Professional Documents
Culture Documents
Learning Block 7
Maintenance and Quality
Course Agenda
1. Manufacturing and Service Operations Overview
2. Strategic Decisions in Manufacturing
3. Manufacturing Planning and Control
4. Operational Improvement
5. Performance Metrics
6. Systems and Technology
7. Maintenance and Quality
2
Learning Block Agenda
1. Maintenance Service Operations
2. Types of Maintenance
3. Total Productive Maintenance
4. Maintenance Spares
5. Housekeeping
6. Manufacturing and Service Quality
Description
• The maintenance department ensures that the physical
plant’s machines, conveyors, and other equipment are
functioning properly.
– They may have a formal program to prevent breakdowns and
failures.
– They perform fixes when such problems occur.
– They may also conduct housekeeping and maintain the upkeep of
the entire property of the facility.
4
Learning Objectives
• Recognize the role and importance of maintenance service operations
in helping to ensure equipment availability and reliability
• Understand the differences between preventive and corrective
maintenance
• Analyze the key aspects of housekeeping and cleaning services in a
manufacturing environment
• Summarize the concept of outsourcing, including how inventory
management works with a third party
• Differentiate between quality assurance and quality control in
operations
Unit 1: Maintenance Service Operations
• Equipment breakdowns and failures disrupt manufacturing
process flows, create idle worker time, and hinder a
company’s ability to meet demand.
– Equipment readiness indicates the proportion of time that
equipment is functioning and producing goods.
• No equipment functions 100% of the time, due to routine maintenance.
• Machinery does not always operate at its intended output rate due to
wear-and-tear, poor installation, or inadequate setup.
The Maintenance Function
• The primary goal of
maintenance is to plan
activities and work tasks to
mitigate equipment failure.
– Components should be
replaced before they break.
– Overhauls and equipment Figure 68. Machine failures may be avoided with preventive
maintenance.
Overhaul •Repairing and maintaining a piece of equipment or machinery to restore it to working condition
Rebuild
•Restoring a piece of equipment to working condition after it has reached the end of its working life or after it has been
damaged
Inspection
•A physical examination or review to assess equipment functionality and performance
•May encompass a range of activities, including taking measurements or performing tests
Replacements •Changing out a piece of equipment or its components when it has reached the end of its useful life
Unit 2: Types of Maintenance
• Maintenance actions can be defined in two categories:
preventive and corrective maintenance.
Preventive
Corrective maintenance is performed based
to troubleshoot,
on a predetermined
isolate, and
schedule
repair atodefect
prevent
or
fault in response
sudden
to equipment
equipmentbreakdown
failure. or failure.
Preventive Maintenance Tasks
• There are three basic types of preventive maintenance:
Scheduled inspections are used to detect potential failures and may result in the recall or repair of an item
that does not meet required standards.
Scheduled rework restores the functionality of worn items that develop a greater probability of failure
towards the end of their lifespan.
Scheduled discard takes place once an item has reach its life limit, or its predetermined lifespan. Life limits
may be established due to either safety or economic concerns.
Services and Lubrication
Planned Maintenance More efficient, cost- Maintenance teams Daily and periodic inspections
effective maintenance Predictive maintenance
Lengthen equipment life
Spare parts control
Breakdown analysis
Lubrication control
Maintenance and Operator Skill Higher skill levels for Operators Maintenance fundamentals
operators and maintenance Maintenance workers Predictive technology
Training workers Repair skills
Troubleshooting and diagnosis
Maintenance Prevention During More reliable equipment Production design Design goals, rules, and specifications
is easier to maintain Maintenance staff Design reviews
Design
Equipment Installation and Upgrade Services
• Machinery ages over time and
eventually needs to be
replaced.
– Parts of the manufacturing
process may be shut down to
accommodate the removal of
existing equipment and Figure 72. Equipment installation. Developed by LINCS
in Supply Chain Management Consortium.
•These materials •These spares are •These are used •These are used •These spares are
are used on a typically used for a planned used to protect
whenever a when against natural
regular basis; project, and
typical examples planned breakdowns disasters; they
maintenance task is could include
are fasteners, occur to could consist of
performed; they internal parts to
cleaning materials,
could include rebuild a replace broken an entire machine
lubrication or set of machines
materials, and
internal machine
machine to a or non-
parts and roller to enable
other significant functioning manufacturing to
bearings on
consumables. conveyors. extent. parts. continue.
Unit 5: Housekeeping
• Housekeeping ensures that the workplace is kept neat,
organized, and clean.
– Examples of housekeeping in an industrial context:
• Providing adequate workspace
• Adequate storage arrangements close to workstations
• Sufficient clearance around machinery for worker mobility
– Effective housekeeping can reduce or eliminate workplace
dangers.
Unit 6: Manufacturing and Service Quality
• Quality Assurance vs. Quality Control
– Quality assurance consists of the systematic management
activities that take place to help achieve product and service
requirements.
– Quality control is an evaluation of a product or service that
indicates if the desired results were achieved.
• Manufacturing plants typically have quality control inspection points
where products can be subjected to in-process inspections.
Summary
Optional Supplemental Resources
The optional supplemental resources listed below may be used to reinforce the
content covered within this learning block.
• Davis, M., & Heineke, J. (2005) Operations Management: Integrating Manufacturing and Services
(5th ed.). Waltham, MA: McGraw-Hill.
• Sanders, N., (2014). The Definitive Guide to Manufacturing and Service Operations (3rd ed.).
Upper Saddle River, NJ: Pearson.
Practice Questions
1.What is the primary goal of the maintenance function?
a. Plan activities and work tasks to mitigate equipment failure
b.Retain and restore equipment to a specified condition to achieve its minimum useful life
c. Retain and restore equipment to an unspecified condition to achieve its maximum useful
life
d.Destroy equipment once it has reached its maximum useful life
e. Planned maintenance
f. Perform in response to a machine breakdown or failure
g. Maintenance prevention during machine design
h.Maintenance and operator skill training
Practice Questions
7. Which choice best defines maintenance spares?
a. Items that are consumed in the production process to make products
b.Items used to ensure that the plant and equipment are kept in a reliable and safe
condition
c. Utility backup systems such as generators
d.Part-time maintenance department employees