7, then ρ curve to use is:
ρ = λ = 30 = 0.78
nµ (7)(5.5)

• This will result in obtaining: Ws = 0.237 week

• When n = 6, then C(n) is:
C(n) = n Cl + Ws λ Cd
= 6(200) + (0.437)(30)(500)
= $7755 © A.K.S. JARDINE 7
Lathe Requirements in
Maintenance Workshop
(Section 5.4, page 192)

© A.K.S. JARDINE
 Initial Perspective of Lathe System
µl LARGE LATHES
µl

µl
|
|
p |
DEPARTURES
ARRIVALS

(1 – p)
µm

µm

µm
|
|
MEDIUM LATHES
|

© A.K.S. JARDINE 9
 Second View of Lathe System

LARGE LATHES

1
MEDIUM LATHES
INCOMING
2
JOBS DEPARTING JOBS
3
4
5
6
7
8
SMALL LATHES

© A.K.S. JARDINE 10
Representation of Maintenance Workshop
LATHES
A QUEUE
A JOBS 1
p = 4.90 ∑ = 50 µ = 3.08
∑ = 36 λ = 2.28
λ = 1.64 B QUEUE
∑ = 14
B JOBS 2
p = 10.1 ∑= 37 ∑ = 135 µ = 7.25
INCOMING ∑ = 74 p = 24 λ = 6.14
JOBS λ = 3.36 ∑= 114
p = 76 3
∑ = 76 µ = 4.10
∑ = 733 D QUEUE ∑ = 151 λ = 3.46
λ = 33.32 4
D JOBS p = 15.2 ∑= 88 µ = 4.75
∑ = 111 λ = 4.00
λ = 5.05
∑ = 128 5
E QUEUE 6
E JOBS 7
p = 69.8 ∑ = 384 8 µ = 17.8
∑ = 512 λ = 17.45
λ = 23.27
p = Percentage of jobs going along branch ; ∑ = Total number of jobs going along branch in 22 weeks;
λ = Arrival rate of jobs/week during 22 week period; µ = Service rate of jobs/week during 22 week period
© A.K.S. JARDINE 11
 Results
Lathe Idle Time as a Mean Wait of
Situation Number Percentage of Jobs in Queue
Hours Available (days)
1 26.4% 6.55
2 15.4% 5.25
Existing State 3 15.5% 9.37
4 15.7% 8.1
5, 6, 7, 8 2% 5.11
1 44.6% 2.95
Additional 2 38.8% 1.65
Machine in 3 43.0% 1.97
Group 6 4 36.4% 2.45
5, 6, 7, 8, +1 2% 2.83
1 44.6% 2.95
Additional 2 42.2% 1.49
Machine in 3 39.4% 2.56
Group 4 4+1 12.6% 2.46
5, 6, 7, 8 20.8% 1.77
© A.K.S. JARDINE 12
 Petrochemical Plant
(Crew size and shift patterns)

LINE 1

LINE 2

LINE 3

MIXING TANK
Use Queuing Theory
© A.K.S. JARDINE 13
Why Use Simulation Modeling of Butyle 1?

Answer: Complexity and ease of evaluating affects of

different production/equipment/manpower strategies
such as:
i) changing operating rules;
ii) adding another finishing line;
iii) modifying level of maintenance personnel.

© A.K.S. JARDINE 14
 Maintenance Crew Size Simulation
TTF = E, MTTF = 2950 tonnes line Baler 1
TTR = Weibull 1
β = 4.20 Cyclones
Expellers Wrapper
η = 2.29 hours
Po l y Conveyors
Baler 2
Gene Good Product
rato
rs Coagulator
North line
2 Baler 3
Cement Cyclones
Halogenator Reslurry TK18XB Wrapper Scrap
Make-up Expellers
system Conveyors
Baler 4
Coagulator
South

line Off. Spec.

3 Baler 5
Cyclones Wrapper
Expellers
Conveyors
Baler 6

TTF = E, MTTF = 209 tonnes

TTR = Weibull
MTTR = 2.47 hours
Crusher η = 2.76 hours
East β = 1.62
Simulation Environment

Reblend
Piles
Crusher
West

Simulation model: plant schematic

© A.K.S. JARDINE 15
 Lakeview Coal Power Station
A Case Study Using Simulation Modelling

© A.K.S. JARDINE 16
 Lakeview Coal Power Station

• In order to determine the best course of

action in optimizing the Lakeview Power
Plant, many different courses of action were
simulated.
• The results from each simulation were
obtained, and an appropriate course of
action was selected based on these results.
• Then, this course of action was actually
implemented…
© A.K.S. JARDINE 17
Lakeview Coal Power Station

© A.K.S. JARDINE 18
 Summary of Simulation Model Validation
Results compared to actual data for previous year

Actual Results Simulation Results

Energy Produced (MW) 3,763 4,098

Total Operating (hrs) 22,089 19,623

Equivalent F.O. (hrs) 7,235 5,064

CAWN (%) 87.20 91.80

DAFOR 25.70 23.70

F.O. Occurences 351 298

Quite Similar
© A.K.S. JARDINE 19
 Truck Shop Optimization

• A mine operation involves the use of many pieces of equipment (haul

trucks, drills, shovels, loaders, dozers, graders, service trucks, etc),
with preventive (PM), corrective (CM), emergency, and overhaul
maintenance performed on each, making the optimal size, or number
of bays, for a truck shop difficult to determine. The task becomes even
more complicated when considering other factors such as differing bay
heights or that some jobs require two adjacent bays.

• The purpose of the project is to develop a simulation model of the

maintenance truck shop in a gold mine to optimize the number of truck
bays based on minimizing the capital costs, minimizing the number of
vehicles waiting for service, and maximizing the availability of the
vehicles. A simulation model is being created in Arena 4.0 using the
equipment roster from a specific mine. The model is then to be
generalized so that it can be used by the company as a reliable tool for
selecting the size of truck shops for future mining projects. In this way
the company will be able to spend the correct amount of capital on its
trucks shop to provide a safe and profitable working environment.

© A.K.S. JARDINE 20
Right Sizing a Fleet of
Mobile Equipment
(Section 5.5, page 207)

© A.K.S. JARDINE
 Trend in Truck Operating Cost

60

$ per truck
operating
hour, c(k)

20

5K 10K 15K 20K 25K 30K

Cumulative operating hours
per truck
© A.K.S. JARDINE 22
 Total Demand = 108,000 hours of work
16 @ 7,000 h/yr, 18 @ 6,000 h/yr, 22 @ 5,000 h/yr

Equivalent
Economic Total Annual
Fleet Size Annual Cost
Life (Yrs) Fleet Cost ($)
(E.A.C.) ($)

16 5 506,102 8,097,632

7,995,132
18 5 444,174
(min)

22 6 381,299 8,388,578

© A.K.S. JARDINE 23
Optimal Contracting-out Decision (Section 5.6, page 209)

Optimal
level of Total cost/unit time
maintenance
resource
Fixed cost/unit time

Cost
Internal
processing
cost/unit time

Alternative service
deliverer’s
processing
Cost/unit time

Level of Maintenance Resource

© A.K.S. JARDINE 24
Maintenance Management

© A.K.S. JARDINE 25
 Some Simulation Packages

SimProcess (www.simprocess.com)
Flexsim (www.taylorii.com)
Micro Saint (www.maad.com)
Witness (www.lanner.com)
Arena (www.rockwellsoftware.com)

© A.K.S. JARDINE 26
Maintenance Resource Requirements

Problems: Pages 220

Answers: Page 312

© A.K.S. JARDINE 27