1. Maintenance Management

2. MAINTENACE All activities that maintain
facilities and equipment in good
working order so that a
system can perform as intended

3. Equipment Malfunctions
Equipment malfunctions have a direct impact on:
Production capacity
Production costs
Product and service quality
Employee or customer safety
Customer satisfaction

4. Maintenance Departments
A maintenance manager typically is a plant engineer who reports to a plant or manufacturing manager
Maintenance departments are usually split into two groups:
Buildings and Grounds
Equipment

5. TYPES OFMAINTENANCE 1. BREAKDOWN MAINTENANCE 2. PREVENTIVE MAINTENANCE
3. PREDICTIVE MAINTENANCE

6. BREAKDOWN MAINTENACE Reactive approach; dealing with
breakdowns or problems when they occur

7. Repairs
Repair activities are reactive.
Breakdowns and malfunctions typically occur when equipment is in use.
Standby machines and parts can speed repairs

8. PREVENTIVE MAINTENACE
Proactive approach; reducing breakdowns
through a program of lubrication, adjustment, cleaning, inspection,
and replacement of worn parts

9. Preventive Maintenance (PM)
Regularly scheduled inspections are performed.
PM activities are performed before equipment fails.
PM is usually performed during idle periods.

10. PREDICTIVE MAINTENCE PREVENTIVE MAINTENANCE AS PER
CONDITION MONITORING

11. Bath Tub Curve Bathtub Curve Constant failure rate Failure Rate
Infant Mortality
Wear out
Failure Rate
Bathtub Curve
Constant failure rate
Time (t)

12. MAINTENANCE MANAGEMENT
OBJECTIVES
REDUCE DOWN TIME
REDUCE LOSS OF MATERIALS IN PROCESS
INCREASE LIFE OF EQUIPMENT
REDUCE OVERTIME
OPTIMISE SPARES INVENTORY
MAINTAIN PRODUCT QUALITY
OPTIMISE OPERATIONAL COST OF EQUIPMENT

13. DISADVANTAGES OF BREAKDOWN MAINTENANCE
Due to urgency, machine may not get adequate maintenance
Due to uncertainty, production plan gets completely disrupted
Planning of maintenance work not possible
Distribution of workload is difficult
Increased overtime

14. Reasons for a PM Program
Reduce the frequency and severity of interruptions due to malfunctions
Extend the useful life of equipment
Reduce the total cost of maintenance by substituting PM costs for repair costs
Provide a safe working environment
Improve product quality by keeping equipment in proper adjustment

15. Tradeoff Between Repairs and PM
At minimum level of PM, it is a remedial policy
fix machines only when they break
the cost of breakdowns, interruptions to production, and repairs is high
As the PM effort is increased, breakdown and repair cost is reduced
At some point, the total maintenance cost (PM, breakdown, and repair) reach a minimum

16. Tradeoff Between Repairs and PM
Annual Cost ($)
Minimum Total
Maintenance Cost
Total
Maintenance
Costs
Minimum
Level of
Preventive
Maintenance
Preventive
Maintenance
Cost
Breakdown
and Repair
Cost
Degree of Preventive Maintenance

17. BREAKDOWN MAINTENANCE IS SUITABLE
WHERE PLANT CAPACITY EXCEEDS MARKET DEMAND
STANDBY EQUIPMENTS ARE AVAILABLE
PROCESS IS OBSOLETE AND MORE MODERN EQUIPMENT IS UNDER CONSIDERATION
MAY BE ECONOMICAL FOR NON CRITICAL EQUIPMENTS

18. Repair Programs Objectives
Get equipment back into operation as quickly as possible.
Control cost of repairs crews.
Control cost of the operation of repair shops.
Control the investment in replacement spare parts.
Control the investment in standby or backup machines.
Perform the appropriate amount of repairs at each malfunction.

19. How Speedy Should Repairs Be?
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
Slow
Speed of Making Repairs
Fast

20. Extent of Repairs
Do just enough repairs to get equipment running again.
Repair the malfunction and replace some parts that are worn.
Perform a major overhaul of the equipment.
Replace the old equipment with new.

21. Secondary Maintenance Responsibilities
Housekeeping, grounds keeping, janitorial
New construction, remodeling
Painting
Security, loss prevention
Pollution control
Waste recycling
Safety equipment maintenance
Public hazard control

22. Maintenance issues are not limited to manufacturing
Transportation firms (airlines, trucking companies, package delivery services, railroads) must keep their vehicles in top operating condition
Highway departments must maintain roadways
Office personnel are reliant on copiers, printers, computers, and fax machines working properly
As services become increasingly automated, service firms face more and more maintenance issues

23. When is it time for 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?

24. Trends in Maintenance
Production machinery is becoming more and more complex and maintenance personnel must keep pace
Special training programs to maintain worker skill level
Subcontracting service companies
Production workers maintain own equipment
Computer assistance in maintenance

25. Wrap-Up: World-Class Practice
Empower workers so they “own” their machines
Implement JIT to help reduce inventories and cycle time
Invest in factory and service automation projects
Utilize automated process sensing and control systems
Use computers in maintenance management