Maintenance and © y ' PRC Bey ar Chapter Outline }OLOBAL COMPANY PROFILE: ORLANDO UTILITIES ‘COMMISSION Strategic Importance of Maintenance ané Reliability 632 Reliability 683. Naintons 636 Total Productive Maintenance 690 Techniques for Enhancing Naintonance. eotGLOBAL COMPANY PROF! ORLANDO UTILITIES COMMISSION. MAINTENANCE PROVIDES A COMPETITIVE ADVANTAGE FOR ORLANDO UTILITIES COMMISSION he Oriando Utes Commission (UC) owns ‘and operates power pints that supply power to two contral Florida counties. Every year, OUC takes each one of its power-generating unite offline for 1 to 8 weeks to perform malatenance work, Addionally, each unit I also taken offline avery 8 years for a complete overhaul and tutine generator Inepection, Qvernauls are scheduled for eprng and fal, when the weather ie midest and domend for power is low. These overhauls last from 6 to 8 weeks, Unis at OUC'S Stanton Energy Center require that ‘maintenance parsonnel perform approximately 12,000 repair and preventive maintanarce tasks a yaar. To ‘accomplish thove tasks etfclent, many of these jobs are scheduled dally vie @ computorizod maintenance ‘management program. The computer generates preventive maintenance work orders and lists of roquited materials Every day that a plant is down for maintenance c0ste OUC stout $110,000 extra for the replacement “a Stanton Energy Canter in Oren. cost of power that must be generated elsewhere. However, these costs pale beside the costs associated ‘wih a forced outage. An unexpected outage could cost ‘OUC an adcitional $350,000 to $600,000 each day! Scheduled overhauls are not easy; each one has 1,000 ctinct tasks and roquiros 72,000 labor-hours. But the value of preventive maintenance was tustrated by the fist overhaul of a new turbine (generator Workers discovered a cracked rotor blade, ‘hich could have destroyed a $27 milion place of ‘equipment. To find such cracke, which aro invisible to the naked eye, metals are oxamnined using dye teste, Xetays, and ulisound, ‘At OUC, preventive maintenance is wort is weight in gold. As a result, OUC's electric distbution ‘ystem hae been ranked number one in the Southoaet U.S. by PA Consulting Group—a leading ‘consulting firm. Effective maintenance providos a ‘competitive advantage fr the Orlando Uities Commission.Two mnpoyoes se on sstfo.ing nia he tap of Starkon Enecy Carts 28try hgh oll, ehacing an realing Spr heats -AThis inspectors ecurinng a or-pressre lads wit rave at supersonic speds of 1,800 mes per hour wen the lt operation. Acrack fone ofthe Blados 629 couce catastrophic flue, i f 3 | Mairtonance of capi-infonsve fotos rogues good pring to inimize downtime, Hero, kebine cvehaul io undar way: Orgrtaing the thoueande of parts and pieces necessry fore shutdown isa mar ef. TaAWO UTS HORT(082 PART Menageg Opeaone ‘Manna Des Pots ‘arate Maintenance Toate mons ‘acpngaejctmsoqmst Inorg ae Reliability “Tow pbaity tats matine Prtor pode lice Peps ars pets tins Siders condone Enpoyeeconeteat de ay ce Chapter 17 Learning Objectives TO: Desc bow to inprow sytem LOB: Descbe how to improve ratty 23 muimerance __9e7 |L02: Determine ester ray {688 LOG: Cerpare prevrte and breakdown LO: Determine mean tine betwoen —__fhtaranescosts_688 falres (MTBF 608 107s Dufrosutonorovt martnance 690 {Loar Distegush betwen preventive and ‘brakdoan maltananee ‘THE STRATEGIC IMPORTANCE OF MAINTENANCE AND RELIABILITY ‘Manages at Orlando Uities Commission (OUC), the subject ofthe chaper-opening Global Company Profi, ght for reliability to avod the undesirable results of equipment file. At (OUC,e generate flue i very expensive fr both the company ands customers. Power outages ‘are instantaneous, with potentially devasatng consequences, Similarly, managers st rico-Lay, ‘Wal Disney Company, and United Parcel Service (UPS) ace intolerant of flares or breaiiowns. ‘Maintonance is extial at Frito Lay to achieve high plant utilization and excellent sanitation. At Disney, eptiding-clan facilities and sa rides ate necessary to retain it standings one of the mot popular vacation destintions inthe world Likewise, UPS's famed maintenance trategy Ieeps is delivery vehicles operating ad looking as gcod as new for 20 years or more. “These companies, lke most oers, know that poor muintenaace can be disrptive,inconve- ion, wasteful, and expensive in dollars and even in ives. As Figae 17.1 iustraes the iterde- pendency of operator, machine, and mechanic is a ellmack of successful maintenance and febiabilty, Good maintenance and reliability management enhances a firm's performance and protects investment