Maintenance Planning and Control : Modeling and Analysis

Slides on chapter 1

Lecture 1 OBJECTIVE1. Enable Students To Understand The Role of Maintenance in Meeting

Organizational Objectives. 2. Enable Students To View

Maintenance As A System That Has Activities That Needs Planning, Organizing , Designing,

Measurement and Control

Maintenance

Maintenance is defined as the combination of activities by which equipment or a system is kept or restored to a state in which it can perform its designated function. It is an important factor in product quality control and can be used as a strategy for successful competition

MAINTENANCE

BS 3811 : 1964 defines Maintenance as :

Work undertaken in order to keep or restore every facility to an acceptable working condition/standard.

Maintenance Versus Organization ObjectivesThe objectives and goals of an organization

depends on the organization state of mind and type of business. Some objectives areMeet or exceed customer satisfactionMaximizing profit, Meet set targetsMeet set safety standard, Zero product defect

Does Maintenance affect these goals?

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

CostsMeet Set TargetsImprove UtilizationImprove Equipment Improve Product QualityReduce Performance

Maintenance Versus Organization Objectives

A system is a collection of components that work together towards a common objective. Maintenance can be considered as a system with a set of activities carried out in parallel with production systems. A diagrammatic relationship among organizational objectives, the production process, and maintenance is shown in Figure 1.1

Organizationalobjectives

QuantityQuality

Delivery

Productionprocess OutputInput

Feedback

Productioncapacity

Maintenanceprocess

Demand formaintenance

Maintenance System Output

• A maintenance system can be viewed as a simple input output model. The inputs to such a model are labor, management, tools, spares, equipment, etc. and the output is equipment that is up, reliable and well configured to achieve the planned operation of the plant.

Maintenance System Output

• This enables us to optimize the resources for maximizing the output of a maintenance system. A typical maintenance system is shown in Figure 1.2. Activities needed to make this system functional, namely, planning, organizing, and control, are shown in this figure

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 activitiesPlanning activities generally include the following :1. Maintenance philosophy2. Maintenance load forecasting3. Maintenance capacity4. Maintenance organization5. Maintenance scheduling.

MAINTENANCE STRATEGIES(MAINTENANCE FORM)

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

Fault finding

Maintenance strategies

Replacement Overhaul Preventive maintenance

Design modification

Breakdown/ corrective or run to failure

Condition

based

Statistically and reliability based

Off line On line Time based

Use based

Maintenance strategies

Replacement Overhaul Preventive maintenance

Design modification

Breakdown/ corrective or run to failure

Condition

based

Statistically and reliability based

Off line On line Time based

Use based

Opportunity Maintenance

Maintenance Load Forecasting

Maintenance load is a random variable

and forecasting is the process by which

maintenance load is predicted. Load

forecasting is essential for capacity

planning. Many factors affect the load,

they include equipment age, climate,

quality of maintenance, etc.

Information on most recentmaintenance load demand andbacklog of maintenance work

Maintenanceload forecasting

Maintenance Maintenancemaintenance systemcapacity planning scheduling

Controlling

maintenance systemOutput of

Maintenance SchedulingMaintenance scheduling is the process of assigning resources and manpower for jobs to be accomplished at certain times. It is necessary to ensure that the needed craftsmen, the parts, and materials required are available before a maintenance task can be scheduled.

Maintenance Capacity PlanningMaintenance capacity planning determines the resources needed to meet the demand for maintenance work. Those resources include manpower, material, spare parts, equipment, and tools. Critical aspects of maintenance capacity are the numbers and skills of craftsmen, required maintenance tools, etc.

Maintenance Organization

Maintenance Organization Depends On Maintenance Load, Plant Size, Trade and Skill, Maintenance Could Be Centralized Or Decentralized Or A Combination of Both. See Figure 1.5 In Text Book

Production

area A

Production

area B

Production

area C

Maintenance

for production

area A

Maintenance

for production

area C

Maintenance

for production

area B

Overload

Overload

Overload

maintenance

Central

unit

contractor

Outside

help

Overload

Organizing Activities

1. Job Design

2. Standard Time

3. Project Management

Job Design

Job design, as related to maintenance work, comprises the work content of each job and deter mines the method that is to be used, special tools needed, and the skilled persons required.

