Presentation on theme: "Maintenance Planning and Control : Modeling and Analysis"— Presentation transcript:
1 Maintenance Planning and Control : Modeling and Analysis Slides on chapter 1
2 Lecture 1 OBJECTIVE1. Enable Students To Understand The Role of Maintenance in Meeting Organizational Objectives.Enable Students To View Maintenance As A System That Has Activities That Needs Planning, Organizing , Designing,Measurement and Control
3 MaintenanceMaintenance is defined as the combination of activities by which equipment or a system is kept or restored to a state in which it can perform its designated function. It is an important factor in product quality control and can be used as a strategy for successful competition
4 MAINTENANCEBS 3811 : 1964 defines Maintenance as :Work undertaken in order to keep or restore every facility to an acceptable working condition/standard.
5 Maintenance Versus Organization Objectives The objectives and goals of an organization depends on the organization state of mind and type of business. Some objectives areMeet or exceed customer satisfactionMaximizing profit, Meet set targetsMeet set safety standard, Zero product defectDoes Maintenance affect these goals?
6 Improve Equipment Improve Product Quality Reduce Performance In any organization Maintenance is the backbone of all successful enterprises and contributes to:CostsMeet Set TargetsImprove UtilizationImprove Equipment Improve Product QualityReduce Performance
7 Maintenance Versus Organization Objectives A system is a collection of components that work together towards a common objective. Maintenance can be considered as a system with a set of activities carried out in parallel with production systems. A diagrammatic relationship among organizational objectives, the production process, and maintenance is shown in Figure 1.1
9 Maintenance System Output A maintenance system can be viewed as a simple input output model. The inputs to such a model are labor, management, tools, spares, equipment, etc. and the output is equipment that is up, reliable and well configured to achieve the planned operation of the plant.
10 Maintenance System Output This enables us to optimize the resources for maximizing the output of a maintenance system. A typical maintenance system is shown in Figure Activities needed to make this system functional, namely, planning, organizing, and control, are shown in this figure
15 Maintenance Load Forecasting Maintenance load is a random variable and forecasting is the process by which maintenance load is predicted. Load forecasting is essential for capacity planning. Many factors affect the load, they include equipment age, climate, quality of maintenance, etc.
17 Maintenance Scheduling Maintenance scheduling is the process of assigning resources and manpower for jobs to be accomplished at certain times. It is necessary to ensure that the needed craftsmen, the parts, and materials required are available before a maintenance task can be scheduled.
18 Maintenance Capacity Planning Maintenance capacity planning determines the resources needed to meet the demand for maintenance work. Those resources include manpower, material, spare parts, equipment, and tools. Critical aspects of maintenance capacity are the numbers and skills of craftsmen, required maintenance tools, etc.
19 Maintenance Organization Maintenance Organization Depends On Maintenance Load, Plant Size, Trade and Skill, Maintenance Could Be Centralized Or Decentralized Or A Combination of Both. See Figure 1.5 In Text Book
21 Organizing Activities 1. Job Design2. Standard Time3. Project Management
22 Job DesignJob design, as related to maintenance work, comprises the work content of each job and determines the method that is to be used, special tools needed, and the skilled persons required.
23 Time StandardsTime Standards are Needed For Effective Planning. It is The Time That Takes A Qualified Worker Worker At 100% Pace To Complete The Job. Techniques Used For Developing Time standards Are Work Measurement, Work Sampling. Estimation and Slotting
24 Project ManagementTechniques Such As CPM, PERT Are Needed For Large Jobs Such as Overhauls.They will Enable Better Control OF Cost and work. They Usually Results In Better Utilization Of Resources
25 Control activities 1. Work control 2. Inventory control Control is an essential part of Scientific management. control as applied to maintenance includes:1. Work control2. Inventory control3. Cost control4. Quality control
26 Work Control. The management and control of the maintenance work is essential for achieving set plans. The work order system is the tool used for controlling the maintenance work. A well designed work order with a sound reporting system is the heart of the maintenance system The essential tools for effective control of the maintenance work including the design of a work order are covered in chapter 2.
27 Inventory ControlMaterial and spare parts are essential for maintenance work. Prior to scheduling maintenance work spare parts must be available. Techniques for inventory control are covered in chapter 7 of the text.