The objecive of mabwenonce and reliability is to maintain the capability ofthe syste. Good ‘mainteaanse removes variability. Systems must be designed and maintained to ceach expected performance end quality stendards. Malntenance inludet all activi involved in keeping "ystem’s equipment in working order. Reliability is the probability tha a machine par or prod ‘et will funtion propery fors specified tine uncer stated conditions. "a ths chapter, we examine four imgerient tactics for improving the reliability and msite- nance not only of products and equipment but also ofthe systems that produce them. The four tecles ere organized eroand reliability and maintenance. “The reilly tactics are: 1. Improving individual components 2, Providing redundancy Employee involvement Partnoing with maniacs pore Salting > mounE 417.4 ‘Rabati engoment Requires Empayeo Invent end Good Proeatures Reward sjstom = Enployee erooworien Recined imertoy, Improved cua aitonanoe and Relabity proves espacty Procedures Repuaton or quaty Cloen and verte Feder Morr ana cust Resveos verb ity ake miner rope ap computor wears‘Ghaptor 17. Marterance and Ralibity Dede 089 “The waimenance tates ae: 4, limplemeatiag or improving preventive maintenance 2. creasing repair capabilites or speed ‘arity corrupts processes and creates wast, The opeations manager us rive out variabil- ly: Designing fr reliability and managing fr maintenance ae crucial ingredient or doing co RELIABILITY ‘Systems ae composed of series of individual intereated components, each pvforming a spe- cif job. If any one component fils to perform, for whatever reason, the overall eystem (for ‘example, an sizplane or rachine) can fi. Fst, we discus inproving individ componea's, and then we discuss providing redundancy Improving Individual Componente ‘Besant failures do occur inte real word, understanding their occurence sen important relia: bitty concept. We now examine te impact of filure ina series. Figure 17-2 shows that athe number of components ina series incroases, the reabilty of the whele system cecines very asieldy. system of n= 50 interacting prs, cach of which has a 99.5% reliably. all reiabiiy of 78%. [be system or machine ha 100 itersctng pars, each with an incividual reliability o 9.5%, the overall reltily willbe only about 60%! © To measure reliability in a system in which each individual part or component may have its ‘own unique rte of reliability, we cannot ute the reliability curve in Figure 17.2. However, the ‘method of computing ystem reliability (R) is simple [t consists of finding the producto indi- vical elias a fellows: Be= RX RH BM soe X Ry sr) where Ry = coil of component 1 Ry = celibility of component snd s000. Equation (17-1) asus thatthe reisiliy of an individual component doesnot depend or the reliability of other components hats, each component i independent). Additionally, i hie ‘quation asin mos reliability discussions, reliabilities are presented as probabiles. Thus, 2.90 reliability mean that he unit wil perform intended 90S ofthe te. I lgo mest tat will {ail 1 ~ 90 = .10 ~ 108 of the time, We can use this method to evaluate the reliability of « service ofa prodact, uch as the cne we examine in Example 1 Los: Dessite how to Improve gyro rab Ifde love peeing cnt (80 ia eplced by a lik pertors- 33 ety ota se new exec eg (Aner 46 = ELATED PROBLEMSE: 175,172,105,0011 ‘eTIVENepEL 17. Ticoan rt tie hig 1 we remains me Component rtiabilty is often a desig or specification isse for which engineering design por~ ‘sonnel may be responsible. However, supply-chain personnel may be able to improve compo- hens of syste by staying abcess of suppllers’ products and research efurts. Supply-chain petsonnel can also conteibute directly te the evaluation of supplier performance. "The basic unit of measure for reliability is the product failure rate (FR). Firms producing high-technology equipment often provide failure-rate data on their products. AS Sowa in Equations (17-2) and (173), te failure rate measures the percent of failures among {he total numberof products tested, FRG), oF a number of failures during a period of time, PRON): Number of faites PRO’) = eg * 1008 «a [Number of failures “Number of unichouss of operation ime FR(N) = ons Pechaps the most commen term in reliability analysis is the mean time between failures (MTBF), which ith rosiproeal of FRO: 1 MTBF = eR ors) Ia Bxaunple 2, we compute the percentage of file FR(S), umber of fallues FR(M), and mess tlie between failures MTBF). Tay Bay Gan Saige ME IE A main eo ESSE THonidarsehnSee tev altene tcp