Maintenence Planning

7/30/2019 Maintenence Planning

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Maintenance Planning

Planning of maintenance jobs basically deals

with answering two questions, what and Howof the job; what activities are to be done? and

how those jobs and activities are to be done?

PRODUCTION MANAGEMENT


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Steps of Job Planning

1. Knowledge base: It includes knowledge about equipment, job,

available techniques, materials and facilities.

2. Job investigation at site: It gives a clear perception of the total

jobs.3. Identify and document the work: Knowing the earlier two

steps and knowing the needs of preventive, predictive and

other maintenance jobs.

4. Development of repair plan: Preparation of step by stepprocedures which would accomplish the work with the most

economical use of time, manpower and material.



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5. Preparation tools and facilities list indicating the needs ofspecial tools, tackles and facilities needed.

6. Estimation of time required to do the job with work

measurement technique and critical path analysis.



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REASONS FOR GENERATION

AND ACCUMULATION OFOBSOLETE, SURPLUS AND

SCRAP ITEMS.



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1. Changes in product design

2. Cannibalization

3. Faulty planning and forecasting4. Faulty purchase practices

5. Other causes


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IDENTIFICATION AND CONTROL OF WASTE


The combining process of combining the stock

records and movement analysis has been found

very effective in locating such stocks in the

total inventory.Sl. No. Part description A

B

C

Date of issue Stock on

hand

Value


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Whenever changes in production programme,design and product lines are contemplated, a

senior executive from materials management

must definitely be kept in the picture. This helpsin several ways. He is in a position to inform topmanagement of the amount of stock of materialson hand that are likely to be rendered obsolete if

and when the changes are introduced.



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Disposal of scrap when handled in an imaginativemanner can result in handsome returns to the

organization. An effective disposal requires acompact disposal organization reporting to thematerials manager, continuous market survey onthe prices of various categories of scrap generatedin the plant and constant touch with the industrieswhich generate similar scrap and with the end-users.


DISPOSAL OF SCRAP


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AUTOMATION

Automation is a technology concerned with theapplication of mechanical, electronic, and

computer based systems to operate and control

production.



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TYPES OF AUTOMATION

1. Fixed automation,

2. Programmable automation, and

3. Flexible automation.


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1. FIXED AUTOMATION The typical features of fixed automation are:

(a) High initial investment for customEngineeredequipment.

(b) High production rates.

(c) Relatively inflexible in accommodating product changes.


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2. PROGRAMMABLE AUTOMATION


(a) High investment in general-purpose equipment.

(b) Low production rates relative to fixed automation.

(c) Flexibility to deal with changes in product configuration.(d) Most suitable for batch production.


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3. FLEXIBLE AUTOMATION

(a) High investment for a custom-engineered system.

(b) Continuous production of variable mixtures of

products.

(c) Medium production rates.

(d) Flexibility to deal with product design variations.


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REASONS FOR AUTOMATION

1. Increased productivity

2. High cost of labour

3. Labour shortages

4. Trend of labour toward the service sector

5. Safety6. High cost of raw materials


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7. Improved product quality

8. Reduced manufacturing lead time

9. Reduction of in-process inventory

10. High cost of not automating


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AUTOMATION STRATEGIES


1. Specialization of operations.

2. Combined operations.

3. Simultaneous operations.4. Increased flexibility.

5. Improved material handling and storage

systems.


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7. On-line inspection.8. Process control and optimization.

9. Plant operations control.

10. Computer integrated manufacturing(CIM).


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COMPUTER INTEGRATED

MANUFACTURING


The computers had done a dramatic impact on the

development of production automation technologies.

Nearly all modern production systems are implemented

today using computer systems. The term computerintegrated manufacturing (CIM) has been coined to

denote the pervasive use of computers to design the

products, plan the production, control the operations, and

perform the various business related functions needed ina manufacturing firm. Computer Aided Design and

Computer Aided Manufacturing (CAD/CAM) in another

term that is used synonymously with CIM.


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AUTOMATED FLOW LINES


An automated flow line consists of several

machines or workstations which are linked

together by work handling devices that

transfer parts between the stations.


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Production

Auto 1

Production

Auto 2

Production

Auto 4

Production

Auto 3

Production

Auto 5


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The objectives of the use of flow lineautomation are:

1. To reduce labor costs.

2. To increase production rates.3. To reduce work-in-process.

4. To minimize distances moved between operations.

5. To achieve specialization of operations.

6. To achieve integration of operations.


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In-line Type Rotary Type

There are two general forms that theworkflow can take.


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AUTOMATED GUIDED VEHICLESSYSTEMS

An automated or automatic guided vehicle

system (AGVS) is a materials handlingsystem that uses independently operated,

self-propelled vehicles that are guided along

defined pathways in the floor.


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Types of AGVS

1. Driverless trains: The type consists of a towing

vehicle (which is the AGV) that pulls one or

more trailers to form a train.


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2. AGVS pallet trucks: Automated guided pallet trucks are used to

move palletized loads along predetermined routes. In thetypical application the vehicle is backed into the loaded pallet

by a human worker who steers the truck and uses its forks to

elevate the load slightly.


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3. AGVS unit load carriers: This type of AGVSis used to move unit loads from one station to

another station. They are often equipped for

automatic loading and unloading by means ofpowered rollers, moving belts, mechanized lift

platforms, or other devices.


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END

Maintenence Planning

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