MAINTENANCE MANAGEMENT

Types of company based on maintenance point of view

Unaware company: maintenance as necessary evil, kepentingan kejahatan an expense to the organization, beban bagi organisasi a non-value added function, fungsi tambah non-nilai Competitive company: maintenance as a means for reducing the cost of production, sebagai sarana untuk mengurangi biaya produksi use this competitive advantage to lower prices, improve margin profit, and increase shareholder value, menggunakan keunggulan kompetitif ini untuk harga yang lebih rendah, meningkatkan marjin laba, dan meningkatkan nilai pemegang saham Why this condition happen?

Competition is something that every company faces, but do companies truly understand the definition of competition?

competition is the rivalry between two or more businesses striving for the same costumer or market., kompetisi adalah adalah persaingan antara dua atau lebih bisnis berjuang untuk costumer yang sama atau pasar

Companies must constantly improve themselves in order to avoid being surpassed by competitors, Perusahaan harus terus memperbaiki diri dalam rangka untuk menghindari dikalahkan oleh pesaing

But. The companies today do not have exclusivity in their assets and process when providing a product or service to the marketplace they use the same materials and assets to produce their goods Perusahaan-perusahaan saat ini tidak memiliki eksklusifitas dalam aset dan proses mereka,ketika memberikan produk atau layanan ke pasar mereka menggunakan bahan dan aset yang sama untuk memproduksi barang-barang mereka

How do they differentiate themselves from their competitors?

Contoh dari organisasi yang bersaing dengan aset yang sangat identik dalam lingkungan bisnisnya, sebagai contoh NASCAR Racing

Goal: To Finish at 1st place

Fokus seluruh organisasi (tim) melakukan bagian mereka untuk mendapatkan kapasitas maksimum dari aset

 bagaimana jika pengemudi didikte kru pit kapan dan bagaimana melakukan sesuatu? bagaimana jika kru pit mengabaikan masukan pengemudi tentang performa mobil? bagaimana jika para setup engineers tidak mempertimbangkan apa jenis track balapan? what if.

DECISION

Worse
lebih buruk

Evolve
berkembang

Best
terbaik

Selective learning process Adopted from Darwinian Model managers strategically develop their vision for how the companys products and services will fill the need in the market. They select the Best Practice to achieve their vision while changing or eliminating set a inferior practices or policies Manajer strategis mengembangkan visi mereka untuk bagaimana produk dan layanan perusahaan akan memenuhi kebutuhan di pasar. Mereka pilih Best Practice untuk mencapai visi mereka saat mengganti, menghilangkan, menetapkan praktek atau kebijakan

The managers: harus menetapkan arah yang jelas, fokus pada visi perusahaan memerlukan alat navigasi yang baik untuk membantu mereka mengarahkan organisasi dan memonitor kemajuan

Production Process continuity is affected by Maintenance System

Proses Produksi kontinuitas dipengaruhi oleh Pemeliharaan Sistem

Input

Process

Output

Feed-back

Main goal of maintenance is reliability . Production process at optimum speed

Tujuan utama dari pemeliharaan keandalan .... Proses produksi pada kecepatan optimal ...

When a guy goes out on the floor to fix a machine Hes not doing maintenance! Hes doing repair!!!
(Ellis New Productivity Inc.)

MAINTENANCE DEVELOPMENT

Breakdown Maintenance / kerusakan Preventive Maintenance / pencegahan Productive Maintenance Total Productive Maintenance Reliability Centered Maintenance

BREAKDOWN MAINTENANCE

Until after World War II (1950s) Mechanical development was limited Downtime was not a problem; Breakdown prevention was not a priority simple technology and built to last principle occurred Needs for maintenance skill was rarely happen

PREVENTIVE MAINTENANCE

Until 1960s; changing of human mind-set after World War II Permintaan meningkat sementara pasokan menurun drastis Kebutuhan mekanisasi meningkat Ketergantungan pada mesin meningkat, juga lebih kompleks Berfokus pada down-time tetapi kegagalan mesin dapat dideteksi dan dihindari Needs for maintenance skill increased Biaya maintenance meningkat dan situasi ini dapat dikelola dengan perencanaan maintenance dan kontrol, sehingga kegiatan maintenance bisa lebih efektif dan efisien.

Selama liburan atau masa perencanaan Shutdown machine , mesin diperiksa tingkat keausannya. Tindakan yang diperlukan seperti, perubahan tepat waktu bagian usang,perbaikan dll, dilakukan. operasi pembersihan besar, meminyaki, pemeriksaan dari set up, keselarasan dll, dilakukan. membantu menciptakan kesadaran dan pengakuan tentang pentingnya keandalan dan efisiensi ekonomi dalam perancangan pabrik dll

PRODUCTIVE MAINTENANCE

Until after World War II (1950s) Mechanical development was limited Downtime was not a problem; Breakdown prevention was not a priority simple technology and built to last principle occurred Needs for maintenance skill was rarely happen

'Productive Maintenance' came into existence. Kesadaran menciptakan sistem cek rutin pada hari ke hari seperti memeriksa ketatnya mur, baut, kebocoran dll Hal ini menyebabkan'Maintainability Improvement'. Preventive maintenance and maintainability improvement membantu kepada'Maintenance Prevention' i.e., mempertimbangkan pengurangan di dalam aktivitas maintenance

TOTAL PRODUCTIVE MAINTENANCE

Japan adopted Preventive maintenance and Productivity maintenance in their plants. Seiichi Nakajima in 1971 made Productive Maintenance as Total Productive Maintenance. If quality can be responsibilities of the process control people, why not the machine they use also? He created a comprehensive system wherein autonomous maintenance became an integral part of productive maintenance system. TPM is achieving PM efficiencies through comprehensive system based on respect for individuals and total employee participation and it brought in autonomous maintenance in to the system.

Seiichi Nakajima offered concept of TPM in 1972 (Japan) after studying by visiting many European and American manufacturers from 60s (1962)

workers productivity increased by 60% accidental breakdown reduced up to 1/100 1/500

Close to zero

Parlor factory

Parlor factory : zashiki part of Japanese home where they entertain their guests (it keeps immaculately clean)

Aims at building up a corporate culture that thoroughly pursues production system efficiency improvement (OEE : overall equipment efficiency) Constructs a system to prevent every kind of loss, for example, to achieve zero accidents, zero defects and zero failures based on Gemba (actual site) and Genbutsu (actual thing) over the entire life cycle of a production system. Covers all departments including production, development, marketing, and administration.

Requires all and full involvement from top management to frontline employees.
Achieves zero losses by overlapping small-group activities.

TPM can be considered as the medical sciences of machines

Increase production

Employee morale Job satisfaction

Brings maintenance into focus as necessary and vitally important part of the business; no longer regarded as a non-profit activity