Thee rans aed dain > (coc fes 20 br ltteer DORE ae “APPMAGHD Ts deci e prot of cs PG). ember of ins tw of {he (PROV ate ein wer les QUTBF we ae Eqns (1-2, C0, 2 (Gia reais : =[Shepter 17 Marierance and Relat Osesers 686 SOLUTION Recentge of ie: Nanbor tft 2 Romer ef wits tered ~ 201000") = 10% [Number of fllnes pe opering howe FRO) = nde of tres FR = Opetng tine ‘Tol ime = (00020 une) = mao miteur Nonopating tine = 80) for et fle + 400 for fear = 120 wichow ‘Operag ts» Tel ine ~ Nonoperaig tine 2 2 FRU) = Sc gag = 1200 7 18,800 100106 falls hur, 1 ei ORE = Ta : 1 {103 Detain ean tine Mater = aig S44 (TBE) se ype space sie pst 6 ar, NASA yeti i te fare ae pe tp. rm le = (Fane s)(24 ea) (6 dys) = (m1009(24)6) = 0153 fallaeip USENET Mean tine betwee fees (MTBF) ithe sanded means of sig ely. LEARNING EXEACIOR If non operating time dope to 800, Wha isthe nes MTBET nse: 9,506 br] ELATED PROBLEMS) 176,117 1 the fate rave ecard in Example 2 is too high, NASA will bave to cither increase the relia: bility of individual companens, nd thas ofthe gym, ce install several backup aircondioning ‘nis on each space shutle, Baciup unis provide redundancy. Providing Redundancy ‘To increase the reliably of systems, redundancy is aed, The technique here i to “tack wp” Redundancy ‘components with additions] componets. This isknowa a putting unis in parallel andi astan- Te set emponarts n Sard eperations management tactic. Redundancy is provided to ensure that if one component PH rae wey falls, the system has reeoure to another. For instance, sy tat relsbilty ofa component is $0 ‘and we back i up with note: component with reliability of 20. The resalting reliably ia the ‘probebity of the fat comporert working plus the probability ofthe backup (or pralleD com- Ponent working muhipled bythe probability of needing the backup component (1 ~ 8 = 2). - He ‘working ‘working? \ component (8) + (8) x = 8) = 8416 = 56606 PARTS Manapng Operators Sse Reliability with a parallel process Preventive maintenance Aplan tat tes one ‘petro an ‘ing ssn reac preven Breakdown ‘maintenance Pama mitrnoe at ‘ss when eet as ustesmpare oe a ‘eergeney erat a, {ofan mortality ‘ne tata ay tee a wee ros. 104: Disiaguish tween verti and breakdown saienance Example 3 shows bow redundancy can improve te reliability ofthe Loan process presented in Beample I "Rs Naond Bak anda omoppion oes a lily onl 79 Gee nape) od weld io igre ton. [APPROACH > ‘Tie bak cident provide racy fr the est elle SSOLUTIGe Tie rocedre ent int folbwleg 9sem: RS RRO 50. 630, yal hs ox Om Bae ise ie mal ie 9 (ODN RLB 4 (AX the Joan poss rom 713 94. Lennie mxenese> eta ita ch (dekh aly 990 ab = 8 RELATED PROBLEMS m 178,179, 1710.17.12, 1719 1714, 1716 1748 « AomvE woou 2h oe tt tn ia 2 xh me MAINTENANCE ‘There are two types of maintenance: preventive maintenance and breakdown maintenance. Preventive maintenance involves pecorming routine inspection and servicing and keeping facilites in good repair. These activites are fended to build a system that will find potential fallares and make changes r pits that wil prevent file. Preventive maintenance is mach tore than jst Keeping machinery and equipment running. I also involves designing techaical tnd hamen systems that will keep the productive proosst working within tolerance; it allows the ‘stem to perform. The emphasis of proveaive mntceance ison undertanding the process and [Keeping it working without interruption. Breakdown maintenance occurs when equipment fils and mst be repited on an emergency or priority baie. Implementing Preventive Maintenance Preventive maintenance implies tha! we can determine when asym needs service or will need ‘epaiz. Therefore, o perform preventive maiteaance, we mast Enow when asysem quires Se ‘ice or when itis Hkely to fal Failures occur at diferent rates during the life of «product. A high initia fale rte, Enown as infant mortally, may exist for many prodacs! This is why many ‘lectreni fms “bam ia thee produets prior to shipment: Tati to say, hey execute 2 variety of tects (euch as a fll wash eycle st Whisloo!) to detect “startup” probes poet shipment Fras may alo provide 90-day warranties. We should note that many infant raotality failures tre noe product Files per se, but rather failure doe to improper use. Thi fact points up the Importance in many indestes of operations managemen’s tuiling an aftersales service 5y5- ‘ern that inelndes installing and tsining. ‘Once the profit, machine, o process “sets in;" study can be made of tho MTBF (meas time besweea files) isibation. Soch distributions often follow a