MEM675
Industrial
Engineering
Chapter 9 – Maintenance
Management
School of Mechanical Engineering,
College of Engineering, UiTM Shah Alam
*Contents are based on Heizer, Jay, and Barry Render, Operations Management, 10th Edition, Pearson Education, USA,
2011 1
Learning Objectives
√ Understand Maintenance management
system, reliability and its enhancements
√ Able to differentiate Types of maintenance;
Preventive, Breakdown, others
√ Understand Total Productive Maintenance
(TPM)
Industrial Maintenance
3
Industrial Maintenance
➢ Industrial maintenance, also called plant
maintenance, is the process of maintaining a
company’s assets and resources in good
working condition.
➢ The purposes: reduce breakdowns, increase
uptime, and promote overall reliability, so that
production can proceeds efficiently, and all the
resources are used effectively.
➢ Good maintenance plan reduces maintenance
costs, maximizes uptime potential, and
ultimately increases profitability. 4
Industrial Maintenance
Maintenance Roles/ Activities
5
Source: https://metasmartfactory.com/msf-maintenance-module/
Maintenance and Reliability
Maintenance is all activities involved in
keeping a system’s equipment in working
order
Reliability is the probability that a machine will
function properly for a specified time under
stated conditions.
The objective of maintenance and reliability
is to maintain the capability of the system
while controlling costs
6
Important Tactics
Reliability
1. Improving individual components
2. Providing redundancy (backup)
Maintenance
1. Implementing or improving preventive
maintenance
2. Increasing repair capability or speed
7
Important Tactics
Source: https://www.opuskinetic.com/2020/05/why-is-maintenance-and-reliability-
8
management-important/
Overall System Reliability
100 –
Reliability of the system (percent)
80 –
No. of
60 – components
40 – Reliability
20 –
0 |– | | | | | | | |
100 99 98 97 96
Average reliability of all components (percent)
9
Reliability Calculation’s Example
➢ Systems are composed of a series of individual
interrelated components, each performing a
specific job.
➢ If any one component fails to perform, for whatever
reason, the overall system can fail.
➢ Example: an airplane, a car or a machine.
➢ Two basic systems: series and parallel, and their
combinations are also possible.
10
Reliability Calculation’s Example
1. Series system
➢ System fails if any of its elements
fails.
2. Parallel system
➢ System fails only if all its elements
fail
11
Source: https://www.intechopen.com/books/concise-reliability-for-engineers/reliability-of-systems
Reliability Calculation’s Example
R1 R2 R3
.90 .80 .99 Rs
Reliability of the process is:
Rs = R1 x R2 x R3 = .90 x .80 x .99 = .713 or 71.3%
12
Providing Redundancy
➢ Redundancy is added in the form of backup
components or parallel paths (as in parallel
system).
➢ The objective is to ensure that if one component
or path fails, the system has recourse to another.
➢ Redundancy can be active (the parallel elements
work or are loaded simultaneously) or in
standby mode (by backup component/s).
13
Redundancy Example - Backup
A redundant process (backup) is installed to
support the earlier example where Rs = .713
R1 R2 R3
0.90 0.80 Backup
0.90 0.80 0.99
R1 R2 R3
Reliability has = [.9 + .9(1 - .9)] x [.8 + .8(1 - .8)] x .99
increased from 0.713
= [.9 + (.9)(.1)] x [.8 + (.8)(.2)] x .99
to 0.94
= .99 x .96 x .99 = .94 14
Redundancy Example - Parallel
The reliability of the system could be improved by having
machines in parallel, but expensive. To calculate reliability
of a parallel system:
1 Calculate reliability for the middle
path:
= R2 x R3
= 0.975 x 0.975
= 0.9506
2 Determine the probability of failure
for all 3 paths:
= (1-0.95) x (1-0.9506) x (1-0.95)
3 = 0.05 x 0.0494 x 0.05
= 0.00012
Thus, reliability of the new design:
= 1 – 0.00012 Reliability of the system is higher than
= 0.99988 of the best element in the system 15
Types of Maintenance
➢Preventive maintenance: Proactive
approach; reducing breakdowns through a
program of lubrication, adjustment, cleaning,
inspection, and replacement of worn parts.
➢Predictive maintenance: An attempt to
determine when best to perform preventive
maintenance activities; to determine the
condition of equipment & machines in order to
know when maintenance activity can be done.
➢Breakdown maintenance: Reactive/
corrective approach; dealing with breakdowns
or problems when they occur.
16
Types of Maintenance
➢Routine maintenance: perform activities
such as cleaning, oiling, lubricating,
replacing batteries & changing the oil
which can take place on a weekly or half
month basis. It depends on the equipment
work.
➢Emergency maintenance: to prevent a
threat to lives, the property of a company;
to keep the facility operational and safe.
Emergency maintenance is mostly used in
chemical plants, tenant buildings, etc.
17
Maintenance
18
Elements of Preventive Maintenance
➢ Routine maintenance – to prevent wear and
deterioration e.g. oiling, cleaning, adjusting,
collecting scraps
➢ Periodic inspection – to detect necessary repairs
or replacements well in advanced of actual
breakdowns
➢ Monitoring – to detect early warnings of
deterioration e.g. excessive vibrations and noise
19
Breakdown Programs
➢ Standby or backup equipment that can be
quickly pressed into service
➢ Inventories of spare parts that can be installed
as needed
➢ Operators who are able to perform minor
repairs
➢ Repair people who are well trained and readily
available to diagnose and correct the problems
using proper equipment.
