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Introduction and Course overview

by

S. O. Duffuaa

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Module Outline

  Role of Maintenance in a

Company Production and

Maintenance Relationship Maintenance as an input

output system.

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Module Outline

 Maintenance costs

Maintenance planningMaintenance Strategic

Planning

Overview of the course

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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

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  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

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Maintenance is the backbone of all

successful enterprises and contributes

to:

Improve Product Quality

Reduce Costs

Meet Set Targets

Improve Utilization

Improve Equipment Performance

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Figure 1: Dependenc y between produc t ion/Service and 

maintenance.

Production/

Service

Quality

Maintenance

Equipment Condition

Demand for

Maintenance

Production

Capacity

Primary Input Primary Output

Product Quality

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Maintenance Cos ts 

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

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Maintenance 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.

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PLANNING ORGANIZING

Maintenance

Process

Maintenance Philoso h

Maintenance Load Forecasting

Maintenance Capacity

Maintenance Organization

Maintenance Scheduling

Job Design

Standards

Work Measurement

Project Management

MONITOR

FEEDBACK

CONTROL

Work control

Material control

Inventory control

Cost control

Managing for quality

INPUT OUTPUT

Operational

Machines

Equipment

&

Facilities

Labor 

Equipment

Management

Spares

Variations in

Maintenance

Demand

* Scheduling

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Maintenance Plann ing 

activi t ies  Planning activities generally include the

following :

1. Maintenance philosophy 2. Maintenance load forecasting

3. Maintenance capacity

4. Maintenance organization 5. Maintenance scheduling.

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Main tenance Strateg ies 

1. Breakdown Maintenance (Run ToFailure)

2. Fault Finding (FF)

3. Time directed PreventiveMaintenance(TD)

4. Condition Based Maintenance (CBD)

5. Design Modification (DM)6. Replacement Instead of Maintenance

7. Planned Replacement (Car Fleet)

8. Opportunity Maintenance

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Maintenance an Internal Part of anOrganization

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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 effectiveness1940 1950 1960 1970 1980 1990 2000

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Production System, MaintenanceSystem & Operations System

Relationship

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 Availability Performance

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Conceptual PresentationOf Availability Performance

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Maintenance Strategies

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Strategic Planning in Maintenance

Vision

Mission

Objectives

Measures/ balanced scored card

Strategies

Implementation

Targets or goals

 Action plans

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Vision

 “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 themaximum availability maintained with

minimum cost.

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Objectives

  “ What to pursue to achieve missionand objectives.” 

  Recruit and maintain the besttechnical staff.

Adopt effective and proactivemaintenance strategies using latest

knowledge and technology.    Avail the needed spare parts at the

minimum cost.

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Measures

MTBF for reliability

Availability

Costs

Employee learning

Utilization

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Strategies

TPM

Intelligent maintenance.

  Reliability Centered Maintenance

(RCM)

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Course Overview

May15-18, 2005Day 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    L

  u  n  c   h

Case Study