normal cuve. When these Preventive Maintenance Saves Lives “The National Tranaportaton Salty Soars sus inthis ‘tuations a preventive mabenance error made two dye Drier othe eras. The mechan and a supervisor skioped [atleast 12 steps recued nthe maintenance of te {onson of pictreontol cables Gung the Det @ check that hetide he ptch ofthe contol cable tension. Data ‘hou that th conte catumn pesiion changed curing the From the tat moments of he fight: ‘mairtonance and tho plane lost about two-thirds down ‘lovato: capabity,Imestigtors bole thatthe aicrat ‘would have been fable wi fay fanctoring contol had Itbeen given proper pravonive malienance. Maintenance ‘ean rnprove qualy, fous cost, ad win orders. Ian tls be a mate ofl end do £8:47:09-—Capt Kato Lecio:"Help ma... . You got i?" 8:47:¢5—Givbs:"Oh (expletive). Puch down” 8:47:12—Losle."Push the nose down? ‘emergency fer Ar Midwest you eighty or Ft ele em pasar woe Dodoy™ ‘Sapo ian Woot rd Space eg ay 25.0 5 US Say Oars) Xa Te rat Sot ara la 23,205 08 ty 0 200. 8:47gt— To deem if the CPA fn tn alow rw tenon” poly or eure forrevenuvemanenece, He flow 2 -nep proes: ‘STEP 1. Compute the apecied ober of beans (bce 2 pst history) ithe Sa cosnaee bis without eve contact “STEP 2. Compute he expected treat cot per eet Wino preveave malnerance contact ‘STEP 3. Comput the cox of preventive mumerance ‘STE 4. Compare the to open and slet he co ta Wiles les LOG: Compare proventve and breadown maiatnarco cats ‘soLuTIONy step. coon) (ormie) - oes) (oe = (A) + ANA) H2N3) + G2) ceataese Sou Sepiedumademeat « (Sean) (jean) = (1.6)($300) oo ee yee (an) (Sr) + (aa) 8 (1 teeadowa/noin}( 9300) + $150/ mnt = $450/mouts(090 PARTE Manacing Qprtons ‘STEP 4. pesanoitileeexpenive veal thie a msienance serves rm (490th to mt do 10 (480), Farle & Halen doa hie the grvicn fw, {M4StaOEY > Deicrnlag the expeced number of breakdowns fo cach optim is cuca to making od dedson. This typi eps gon anienance coda [LBARNENG RICEHCER What ite bet dsiion the preventive msisenasce contract cot Inormes to $195 por month? (Answer: At $195(= $30) + $193) per meth rin unl beakban” Becomes less expensive osaming ha ll cot ae inieedin he $30 pr breakdown cot] FRLATED eROBLEDD F173. 174,177 Using verietions ofthe technique shown in Example 4, operations managers can excmine mai tenance policies. Increasing Repair Capabilities ‘Because eiabiliy nd preventive maintenance we seldom perf, most fms opt fr some level ‘of repair capability. Enlarging or improving repair facilities can ge the system back in operation fase. good malmenance facility should have tse sin features: 1, Well-trsined pertornel 2 Adequate resources ‘3. Ability to ertablish a repair plan and pisities® 44. Abily and authority to do macrial planning ‘5S. Abily to identity the cause of breakdowns 6. Ability to design ways to extend MTBF However, not all repairs ca be done in de firm's facility. Managers must, therefore, decide ‘here repairs are to be performed, Figute 175 provides @ continuum of options and bow they rnc in term of speed, cos, and competence. Moving tothe sight in Figure 17-5 may improve the Competence ofthe repair Work, but a the same ime It increases costs and replacement Gime Autonomous Maintenance Preventive maltenance polices and techniques must inclu an empluss on employees acept- ing rexponsibility forthe “observe, check, adjust, lean, and notify” type of equipment mainte- nance. Such policies are consistent with the advantages of employee empowerment. This spproach is Known a: autonomous maintenance. Employees can predict failures, prevent treaklowns, ad profog equipment life. With autonomous msintenance, the managec is making step turer both employee empostertaent and maining system performance TOTAL PRODUCTIVE MAINTENANCE ‘Many firms have moved to bring otal quality management concest othe practice of preventive maintenance with an spproach known as total productive maintenance (TPM). I ivlves the ‘concept of reducing variability through autonomous maptenance and excellent maintenance prasices. Total productive maintenance includes: ‘otal productive ‘+ Designing machines that are celible, easy to operate, and easy to maintain ‘maintenance (TPM) + Eznghasizing (otal cos of osrership when purchasing machines so tat service and mainte Cm it aaty ‘ance are included into cost, rraagarat wha shag + Developing preventive maintenance plans that wie the best practices of operon, mint ance departments, and depos service + ‘Tining for autonomous maintenance so operators maintain their own machines and parner with maimenance persoane! 