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5) Maintenance - Final

The document discusses maintenance in operations management. It defines maintenance as activities to keep facilities and equipment in good working order. There are reactive and proactive approaches. Proactive maintenance like preventive maintenance aims to reduce breakdowns through inspection and replacement. Preventive maintenance is periodic and done according to a schedule. The consequences of breakdowns include reduced production, delayed orders, increased costs and quality and safety issues. Total maintenance costs include preventive maintenance costs and breakdown repair costs.

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Savya Jaiswal
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197 views13 pages

5) Maintenance - Final

The document discusses maintenance in operations management. It defines maintenance as activities to keep facilities and equipment in good working order. There are reactive and proactive approaches. Proactive maintenance like preventive maintenance aims to reduce breakdowns through inspection and replacement. Preventive maintenance is periodic and done according to a schedule. The consequences of breakdowns include reduced production, delayed orders, increased costs and quality and safety issues. Total maintenance costs include preventive maintenance costs and breakdown repair costs.

Uploaded by

Savya Jaiswal
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

14s-1

Maintenance

Operations Management

14s-2

Maintenance

CHAPTER

Maintenance

14s-3

Maintenance

Introduction

Maintenance

All activities that maintain facilities and equipment in good working order so that a system can perform as intended Reactive approach; dealing with breakdowns or problems when they occur Proactive approach; reducing breakdowns through a program of lubrication, adjustment, cleaning, inspection, and replacement of worn parts

Breakdown maintenance

Preventive maintenance

14s-4

Maintenance

Maintenance Reasons

Reasons for keeping equipment running

Avoid production disruptions Not add to production costs Maintain high quality Avoid missed delivery dates

14s-5

Maintenance

Breakdown Consequences

Production capacity is reduced

Orders are delayed

No production

Overhead continues Cost per unit increases Product may be damaged


Injury to employees Injury to customers

Quality issues

Safety issues

14s-6

Maintenance

Total Maintenance Cost

Table 14S.1

Total Cost

Cost

Preventive maintenance cost

Breakdown and repair cost Optimum Amount of preventive maintenance

14s-7

Maintenance

Preventive Maintenance

Preventive maintenance: goal is to reduce the incidence of breakdowns or failures in the plant or equipment to avoid the associated costs

Preventive maintenance is periodic


Result of planned inspections According to calendar After predetermined number of hours

14s-8

Maintenance

Example S-1

Frequency of breakdown
Number of breakdowns Frequency of occurrence 0 1 2 3 .20 .30 .40 .10

If the average cost of a breakdown is $1,000, and the cost of preventative maintenance is $1,250 per month, should we use preventive maintenance?

14s-9

Maintenance

Example S-1 Solution


Frequency of Occurrence .20 .30 .40 .10 1.00 Expected number of Breakdowns 0 .30 .80 .30 1.40

Number of Breakdowns 0 1 2 3

Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400 Preventive maintenance = $1250 PM results in savings of $150 per month

14s-10

Maintenance

Predictive Maintenance

Predictive maintenance

An attempt to determine when best to perform preventive maintenance activities

Total productive maintenance

JIT approach where workers perform preventive maintenance on the machines they operate

14s-11

Maintenance

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 problems with equipment

14s-12

Maintenance

Replacement

Trade-off decisions Cost of replacement vs cost of continued maintenance New equipment with new features vs maintenance Installation of new equipment may cause disruptions Training costs of employees on new equipment Forecasts for demand on equipment may require new equipment capacity When is it time for replacement?

14s-13

Maintenance

Maintenance Management Total Productive Maintenance (TPM)

Philosophy for all workers of enterprise Involve all departments Involve everyone Prevent all types of losses Maximize effectiveness of production systems

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