MAINTENANCE

five fields of work or basic

maintenance tasks:

• Service: All actions taken to increase the lifespan of the

machine.
• Inspection: Includes all checking and assessment
activities carried out to detect wear on certain parts
and target them for replacement in good time.
• Repair: The actual repair work, restoring the device to
functioning condition.
• Improvement: Targeted optimisation of machines and
plants.
• Weak-point analysis: The process of finding and
eliminating potential faults.
 goal of maintenance
• The most important goal of maintenance is to
secure high machine or plant availability.
Ideally, this would be 100% availability
Utilisation, performance and quality
levels
 The six typical sources of loss in
machines and plants
1. Losses to faults and breakdowns
2. Losses to setup and installation work
3. Losses to short standstills
4. Losses to reduced speed
5. Losses to start-up problems
6. Losses to reduced quality and defects
1. Losses to faults and breakdowns
2. Losses to setup and installation
work
3. Losses to short standstills
4. Losses to reduced speed
5. Losses to start-up problems
6. Losses to reduced quality and
defects
 Typical maintenance figures
1. Overall Equipment Effectiveness (OEE)
2. Total Effective Equipment Productivity (TEEP)
3. Mean Time Between Failures (MTBF)
4. Mean Time to Repair (MTTR)
1. Overall Equipment Effectiveness
(OEE)
 Availability

• Availability (A) describes the relationship

between operating time (TO) and scheduled
time (TS).
•
• A = TO / TS
• Where operating time is the time during
which the machine is actually working.
Accordingly, downtime, setup time or other
non-productive time should be subtracted.
 Performance

• Performance
• Performance describes the relationship between real processing
speed and net processing time.
•
• P = (n total x t planned) / TO
•
• Where n total is the real number of parts produced over the period
of time in question. t planned is the planned cycle time, i.e. the
specified speed of the plant as ordered and delivered. Be careful
not to confuse this time with standard or specified times. Firstly,
these times already include personal distribution times. Secondly,
these standard or specified times are in reference to the staff
member’s activity recording. Although the planned cycle time and
standard or specified time might appear to be related, they are
different in principle because of how they are recorded.
 Quality

• Quality expresses the relationship between

good parts and total parts produced.
•
• Q = (n total – n refinish – n defect) / n total
 Overall Equipment Effectiveness

• The Overall Equipment Effectiveness can now be

calculated based on these three components:
•
• OEE = A x P x Q x 100%
• OEE = (TO / TS) x ((n total x t planned) / TO) x ((n total - n
refinish - n defect) / n total) x 100%
•
• The formula can be simplified as follows:
• OEE = t planned x (n total – n refinish – n defect) / TS x
100%
 Example

• The OEE is to be determined for a lathing centre.

The weekly work schedule comprises 10 shifts of
8 hours each. During this time, the processing
centre was working at full capacity. A total of 572
parts were produced, whereby two were
defective and three needed refinishing. The
planned cycle time is 6:12 min.
• OEE = t planned x (n total – n refinish – n defect) / TS x
100%
• OEE = 372s x (572 – 3 -2) / 288000s x 100%
• GEFF = 73.2375%
• Total Effective Equipment Productivity (TEEP)
Mean Time Between Failures (MTBF)
Mean Time to Repair (MTTR)