2on my esl fem oer dco fostering in Cape 3 ha DP dep cea pth ato (CiNt)inpeve te tebeg of maa Fp. eyChepter 17. Martnaros and elablty Declont 604 Mamenance autores Depot sevice ‘High utizatio of facilites, tight schedaing, tow inventory, and consistent quality demand reliability, Total productive maintenance is the key to reducing variability and improving reliability TECHNIQUES FOR ENHANCING MAINTENANCE ‘Three techniques have proven beneficial to efetive maintenance: simularon, expert systems, ‘and sensors. Simulation Becouse ofthe complenity of some maintenance decisions, compater simulation ‘good to! for evaluating the ipoct of various policies. For instance, operations personne! can decide whether to add more staff by determining the tieofls between machine reliability tnd the costs of edtional labor. Management can alzosimalato th roplcement of parts that have not yet failed ata way of preventing fururebreakowns. Simulation via physical models can elo bo uefa. For example, aphysicel moda can vibrate an airplane to simulate thousands lof hours of fight time to evaluate mainerance needs. Expert Systerss OM managers use expet systems (that i, computer programs that mimic ‘bumnan logic) to assist staff in isolating and replrng various fats in machinery and equipment. Fr instance, General Eletc's DELTA stem asks a ouries of detailed questions that ai the ‘ser in identifying a problem, DuPont uses expert systems fo monitor equipment and to train repuc pertonel ‘Automated Sensors Sensors warn when production machinery is about 1 fil cis bovom ing damaged by heat, vibration, of fui leaks, The goa of such procedures is not only to avid ‘ailaes but asco perform preventive malatenance before machines ae damaged. CHAPTER SUMMARY . + Operations managers focus on design improvements and preventive maintenance. In tu, tei back comporets to imorove reliability, Reiabiltyimprove- able, well-maintained equipment not ‘ment lo can becbained trough te use of preventive maix- only provides higher wilizaion but also tenance and exellent repair faces. improves quality and performance to Fins give employees “ownership” oftheir equipment. schedule. Top firms build and maintain ‘When workers repair or do preventive maintenance on theit systems that drive out variability sothat oo ‘own machines, breakdowns ore les common, Well‘rained tomers can rely on produc and services to be produced to and empowered employees ensur reliable systems through specifications and on time, Key Terms Mines (8 Rattan 0,68 Tacos lana 6 A) ay i Preenve naersnce (£85) ‘al producto nnbtrmace Men int een ats Brakiben eames 8) ‘ain 6 chr Int moray @ 0)(602 PART 3. Nanacng Opeions “ie Spc Shte Clabes vt Tes os 203 tenn o anh The Chnteger eds shor ae ich a Toe An dpa pce inne eh ch ue 196, nach ute es ol ry wre ok. The tab ean tte ny Keka maps ey (Stee nv art i elaiyw nh Ou ae Tete 30 ign wil ves nmr ac. re NASA hat at npsns yee hn Sc 50 Enplye sn her cosh jos bong ey Inet namritha gy Sanson pte Discussion Questions 4, What ithe bjestiv of maintonabc nd reality? 2 How docs one enti acandiate for peeveatve istnancs? | Bapun i notion of iat mortality” ate come of prod ets 4. Why is simulation ofen a appcpite ecblque for mine saves protons? ‘5, What sti deff etneen operator performed maintenance ers supplipevfouednuirenanc? (6 How cana manager ealte the eesveness ofthe maine saves functea? launch te on missions othe see sain and claowbee. Of ‘ou, shone seonpace manager his stated "you can be pest safe and neve ge of te ground ‘Given the hag relly ond maintenance imses NASA faces (esp els euch in cold weather, eat shielding Us falling off boul ators be allowed to fy? (leone Atlas rockets, then were inerted ot ot of wecestiy ut becuse vest pls aed Dolcine thought they shoal be tere) What ae the pos nd oat of ened space exploration from an eblal perspective? ‘Shoold the US, sped billon of dollars otra a asermat © ‘he mooa? 7. How docs machine dosignconsbut to eter inteaing alleviating th mantessceproblon? ‘8, Wacol can efomaoatechsiogy play in he maimeaance funtion? 9, Dereg an angen atthe mets of reverie maiiennce ‘at Windsor Piers, the company oar arked, “Why fx before brea” How mould you, ae the ceeorof mae ance respon? 