28 MAINTENANCE COSTS. 1. DIRECT COSTS 2. STAND-BY COSTS Cost of Periodic InspectionService CostRepair Cost, Overhaul Cost2. STAND-BY COSTSCost of Operating and Maintaining a Standby Unit
29 MAINTENANCE COSTS. 3. LOST PRODUCTION COSTS : 4. DEGRADATION COST Cost due to Equipment down time.4. DEGRADATION COSTCost occurring due to deterioration of the life span of equipment due to no maintenance or inadequate maintenance.
30 Cost ControlThe control of maintenance cost optimizes all the costs in maintenance, while achieving, set organizational objectives such as: availability, “Quality Rate”, and other efficiency and effectiveness measures. Cost reduction and control can be used as an edge for competition in providing products and services. The issues related to cost and its control are presented in chapters 2 and 10
31 Quality ControlIn the case of maintenance work "doing it right the first time" is very essential. Quality may be assessed as the percentage of accepted maintenance jobs according to the standard adopted by the organization. High Quality is usually assured by checking the critical maintenance jobs or by maintenance supervision. The details of maintenance quality control are presented in chapter 8.
32 Managing For Quality and Training Managing for quality is a managerial responsibility.. The key for managing for quality lies first in the awareness of the need to improve and second in selecting appropriate improvement techniques. Chapter 12 focuses on the aspects of continuous improvement.
33 Human BehaviorManagers should try to know how the behavior of subordinates can affect management's planning, organizing, and controlling actions. In maintenance decision making, behavior of subordinates should be of interest to management. It should be ensured that the desired level of craftsmen satisfaction is achieved and maintained.
34 Maintenance TermsAvailability: The ability of an equipment to successfully perform its required function at a stated instant of time or over a stated period of time.Breakdown: Failure resulting in the non-availability of an equipment.
35 Maintenance TermsCondition-based maintenance: The preventive maintenance initiated as a result of knowledge of the condition of an equipment observed through routine or continuous monitoring.Condition monitoring: The continuous or periodic measurement and interpretation of data to infer the condition of an equipment to determine its need for maintenance.
36 Maintenance TermsCorrective maintenance: The maintenance carried out after a failure has occurred and intended to restore an equipment to a state in which it can perform its required function.Emergency maintenance: That maintenance which is necessary in order to avoid serious consequences, such as loss of production time and unsafe conditions
37 Maintenance TermsFailure: The termination of the ability of an equipment to perform its required function.Fault: An unexpected deviation from requirements which require corrective action.
38 Maintenance TermsFeedback: A report on the success or failure of an action to achieve its desired objectives and which can be used to improve a process.Forced outage: Outage due to the unscheduled stopping of equipment.
39 Maintenance TermsInspection: The process of measuring, examining, testing, gauging or otherwise detecting any deviations from specifications.Maintainability: The ability of an equipment, under stated conditions of use, to be retained in, or restored to, a state in which it can perform its required function, when maintenance is performed under stated conditions and using prescribed procedures and resources
40 Maintenance TermsMaintenance: The combination of all technical and and associated actions by which an equipment or a system is kept or restored to a state in which it can perform its designated functions.Maintenance history: A history record showing repair, spares, etc. used to assist maintenance planning.
41 Maintenance TermsMaintenance schedule: A comprehensive list of items and the maintenance tasks required, including the intervals at which maintenance should be performed.Planned maintenance: The maintenance organized and carried out with forethought, control, and the use of records to meet a predetermined plan
42 Maintenance TermsOverhaul: A comprehensive examination and restoration of an equipment, or a major part thereof, to an acceptable condition.Preventive maintenance: The maintenance carried out at predetermined intervals or intended to minimize the probability of failure or the performance degradation of equipment.
43 Maintenance TermsRefurbishment: Extensive work intended to bring equipment up to acceptable functional conditions, often involving improvements.Repair: To restore an item to an acceptable condition by the renewal, replacement or replacement of damaged or worn parts.
44 Maintenance TermsRestoration: Maintenance actions intended to bring back equipment to its original conditionsRunning maintenance: Maintenance which can be carried out whilst the equipment is in service.
45 Maintenance TermsShut down maintenance: Maintenance which can only be carried out when the equipment is out of service.Spare stock: Items which are available for maintenance purposes or for the replacement of defective parts.
46 Maintenance TermsWork order: A written instruction giving detail of work to be carried out including detail of spares, manpower, etc.Work requisition: A document requesting work to be carried out
47 Maintenance TermsWork specification: A document describing the way in which the work is to be carried out. It may define the materials, tools, time standards, and procedures.