Professional Documents
Culture Documents
Management
Lect. 1 - Introduction
By
Maintenance Management
Defined
2
Overview
• Definition.
• Context.
• Historical perspective.
• Critical success factors.
• Course overview.
6
Definition
• In theory …
– The maintenance of the means of “production” can be defined
as “the set of activities required to keep these means of
production in the desired operating condition, or to restore them
to this condition”.
(SAMI, 2009)
8
– Link: Roles in asset management
Asset owner
Asset manager
Asset operator
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• Example: Automotive industry
– Manufacturing Automated lines
• Metal forming
Heavy machinery Hand tools
• Welding
• Painting Calibrated equipment Robots
• Assembling
Dustfree rooms
• Testing Fixtures
• … Transportation equipment
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– Maintenance
• Jobs: Repairing failed machines, Replacing worn-out parts,
Cleaning, Inspecting, Monitoring, Measuring, Calibrating,
Diagnosing problems, Supporing Engineering, …
• Fields: Mechanics, Electronics, Instruments, Hydraulics, …
• Skills: Hands-on, Analysis, Engineering, Planning, …
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– Example: Chemical plant
90,0°
80
C
60
40
20
20,0°
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– Example: Distribution center
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– Example: Hospital
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• Related terminology
• Repair
• Replace
• Refurbish
• Retrofit
• Restore
• Recondition
• Renovate
• Remanufacture
• Rebuild
• Recycle
• Reuse
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Definities
• Repair: failure - ABAO
• Replace: failure or precaution - AGAN
• Refurbish: similar
• Retrofit: new, better
• Recondition: major
• Renovate: major
Society
Management
What and how we decide
Methods & processes
Operations
Technology
Total asset Why we do it
What it is about
life cycle Maintenance services
* Plant & installations
optimization and core production
* Tools/Shops/Cribs
activities
Logistic support
What we need
Planning, delivering, controlling
* Spares * Personnel
23
Exercise: What are these “contexts” for the following examples ?
– Industrial packaging machine
– Chemical plant
– Office photocopier
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Contexts Photocopier Chemical installation
Operations Office – Home Variable/fixed specifications
Continuous/batch
Management Maintenance contract Maintenance strategy
Link production-maintenance
Technology Newest or standard Process risks
Logistics Special paper Training – Maintainability
Innovation Remote monitoring Competitive technologies
User interventions Automation (control, monitoring)
Legal User safety Occupational safety
Environment (toner) Inspection schedules
Environment
Business Critical ? Critical !!
Market Number of suppliers Maintenance services
Buy instead of make
Societal (spares developing countries) 24/24 – 7/7 (shifts)
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“simple” systems ...
“complex” systems
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Required:
theory
inspections
technical skills
management skills
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Historical perspective
maintenance – engineering - production –business
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<1950 1950-1975 >1975 2000-….
equipment:
* not highly mechanized * fully automated
* overdesigned * right capacity
* simple * very complex
* stand-alone * integrated systems
business environment:
* cfr Henry Ford * focus on the customer
* inventory control * MRP, JIT, JIS, …BPR, …
* local business * globalisation
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<1950 1950-1975 >1975 2000-….
CBM
CM PM ! DOM
maintenance expectations:
TPM
BCM RCM
LCC
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<1950 1950-1975 >1975 2000-….
Third Generation:
•Condition monitoring
•Design for reliability
& maintainability
•Small, fast computers
Second Generation: •Decision support tools
•Scheduled overhauls e.g. ES, FMEA, HAZOP,…
First Generation: •Systems for planning •Shift in organizational thinking
• Fix it when it and controlling work e.g. multiskilling, team work,
broke •Big, slow computers outsourcing
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Stuff to think about
Maintenance
aspects Boeing 747
700 hours
between “A” inspections
71 %
8 hours for job
100 hours
Time
(horizon 30 years)
Source: Storck 2004
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1940 1950 1960 1970 1980 1990 2000
Design-out maintenance
O&M Best Practices Guide, 2007 (maintainability & reliability issues)
reactive
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preventive
predictive
other
• The field “maintenance management”
• Is a young management area
• Deals with complex, automated equipment
• Involves high costs
• Sees a growing service sector
• Experiences a closing gap between academics & practice
• Enjoys a growing professionalism
• Focus now on
– competitiveness
– human factor
– ICT opportunities
– new organizational structures
– evolving maintenance concepts
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Critical success factors
Basic + updating
Technology – Analyses
Technical and Challenges
technological equipment and business
background During career
CSF for
Management maintenance
skills management Flexibility