10, Wil preventve maintenance cat all weakdowns? Using Software to Solve Reliability Problems © ieee ont ans POM for Windows may be used wo save relay problems. Thereby nde allow ast ener seer evens Compe) a he aes gh 10: ome ake pri epoca Osh 1) ‘Sad (9) coupenen cell for both series and parallel ds. Solved Problems vies ote ours helps svslibie ot mmupearongobneonscomimyerab ‘y solven pmosLen 17.1 ‘The ontcodaroc ied i he Sullivan Writ Caleta fe, ‘ies, eck of wish has its on elisblity rt. Comgonea! his ela of 90; component 2,95; component, 5 com anes $0; and corponent 5,99. Wat ste relay of ewe “seer ‘Y SOLVED PROBLEM 17.2 ‘Y sowurion *Stmisondusersaiahity, 2 Ba ROR RS 90)(.98)( 88509199) 166 Arent engheeing change a Sra Wis Cala races» bach ccmpona in ech of i two leet lil wns cet Te aw cuts woo ike cing a‘What the eal of e now syste? YeoLuTion Chapter #7. Marterance and Pllably Decors 63 Relay (9.4 (L= 9) x9) x 98 X98 X[94(1~ 8) x 8] x 9, a 2 [9 4 09] K-95 x90 x [9 +05] x 99 BPX 95 % 88H 99% =n Problems* + 47.4 The Beat compuner’eletenieproesing unit con: Ise $0 compnet in tere. The average rib of each corn paseo 99.0%. Ving Figure 17.2, dteine he veal bby fhe processing wt +41 Atosting proces Boeing Aircraft has 400 compo tes veri The verge elie of ec cmpenent 95% ‘Une Figure 172 fd the overall ibility Of he woke ting pe 47.3, What are he expected number of yy breakdowns fee the poner generator Oriando Ue tht has exe the feowing da ov the ps 20 yeas? P< Numberfoeakiowms 0 12 3 4 3 6 ‘Number f yeas in which brenedownecumed 22S + $7.4 Bach beakows of graphic ploter ube st Airbur Indies cont $50, Find the expected diy breakdown cos given the folowing dat: Nanteofbeakionms 0-123 a Dally breakdown probably 1 s+ 478 A now sical cont eysem is bsing designed that mast be 984 reliable, Tis sem consis ofthe components in ‘eres. ial hee of te ecrponees set have te same eel of reinbity, wt evel feat i ogusea? Bk ++ 47.6 Robert Klasen Manuactrig,« medical ecupment manufacture, subjected 100 heart pacemakers to 5,000 hours of ‘eating Halfvay though the teting§ pacers failed. What was ‘befallen terms of i following: 2D Pecenoge of fret? 1) Nombereffailee per uit-boa? 6) Namberf files or witout? 4) 161100 peoplecive poemalerimplaats how many wits car we pesto fl dxing the following yea? eu P2C mes bie ay sre vin POM ter Wao 47-7. A micufuctner of dk ves for atebook computers eats & MTBF of atleast $0000 bors. Receat test esas for 10 Unis ee one fale t 1000 hus, athe at 5,000 hs, and we meat 43.00 hs. The remaining nts were stl renning at 60.000 ours Deteenine te flloving 1) erent of faire. 1) Number f flrs per wihour ©) MTBF this pot ine esting ++ 47.8 What isthe reliably ofthe following production process? Ry = 095, Ry = 090, R3 = 098 a Ay—— a Be bank lane wil be prosteed in the chact a he lal(604 PARE 3. Nanogig Operations ++ 47.40 Merl Kim Sharps system cerngosed of dee come ‘Poosntin pal. The components have the felling ribs y= 090, R= 055, R= O85 ‘Whats the reliability of the syste? (Hin: See Bample 3) ie + 4744 4 wedial contol system has three components ia Seven with india ellis (RR, 3) e shone Fe fe % oof » iy ‘Wha the liability fhe eyetna s+ 4748 0) Whi the relly ofthe ste dow? e os |--{ 20 1) Hoy much ed relabiy impove if he medical conta system. ‘own in Problem 1710 changed the seus parallel 572- temabown hee? P< +5 4.49 Assi afer cari bypass argo, 5 of tins survive th sarc, S8% suri thereover pio afer suger, 20% ae able o mak the lifestyle changes needed to extend their ‘uv to | year oF moe, and only 103 of tase who do wot make the Leste charges scrve more tan ayer. What the iel- ‘od tha a given ata! wi sue more ha a yew? PF ‘nays wid ccmporere slabs inden f=950| A= 030| fas ons What the reid ofthe yen? PS ++ 476 The meinennce deperest ot Mechanic! Dyzais ‘as presented you wih the fowing fallase curve, What does sages tome of tates Tine ++ 47.48 Rick Wing, slespemon for Wave Soldering $y tems, In. (WSS0), has provided you wth propos for impeoy- ing the temperature contol on your prseat machine. The traci ies tnt fe cleanly stove excoe elder from Prloed cre ours; hs «great concept, but the bots tem Dette ceil lacks eabily. According to Wings engineers AWSSI nave imoved the reliably of the erica! temperate ‘contol, The new system gill ha the our seaitve Integrated ‘rls ontoling the fermperatre, but the new tachine has 2 ‘ackup for eat, The four etgeated cites have eibilites of 90,92, 94, and 96 The four backyp circuits al ave ali iyerso, 8) What ie the celoity of he new temperate omer? 1b) you gy a promi, Wig sys he can improve al feu f te ‘ocep anit to 93. What te welbiiy of his option? Pi s+ 177 The fue degareneat has # number of fairs ith ts ‘oyzen masks and i evaluating the possibility of outsourcing preventive melatenance 19 the manufacturer. Because of Fisk astocated with fale, the cost ofeach fllre is es trated et $2,000, The eictet mainerance policy (with states Peforming maintenance) hat yelded the following Nunberofteedows 0212s #8 ‘Romber cf ean which realms occured saisso “The mamaactarer wil gurantee eps on ay and lls as tar of a seeice cont The east of tis service fs 5.000 per je 1) Whats the exposed numberof breakdowns pr yea with sa ton exploycspecfoming matenance? 