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Chap014s - Maintenance

The document discusses maintenance strategies for facilities and equipment. It describes breakdown maintenance which reacts to problems as they occur and preventive maintenance which aims to reduce breakdowns through planned inspections and part replacements. Preventive maintenance can save costs by avoiding production disruptions and costs associated with breakdowns. The total cost of maintenance includes preventive maintenance costs and breakdown repair costs, with an optimum balance minimizing total costs. Predictive maintenance and total productive maintenance strategies also aim to schedule maintenance optimally.

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78 views12 pages

Chap014s - Maintenance

The document discusses maintenance strategies for facilities and equipment. It describes breakdown maintenance which reacts to problems as they occur and preventive maintenance which aims to reduce breakdowns through planned inspections and part replacements. Preventive maintenance can save costs by avoiding production disruptions and costs associated with breakdowns. The total cost of maintenance includes preventive maintenance costs and breakdown repair costs, with an optimum balance minimizing total costs. Predictive maintenance and total productive maintenance strategies also aim to schedule maintenance optimally.

Uploaded by

spchheda4996
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPS, PDF, TXT or read online on Scribd
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14s-1 Maintenance

Operations Management

William J. Stevenson

8th edition
14s-2 Maintenance
14s-3 Maintenance

Introduction
• Maintenance
• All activities that maintain facilities and equipment in
good working order so that a system can perform as
intended
• Breakdown maintenance
• Reactive approach; dealing with breakdowns or
problems when they occur
• Preventive maintenance
• Proactive approach; reducing breakdowns through a
program of lubrication, adjustment, cleaning,
inspection, and replacement of worn parts
14s-4 Maintenance

Maintenance Reasons

• Reasons for keeping equipment running


• Avoid production disruptions
• Not add to production costs

• Maintain high quality

• Avoid missed delivery dates


14s-5 Maintenance

Breakdown Consequences

• Production capacity is reduced


• Orders are delayed
• No production
• Overhead continues
• Cost per unit increases
• Quality issues
• Product may be damaged
• Safety issues
• Injury to employees
• Injury to customers
14s-6 Maintenance

Total Maintenance Cost


Table 14S.1

Total Cost
Cost

Preventive
maintenance cost

Breakdown and
repair cost

Optimum Amount of
preventive maintenance
14s-7 Maintenance

Preventive Maintenance

• Preventive maintenance: goal is to reduce


the incidence of breakdowns or failures in
the plant or equipment to avoid the
associated costs
• Preventive maintenance is periodic
• Result of planned inspections
• According to calendar
• After predetermined number of hours
14s-8 Maintenance

Example S-1

Frequency of breakdown

Number of breakdowns 0 1 2 3
Frequency of occurrence .20 .30 .40 .10

If the average cost of a breakdown is $1,000,


and the cost of preventative maintenance is
$1,250 per month, should we use preventive
maintenance?
14s-9 Maintenance

Example S-1 Solution


Number of Frequency of Expected number of
Breakdowns Occurrence Breakdowns
0 .20 0
1 .30 .30
2 .40 .80
3 .10 .30
1.00 1.40

ected cost to repair = 1.4 breakdowns per month X $1000 =


entive maintenance = $1250
esults in savings of $150 per month
14s-10 Maintenance

Predictive Maintenance

• Predictive maintenance
• An attempt to determine when best to perform
preventive maintenance activities
• Total productive maintenance
• JIT approach where workers perform
preventive maintenance on the machines they
operate
14s-11 Maintenance

Breakdown Programs

• Standby or backup equipment that can be


quickly pressed into service
• Inventories of spare parts that can be
installed as needed
• Operators who are able to perform minor
repairs
• Repair people who are well trained and
readily available to diagnose and correct
problems with equipment
14s-12 Maintenance

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?

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