Documente Academic
Documente Profesional
Documente Cultură
1
Overview
z Introduction
z Repair Programs
z Preventive Maintenance (PM) Programs
z Machine Reliability
z Secondary Maintenance Department Responsibilities
z Trends in Maintenance
z Maintenance Issues in Service Organizations
z Wrap-Up: What World-Class Companies Do
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Equipment Malfunctions
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Maintenance Departments
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Maintenance Activities
z Repairs
z Repair activities are reactive.
z Breakdowns and malfunctions typically occur
when equipment is in use.
z Standby machines and parts can speed repairs.
z Preventive Maintenance (PM)
z Regularly scheduled inspections are performed.
z PM activities are performed before equipment
fails.
z PM is usually performed during idle periods.
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Tradeoff Between Repairs and PM
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Tradeoff Between Repairs and PM
Minimum Total
Maintenance Cost
Total
Maintenance
Costs
Minimum
Level of Preventive
Preventive Maintenance
Maintenance Cost
Breakdown
and Repair
Cost
Degree of Preventive Maintenance
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Maintenance Policies that Reduce
Frequency and Severity of Malfunctions
Reduces Reduces
Maintenance Policy Frequency Severity
Emphasize preventive maintenance X X
Provide extra machines X
Replace machine parts early X
Involve operators in maintenance X X
Overdesign machines X
Design machines for maintainability X
Enhance maint. dept.s capability X X
Increase spare parts supply X
Increase standby machines X
Increase in-process inventories X
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Repair Programs
z Objectives
z Get equipment back into operation as quickly
as possible.
z Control cost of repairs crews.
z Control cost of the operation of repair shops.
z Control the investment in replacement spare
parts.
z Control the investment in standby or backup
machines.
z Perform the appropriate amount of repairs at
each malfunction.
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Repair Crews and Standby Machines
Cost ($)
Minimum
Total Cost
of Repairs Total Costs
of Repairs
Cost of Repair
Crews & Shops,
Spare Parts, and
Standby Machines
Cost of
Interruptions to
Production
0
Slow Speed of Making Repairs Fast
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Breakdowns Trigger
Repairs and Corrective Actions
An equipment breakdown should trigger two actions:
z Fast repair of the malfunction equipment
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Extent of Repairs
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Decision Analysis in Repair Programs
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Example: The Shirt Factory
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Example: The Shirt Factory
ts = 1 ( )
2 = 1/( )
= 12.5 machines per hour
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Example: The Shirt Factory
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Example: Accounting Unlimited
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Example: Accounting Unlimited
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Example: Accounting Unlimited
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Example: Accounting Unlimited
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Advantages of Letting Workers
Repair Their Own Machines
z Greater variety may make job more satisfying
z May be more sensitive to potential malfunctions
z Increase flexibility
z Can make minor repairs faster
z Can avoid minor repairs by cleaning, lubricating,
adjusting and servicing machines
z Operate machines more carefully
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Reasons for a PM Program
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PM and Operations Strategies
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Automation and the Prominence of PM
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Scheduling PM Activities
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PM Database Requirements
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Modern Approaches to PM
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Decision Analysis in PM
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Determining the Number of Spare Parts
to Carry for PM Inspections
Two types of parts demand arise from PM inspection:
z Parts that we routinely plan to replace at the time of
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Expected Number of Breakdowns
n
Bn = N( p n ) + B(n 1) p1 + B(n 2) p 2 + ... + B1p (n 1)
1
where:
Bn = expected number of breakdowns for each of the
PM policies
pn = probability that a breakdown will occur between
PM inspections when PM is performed every n
periods
N = number of machines in group
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Example: PM Frequency
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Example: PM Frequency
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Example: PM Frequency
n
Bn = N( p n ) + B(n 1) p1 + B(n 2) p 2 + ... + B1p (n 1)
1
B1 = 4(0.2) = 0.800
B2 = 4(0.2 + 0.3) + 0.8(0.2) = 2.160
B3 = 4(0.2 + 0.3 + 0.5) + 2.16(0.2) + 0.8(0.3) = 4.672
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Example: PM Frequency
Exp. Weekly
PM Exp. Number Exp. Weekly Total
Every Number of BDs Cost of Cost
Weekly
n Wks. Of BDs per Wk. BDs of PM Cost
1 0.800 0.800 $6,400 $6,000 $12,400
2 2.160 1.080 8,640 3,000 11,640
3 4.672 1.557 12,456 2,000 14,456
The policy that minimizes total weekly cost is:
perform PM every 2 weeks.
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Large -Scale PM Projects
Large-Scale
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Approaches to Improving
Machine Reliability
z Overdesign - enhancing the machine design to avoid
a particular type of failure
z Design simplification - reducing the number of
interacting parts in a machine
z Redundant components - building backup
components right into the machine so that if one part
fails, its automatically substituted
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Secondary Maintenance Responsibilities
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Trends in Maintenance
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Computer Assistance in Maintenance
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Maintenance Issues in Service Organizations
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Wrap-Up: World
Wrap-Up: -Class Practice
World-Class
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End of Session
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