facility maintenance. typical job categories for maintenance plant maintenance general mechanics...
TRANSCRIPT
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Facility Maintenance
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Typical Job Categories for Maintenance Plant Maintenance Electricians Tinsmiths Welders Pipe fitters Fire/emergency People Steam fitters
Bricklayers Painters Glaziers Concrete Workers Carpenters Millwrights
Heavy Movers Window Washers Janitors Gardeners
Machine Maintenance
General Mechanics Machinists Sheet Metal Workers Welders Electronic Technician Computer Technicians
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MAINTENANCE PROCEDURES Emergency Maintenance Preventative Maintenance
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CLASS EXERCISE - EMERGENCY STAND-BY CAPACITY A production line has 20 electric resistance welders It costs $40 per day to won each welder If one or two welders are down, replacement spares can be rented at $50 per day per
machine If 3,4, or 5 welders are out, they can be rented but production slow downs result and
the total cost is $100 per day per extra machine (rental + slow down) If 6 or more machines are out, the total cost (rental + slow down) is $500 per day per
extra machine
Objective: Calculate how many spare welders need to be purchased by your company to minimize the total operating costs.
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Cost to Rent Number of Machines Out of OrderProbability that Number of Machines will be broken: Total =100%
Emergency – Standby Capacity
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We have a line with 50 robot GMA weldersThe cost to do a preventative maintenance overhaul
on each machine is $200/machineAverage breakdown repair costs are $700/machine
Objective: Calculate the cost if we elect to repair only when a machine breaks down. How much must we set
aside each month?
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Probability of Breakdown as a function of months after overhaul of all machines.
1.00
The months time the probability results in the partial expected time for failure.
Since the partial probabilities add to 100%, the partial times add to the expect time for a failure = 8.42 months
They Add to 100%
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The cost of repair-on-breakdown then = ($700/machine) /(8.42 months) * 50 machines
= $4157/month Thus, we better place $4157 in a fund every month if we decide to do repair-on-breakdown policy.
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We have a line with 50 robot GMA weldersThe cost to do a preventative maintenance overhaul
on each machine is $200/machineAverage breakdown repair costs are $700/machine
Objective: Calculate if preventative maintenance should be done and if so what the schedule should be.
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Calculate Cost for Preventative Maintenance
For every preventative maintenance overhaul we do it will cost:
= $200/machine * 50 machines = $10,000
If we do a preventative maintenance every month, it will cost $10,000/month
If we do a preventative maintenance every 2 months, it will cost $5,000/month, etc.
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Even though we do preventative maintenance, we can expect some breakdowns to occur anyway. We can calculate the number of expected breakdowns each month using the following equation.
Where:Bn = expected number of breakdowns
N = number of machinesPn = probability of machine
breakdown in period n
1n122n11n
n
1nn PB......PBPBPNB
50.2)05.0(50NPB 11 That is, 2.5 breakdowns in the first month
63.3)05(.50.2)02.05(.50PB)PP(NB 11212 That is, 3.63 breakdown in first 2 months
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Expected Cost = Ave. Number * $700/machine = 2.5 * $700 = $1750
Total Cost = Expected Cost + Prev. Maint. Cost = 1750 + 10000 = 11750
PL
OT
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$4157
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