20
Costs Occur When Breakdown
➢ Costs due to machine downtime
➢ Probable loss of sales to customer
➢ Costs due to idle direct or indirect labour
➢ Costs due to delays in other processes that may
depends for material supply on the machine that is
down
➢ Increased scrap costs
➢ Repair costs
➢ Costs due to customer dissatisfaction from possible
delays in deliveries
21
Maintenance Cost Example
Should the firm contract for maintenance on their
printers if the cost of hiring the maintenance services
monthly is RM 150?
Number of Frequency That
Breakdowns Breakdowns Occurred
0 2
1 8
2 6
3 4
Total: 20
Average cost of breakdown = RM300/breakdown
Routine servicing cost = RM300/service
22
Maintenance Cost Example
1. Compute the expected number of breakdowns
Number of Frequency Number of Frequency
Breakdowns Breakdowns
0 2/20 = .1 2 6/20 = .3
1 8/20 = .4 3 4/20 = .2
Expected number
of breakdowns = ∑ Number of
breakdowns x
Corresponding
frequency
= (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2)
= 1.6 breakdowns per month
23
Maintenance Cost Example
2. Compute the expected breakdown cost per
month with no preventive maintenance
Expected Expected number Cost per
breakdown cost = of breakdowns x breakdown
= (1.6)($300)
= $480 per month
24
Maintenance Cost Example
3. Compute the cost of preventive maintenance
Preventive = Cost of routine Cost of
maintenance cost maintenance if service + service contract
contract signed
= (1 routine service/month)($300) + $150/month
= $450 per month
Hire the service firm; it is less expensive
25
Preventive vs. Breakdown
Frequency of breakdown
Number of breakdowns 0 1 2 3
Frequency of occurrence .20 .30 .40 .10
If the average cost of a breakdown is RM1,000, and
the cost of preventive maintenance is RM1,250 per
month, should we use preventive maintenance or
otherwise?
26
Number of Frequency of Expected number of
Breakdowns Occurrence Breakdowns
0 .20 0
1 .30 .30
2 .40 .80
3 .10 .30
1.00 1.40
Expected cost to repair = 1.4 breakdowns per
month X RM1000 = RM1400
Preventive maintenance = RM1250
→ PM results in savings of $150 per month
27
Economics of Maintenance
Total Cost
Cost
Preventive
maintenance cost
Breakdown and
repair cost
Optimum Amount of
preventive maintenance
28
Economics of Maintenance
➢ For highly complex automated machines with
expensive parts & highly skilled labour, preventive
maintenance is advisable.
➢ Preventive maintenance can be done when time
machines are idle or low production time
➢ If the cost of shutting down the machine is high, it
would be better to wait until breakdown
29
Total Productive Maintenance (TPM)
Direct employee involvement
– a sense of ownership and they would care more of the
machine that they involved with, organize appropriate
operation & maintenance training
Proper documentation
– Organized, computerized and easy access database of
maintenance problems, solutions and schedule by
employees e.g. expert system which assist in
troubleshooting various machine
Utilize machines that are reliable, easy to operate,
and easy to maintain
30
Strategies of Total Productive
Maintenance (TPM)
▶ 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 service
▶ Training for autonomous maintenance so operators
maintain their own machines and partner with
maintenance personnel
Autonomous Maintenance in TPM
▶ Machine operators accept responsibility for
▶ Observe
▶ Check
▶ Adjust
▶ Clean
▶ Notify
▶ Predict failures, prevent breakdowns,
prolong equipment life
How to Schedule for Preventive
Maintenance?
Simulation
By using past data of breakdowns and
random number, good tool to decide
in replacing parts that have not yet
failed
33
Computerized Maintenance
System
Data Files Output Reports
Equipment file
with parts list Inventory and
purchasing reports
Maintenance Equipment
parts list
and work order
schedule
Equipment
Repair history reports
history file
Cost analysis
Data entry (Actual vs. standard)
– Work requests
– Purchase
Inventory of requests
spare parts – Time reporting
– Contract work
Work orders
– Preventive
maintenance
– Scheduled
Personnel data downtime
with skills, – Emergency
wages, etc. maintenance Figure 17.3
34
Establishing Maintenance Policies
Simulation
Computer analysis of complex
situations
Model maintenance programs before
they are implemented
Physical models can also be used
Expert systems
Computers help users identify
problems and select course of action
35
Maintenance Policies – (Example)
➢ Critical component is replace before it breaks down through
the Preventive Maintenance Program
➢ Establish a repair facility and have an adequate maintenance
crew to reduce down time
➢ Use parallel paths of production (for critical stages) so that
breakdowns will not paralyze the entire production
➢ Design critical components in more reliable manner
➢ Establish storage/buffer between stages of production line
➢ Use standby machinery when a particular machine breaks
down
36
Let’s Recap
Understand Maintenance, reliability and its
enhancements
Able to differentiate Types of maintenance;
Preventive, Breakdown, others
Understand Total Productive Maintenance
