Introduction and Course overviewIntroduction and Course overview

byby

S. O. DuffuaaS. O. Duffuaa

Module OutlineModule Outline

Role of Maintenance in a Company

Production and Maintenance Relationship

Maintenance as an input output system.

Module OutlineModule Outline

Maintenance costs Maintenance planningMaintenance Strategic Planning Overview of the course

Role of Maintenance

Predictable Plant Capacity Efficient Energy Use Maintenance and Availability Maintenance and Quality Maintenance and Equipment Life Time Maintenance and Energy Use Maintenance and Economy

Organizations’ Objectives include: Meet or exceed customer satisfaction Maximizing profit Meet deliveries Meet set targets Meet set safety standard Zero product defect

Does Maintenance affect these goals?

Role of Maintenance

Maintenance is the backbone of all successful enterprises and contributes to:

Improve Product Quality Reduce Costs Meet Set Targets Improve Utilization Improve Equipment Performance

Figure 1: Dependency between production/Service and Figure 1: Dependency between production/Service and maintenance.maintenance.

Production/ Service

Quality

Maintenance

Equipment Condition

Demand for Maintenance

ProductionCapacity

Primary Input Primary Output

Product Quality

Maintenance CostsMaintenance Costs

1. DIRECT COSTS– Cost of Periodic Inspection– Service Cost – Repair Cost, Overhaul Cost

2. STAND-BY COSTS– Cost of Operating and Maintaining a Standby

Unit

Maintenance CostsMaintenance Costs..

3. LOST PRODUCTION COSTS :– Cost due to Equipment down time.

4. DEGRADATION COST– Cost occurring due to deterioration of the life

span of equipment due to no maintenance or inadequate maintenance.

PLANNING ORGANIZING

MaintenanceProcess

Maintenance PhilosophyMaintenance Load Forecasting

Maintenance Capacity

Maintenance Organization

Maintenance Scheduling

Job Design

Standards

Work Measurement

Project Management

MONITOR

FEEDBACK

CONTROL

Work controlMaterial controlInventory controlCost controlManaging for quality

INPUT OUTPUT

Operational

Machines

Equipment

&

Facilities

Labor

Equipment

Management

Spares

Variations in

Maintenance

Demand

* Scheduling

Maintenance Planning Maintenance Planning activitiesactivities

Planning activities generally include the following :

1. Maintenance philosophy 2. Maintenance load forecasting 3. Maintenance capacity 4. Maintenance organization 5. Maintenance scheduling.

Maintenance StrategiesMaintenance Strategies

1.Breakdown Maintenance (Run To Failure)

2. Fault Finding (FF)

3. Time directed Preventive Maintenance(TD)

4. Condition Based Maintenance (CBD)

5. Design Modification (DM)

6. Replacement Instead of Maintenance

7. Planned Replacement (Car Fleet)

8. Opportunity Maintenance

Maintenance an Internal Part of an Organization

GrowingMaintenance Expectations

Fix it when it broke

Higher plant availability

Longer equipment life

Lower costs

Higher plant availability and reliability

Greater safety

Better product quality

No damage to the environment

Longer equipment life

Greater cost effectiveness 1940 1950 1960 1970 1980 1990 2000

Production System, Maintenance System & Operations System

Relationship

Availability Performance

Conceptual Presentation Of Availability Performance

Maintenance Strategies

Strategic Planning in MaintenanceStrategic Planning in Maintenance Vision Mission Objectives Measures/ balanced scored card Strategies Implementation

Targets or goalsAction plans

VisionVision

“Where you want to be” To be an Award winning department

at the international level. Mission “ Why you exist?”

– Keep plant equipment and assets well configured, safe to operate with the maximum availability maintained with minimum cost.

ObjectivesObjectives

“ What to pursue to achieve mission and objectives.”

Recruit and maintain the best technical staff.

Adopt effective and proactive maintenance strategies using latest knowledge and technology.

Avail the needed spare parts at the minimum cost.

MeasuresMeasures

MTBF for reliability

Availability

Costs

Employee learning

Utilization

StrategiesStrategies

TPM

Intelligent maintenance.

Reliability Centered Maintenance (RCM)

Course OverviewCourse Overview

May15-18, 2005 Day 8:00- 12:00 12:00- 1:00 1:00-3:00

Sunday May, 15

Overview of

Maintenance Strategies

Introduction to RCM

Monday May, 16

RCM Methodology & Tools

RCM Tools

Tuesday May,17

RCM STEPS

RCM Steps with example

Wednesday May,18

RCM Implementation Lu

nch

Case Study