1) What theo of the ue slatenanc policy? ©) What the more economia ply? 17.38 As VP fr options Brian Normoyle Bagineeing, {ou mnt decide which product sign, Aor Was the igh rel ‘ili. Bis decignd with backsp unt fer components Ry and Ry ‘Wha is the sell of coc sign? Pree Dotgn A A Bs 47.19 A typical veal umsaction consis of sever! smaller og, wtih ca be easier component inet 0 fare. A Ist. ‘of sh componente mig eclide:‘Component Deserptlon Deion of Faure 1 Fdwodoctin proper Cant find prodet sive, col, FEner ese ino Wo es opos Tar too lrg ne xoeiescing difcly ‘J Sean pret UPC Tor Won't sen em nt ace, pis nil; sane incre, 7 Gaoie pacha Tom Wrong weight wong feces, wrong dat, cry, wrong Tae pe ‘Customer nets ear check not soap, _____ ered card efines ‘Mates cage fncorecly Demag aecbanlae hile basing: ‘inte ange 7 Weg wertaalios Te recsp carey, ale or lct lac aa Qies > Maintenance Drives Profits at Frito-Lay Trio-Lay, the mal-bliondol stidny of fot and beverage sant FepiCo,rainains 36 pas inthe US. and Canada. These fete rede dozen of snk acedig the wellAnown Ley Foe, Cheotos, Dros, Res, ad Testo brads, ech of which sells over $1 bilon per ex Foray plans produce in the high-volume, lonraity roves del trmoa to corer hked goods, sel, gas, and {eer infases In hs entoneny, preventive mamiemace ofip- ert ules amar ley aveling cooly dwatine. Te R20, Vice Presider for Fis opendor,etimaestech 1 of dovatine tas a negative anal prt impac of $200,000. eis row of the 1 enscbeduled ovate is placis abe torech-—velleion de Pe that is consered be “wots” benchmark. Ths excelent ‘edormance poeta beast miotnstes epee es a4 ‘soiree eting ho vere or revetve mints. Tit is doe with weekly input the poder che, ‘Maimeaance polcy impoce energy seas well The lt ‘plats wont! manager J Were, ses, By reducing po- ‘ado ietrptons, we rst mn cpp ting eergy and Uiliy ee ander cool. Bgeipmantsintosace an to rc- Coco schedule ave eyo tly elleny- Wik very profue- tin inert, eres sbstanal waste” ‘Aga por ofits tual rodective maimennsce CPN prop.” Frito-Lay empower employee with wha ical the "aa Fiat” syste, Ran Right weachee employee “identify and da" This Ane Lay provenivensieanc,ansnenets mits, sn tl [ectne untae pr of FatLoy pega on a tl Sotve aetna. (chapter 17” Maitonancn ard Relaoity ctons 698 Lat the eh pobabitir of sacns be 92, 94, 99, 8,98, 97 95, and96 Whats the selabiy of he stan, ta i, ho rob tility tat hee wil be w sted customer Ifyou were the tore ‘manager, what do you thnk shuld be an acceptable vale fee is ‘probbiiy? Which conponens would be good candidates fr ‘cp, hich fer redesign? D> Reteren Pyersst© to these ation! homework problems: 1.201724 Video Gase Study ,- cmc ise gstn 2 ‘trig denny eens expe Ta ihc oh) pow wake ble ‘go he tee eu nd pes tee pening ns) it te poe ‘eno dur nd prac ed posi ay one Shaina wits oe leererni on te ve hao evel eh epnse ana ‘ngs magento cn sd eo vente stg neti eae. Bot Spoon hn png ote non Be Potosi tests Eee er engl oars The Somanenn oso ie ae 97ers tne rnb pt td cone wih beg, weg i pom," nae ne hese Silat” pees! ty ma np ome” Discussion Questions“ 1. Wt tte neo pak ety tent eof tetanon raterte' one ae ahetoced Sire 2 Wr eure nd dadvanagt ging moe ‘epi race nonstop? 2. Dao pos nd es of hie mate ale rme ‘You mays vith it tat compan i ct eer Seoerngteve estore ou: Pros Bary Rend Blin Coes, iy Ha Teta eteren Universi) Barry Amer (Sor Aetna User(606 PAR. 9 Managing Oortons Additional Cae Suds: Vist wn.peersnglobaleditionscommyonab ow pearsnglbaleitons.comvcker fr tse foe ease sues Cartak's Depertment Store: Requires te evalation of ie ipsct of an aoa ice veri “Workdide Chena Company? The minrancedopartentin tis company i mei Bibliography ‘aver, Ere, X, Zhang, nd D-A. Kizbe.Prcial System ‘elie. New Sak: Wiey (20), Ban, Rona The Dav of Reb, University Pak I Brodectvity res 2008) Cua, KO, KB. Mokone, nd RO, Sebroder, “Relaonshipe ‘bsweenimplomeniion of TQM, IT, and TPM and Ninnfactrtg Prormaace? Zuma of Operetins ‘Manegenan’ 9, no, 6 (Nesebar 2001): 673-694 ‘ig, Tsai Harpies, “Maintenance Gets Lo “nda ystems 38,40. 