Operations

Management
Maintenance and Reliability
Chapter 17

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

17-1 07458
 Maintenance Management

 All activities involved in

keeping a system’s
equipment working
 Objective: Maintain
system capability &
minimize total costs

© 1995 Corel Corp.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 The Strategic Importance of
Maintenance and Reliability
 Failure has far reaching effects on a
firm’s
 operation
 reputation
 profitability
 customers
 product
 employees
 profits

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Maintenance Performance

Employee Maintenance
Involvement Procedures

Maintenance © 1995
Corel
Corp.

Performance

© 1995 Corel Corp.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Good Maintenance &
Reliability Strategy
 Requires:
 Employee involvement
 Maintenance and reliability procedures

 To yield:
 Reduced inventory
 Improved quality
 Improved capacity
 Reputation for quality
 Continuous improvement

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Employee Involvement

 Information sharing
 Skill training
 Reward system
 Power sharing

© 1995 Corel Corp.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Maintenance & Reliability
Procedures
 Clean and lubricate Maintenance
Procedures
 Monitor and adjust
 Minor repair
 Computerized
records
© 1995
Corel
Corp.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Maintenance Benefits

Lower
operating Faster, more
Reduced
costs dependable
inventory
throughput

Improved Maintenance Higher

capacity productivity

Continuous Improved
improvement quality

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

17-8 07458
 Definitions

 Maintenance
 Preventive Maintenance (PM) - All scheduled
actions performed in an attempt to retain an
item in specified condition by providing
systematic inspection, detection, and
prevention of incipient failures.
 Corrective Maintenance (CM) - All
unscheduled actions performed as a result
of failure to restore an item to a specified
condition.
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.
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 Definitions

 Reliability -The probability that an item

can perform its intended function for a
specified interval under stated conditions.
 Maintainability - The measure of the
ability of an item to be retained in or
restored to specific condition when
maintenance is performed.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Definitions

 Availability - A measure of the degree to

which an item is in an operable and
commitable state at the start of a
mission when the mission is called for at
an unknown random time. AKA System
Readiness.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Tactics for
Reliability and Maintenance
 Reliability Tactics
 improving individual components
 providing redundancy
 Maintenance Tactics
 implementing preventive maintenance
 increasing repair capabilities

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Reliability of
Components in Series

R = R1 * R2 * R3 * ...

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Reliability of Components

 In series
 R = RA * RB * RC * …Rn

 In parallel
 R = 1-(1-RA)*(1-RB)*(1-RC)*…(1-RN)

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Evaluating Maintenance

 Reliability
 Probability that an item will function for a
given time
 Mean time between failures (MTBF)
 Average time between failures of a
repairable item
 Failure rate
 Reciprocal of MTBF

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Failure Rate (%)

Number of failures
FR(%) = * 100%
Number of units tested

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Lifetime Failure Rates
“normal” failure Wearout
failure

Failure
rate Infant
mortality
and
improper use
failure

Lifetime
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.
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Failures Per Operating Hour

Number of Failures
FR(n) =
Operating Time

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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Mean Time Between Failures

1
MTBF =
FR(N)

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Availability

MTBF
A 
MTBF  MTTR

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Availability

 An alternative formula that takes into

consideration planned downtime:

A = A c tu a l R u n n i n g T i m e
Plan n ed R u n n in g T im e

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Providing Redundancy

Probability Probability Probabilit

of first of second y of
component + component * needing = P(R)
working working second
compone
nt

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Maintenance Decisions
 How much preventive & breakdown
maintenance
 Who performs maintenance
 Centralized, decentralized, operator etc.
 Contract or in-house
 When to replace or repair
 How much to replace
 Individual or group replacement

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Types of Maintenance

Preventive Breakdown
 Routine inspection &  Non-routine
servicing inspection
 Prevents failures & servicing
 Bases for doing  Remedial
 Time: Every day  Basis for doing
 Usage: Every 300  Equipment failure
pieces
 Inspection: Control
chart deviations

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Types of Maintenance

 Predictive
 Similarto Preventive
 Used to predict future failures
 Tools Used:
 Infrared sensing devices
 Analytic devices

 Still not widely utilized

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Organizing the
Maintenance Function
 Centralized maintenance department
 Does all maintenance (PM & breakdown)
 Decentralized maintenance department
 Useful if different equipment used in different
areas of company
 Contract maintenance
 Used if little equipment or expertise
 Operator ownership approach

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 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 backup
 Handles non-routine problems
 Provides maintenance training
 Has plant-wide responsibilities

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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A Computerized Maintenance
System

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Maintenance Costs
Traditional View
Cost o st
c e C
na n
i nt e
l M a
To t a o st
c e C
e nan
a i nt
iv e M
e nt
Prev
Breakdown Cost

Optimal Maintenance
Commitment
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.
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 Maintenance Costs
Full Cost View
Cost
Total costs

Full cost of
breakdowns
Preventive
maintenance
costs
Optimal
Maintenance
Commitment
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.
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 Contract for Preventive
Maintenance
 Compute 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

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 Increasing Repair Capabilities:
Features of A Good Maintenance
Facility
 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
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.
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 Operations Manager Must
Determine How Maintenance
Will be Performed
Operator Maintenan Manufactur Depot Service
ce er’s field (return
Departme service equipment)
nt Competence is higher as
Preventive maintenance we more to the right
costs less and is faster
as we move to the left

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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Total Productive Maintenance
 Additional requirements of:
 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
services
 Training workers to operate and maintain
their own machines

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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 A Key To Success

High utilization of facilities, tight

scheduling, low inventory and consistent
quality demand reliability - total
preventive maintenance is the key to
reliability.

© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J.

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