10 (tab 2005) 26-3, ‘Sova Roper, and Las A. Toni. “Toul Prodective Mirenance ‘own Iterations” Yager: nnovrion ar Work 19, 00.1 (is Quuee 2003) 41-44 Sepang, M,P Proto and Reliab Based Moimenaace “Management Upper Sadie River, NI Pestce Hal 2004). ‘Wel Marty, “Beyond Preverive Mainenance” APICS 16,4 (apa 2000) 40-48.Chapter 17 Rapid Review Main Heading Review Material Tiyomiab@D THESTAECIE Pros miners no Srapy pean pa ape WRO 174 MOHAMED: delurandowrioinyttelctgeatony tome ohn nd echne, Nateeuee Dive MeO OE aitionctasesttmanene na sier Pete ay sant inns nd hy aan gia vine and Foto ford pcs peer poe eee Theoden often on 10 mt cepa he ‘Malate sven re ea en's stig ote : ‘sRalabilty~The probaly tat a machine put oped wl function propel for speed ine under sated conor, ‘Toe two ala wets fr impeoweg ent ave 1. improving individual componens 2 Proving edunduaey ‘Tetwo malas for inroveg mainenance se 1. Impementg or inpotng preventive malteasrce 2. treating pa apes cr peed ru "Asses conpored of sere of valerate’ comporens. cach (0. 089-48) Dpefoming apelin ene companest fal operon, the oer ‘patem ean a [asthenia ofcompondte in oes rates, terse ote wale ‘Sytem deces very Quy KERR RRR Ko KR wp heey = lily of omponee I, hy = ebiy of component 2, ed 3 ‘Equatee (17-1) assure at te realy ofa acd cmponen does pe epson te relat of oer component ‘A D0 oily mean the thew il peform a intended SOR of he tine, and ‘Real fal 10% of tine. ‘Te at wit of measure fore sth reds lve PR). FROM iste number offre drag aptod of ine FH) 100% aay None ot ats FR(M) ~ Sater anno of perio me ‘Mean tine beeen flrs (MTBE)—The eae ine between a rep ond ‘te vest fire ofcomponen, icin, rode. or ed. var = (74) RO 2. ‘*Redondaney—The ue of component i pail cise rest ar ‘Tae eelbilty ca consent sore witht bockap guns: (Pei tat st ergeneat works) + [ (Po. that back wos) (Poh ht If) matt, WrsaTH4 1216, 1733, 1749 ‘is Oe He anTEaNCE ‘Piste matatnancr Involves rae ape SONIA, t8d RP ution Ha ea ‘acs in good epi provnt furs. . (or eo ‘sbreakdovn inennace—-Rensdal natnence thet oscar when aipment 6% 174, 1715, 17.17 ‘hls aed mast be oped or wn emergency o prt bsit, ‘font mertalty™‘The fre rt sor inte ie af «producto roses ‘Contin ith ob enichmen: peatces, machine certs must be Md retpasible or peste rlseance tee oa eqn fet an cls.id Review coninved Review Mate Talat and tence eof FC) pone ato HARASS {ete ae no ccrpeteried. ‘Soi at breakout may getignored aca: +The costo invertor matin compensate for devatin { Duetines ich eat hare doesn eo ety and morale an wich ‘Bice sect dtr chee drtepiag cere bon afr ses ‘tAutonemons maintenanee—Parnes operas wih malnenace personel © hvrv, coe, aj clean and not iployecs ce pred aes, preter edovns sd prolong eaieen’ ie ‘ih twosomos nmeanne, te anaperb making a step town th ‘eyes epowerent srl maiisiig stom performance imiyomlab€) TOTAL PRODUCTIVE wtotl productive maintanance(TFM)—Combines ttl ual madvsemet MANTENAUCE rah woetogie view maltose om peocess and equipment een © ‘op. c80-981) povevemataance. “ot rocvecve maateaarce nln ‘= Designing hie at obey perme and ay to main 2 Beplaiing ltl cow of coneehp ten prcasing acts, 0 it yrvice faducatenncs sre incded in te cos + Devlopingpoventye maisteanc plats le best paces of fsa stocane eparment elo eve + Trinng fr autonome antnssc sy epestors muna tel ova ‘uch and paar with raineaace personel FEERMIQUES FOR Thee tecniaes that ave proven beneficial to fect maionaate a auUNCING slrlatlon, exper sates, a ero MAINTENANCE ‘Som sintaton Se good too fx ovskiniag the inact of wait potis, on ‘Expr syste re compote poems tht mn oan oa [Austad sears ar a preton mechier ic abe for Breoreing dango by hoe aration, or lad lak Self Test ‘efor ug ere lero eso objet Tet to bpran of caper ey rms tt a te od tthe hac 101. Tew mala wees forking eyo, LOS Thetwo mints erie aes te on Teemuaaityotaspse wih wlndepenzetcompoens equ: LOG. The appro nsmenanc cy dcp 7 bli, 13 Gea oe srl eos, ‘Bective manocas css wit tekanva salam oo. 3 esac hah smog el compotnt. Frepeeien ct, 23 minum ay snone a enpnan 13 Been naltecaee ot rer ish eat 1 oe poco eecina etaes. 1 Fileakdve co area corsa te eg of hla eles. 2} penrtvemnsoence nite pera atte of he os. Waite fol forte wenn te Neven ares? t 1)" Hembree tare = be ef wou ef Opa ine 4 tation mience mt be promed reps of ie 3 Ramee pmlc Ree tos oe 2 Net offal © Nesberetunteiwteg) 100 107 nlnenace pcs pes wie miso oom ‘Raster oars) 10 Fen ee a 3 TRS) Brecng . Lok The roe a nin fin pete sm 1 Beso 0 sistema ‘Rigeearepim i room 9) Astron S"Selcowsctnnmce, 9) fue wegen, © pretve mttanace ——-@) leibesbove ‘Ase 10 morn indir compet raving endne,LO2 &LO3.b: LOM, LO. implementing Fagor Eee ‘ins enon peepee rope LOS LO?