Time Standards

Time Standards are Needed For Effective Planning. It is The Time That Takes A Qualified Worker Worker At 100% Pace To Complete The Job. Techniques Used For Developing Time standards Are Work Measurement, Work Sampling. Estimation and Slotting

Project Management

Techniques Such As CPM, PERT Are Needed For Large Jobs Such as Overhauls.They will Enable Better Control OF Cost and work. They Usually Results In Better Utilization Of Resources

Control activities

Control is an essential part of Scientific management. control as applied to maintenance includes:1. Work control2. Inventory control3. Cost control4. Quality control

Work Control. The management and control of the

maintenance work is essential for achieving set plans. The work order system is the tool used for controlling the maintenance work. A well designed work order with a sound reporting system is the heart of the maintenance system The essential tools for effective control of the maintenance work including the design of a work order are covered in chapter 2.

Inventory Control

Material and spare parts are essential for maintenance work. Prior to scheduling maintenance work spare parts must be available. Techniques for inventory control are covered in chapter 7 of the text.

MAINTENANCE 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 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.

Cost Control

The control of maintenance cost optimizes all the costs in maintenance, while achieving, set organizational objectives such as: availability, “Quality Rate”, and other efficiency and effectiveness measures. Cost reduction and control can be used as an edge for competition in providing products and services. The issues related to cost and its control are presented in chapters 2 and 10

Quality ControlIn the case of maintenance work "doing it right the first time" is very essential. Quality may be assessed as the percentage of accepted maintenance jobs according to the standard adopted by the organization. High Quality is usually assured by checking the critical maintenance jobs or by maintenance supervision. The details of maintenance quality control are presented in chapter 8.

Managing For Quality and TrainingManaging for quality is a managerial responsibility.. The key for managing for quality lies first in the awareness of the need to improve and second in selecting appropriate improvement techniques. Chapter 12 focuses on the aspects of continuous improvement.

Human Behavior Managers should try to know how the behavior of subordinates can affect management's planning, organizing, and controlling actions. In maintenance decision making, behavior of subordinates should be of interest to management. It should be ensured that the desired level of craftsmen satisfaction is achieved and maintained.

Maintenance Terms

Availability: The ability of an equipment to successfully perform its required function at a stated instant of time or over a stated period of time.

Breakdown: Failure resulting in the non-availability of an equipment.

Maintenance TermsCondition-based maintenance: The preventive maintenance initiated as a result of knowledge of the condition of an equipment observed through routine or continuous monitoring.

Condition monitoring: The continuous or periodic measurement and interpretation of data to infer the condition of an equipment to determine its need for maintenance.

Maintenance TermsCorrective maintenance: The maintenance carried out after a failure has occurred and intended to restore an equipment to a state in which it can perform its required function.

Emergency maintenance: That maintenance which is necessary in order to avoid serious consequences, such as loss of production time and unsafe conditions

Maintenance Terms

Failure: The termination of the ability of an equipment to perform its required function.

Fault: An unexpected deviation from requirements which require corrective action.

Maintenance Terms

Feedback: A report on the success or failure of an action to achieve its desired objectives and which can be used to improve a process.

Forced outage: Outage due to the unscheduled stopping of equipment.

Maintenance TermsInspection: The process of measuring, examining, testing, gauging or otherwise detecting any deviations from specifications.

Maintainability: The ability of an equipment, under stated conditions of use, to be retained in, or restored to, a state in which it can perform its required function, when maintenance is performed under stated conditions and using prescribed procedures and resources

Maintenance TermsMaintenance: The combination of all technical and and associated actions by which an equipment or a system is kept or restored to a state in which it can perform its designated functions.

Maintenance history: A history record showing repair, spares, etc. used to assist maintenance planning.

Maintenance TermsMaintenance schedule: A comprehensive list of items and the maintenance tasks required, including the intervals at which maintenance should be performed.

Planned maintenance: The maintenance organized and carried out with forethought, control, and the use of records to meet a predetermined plan

Maintenance TermsOverhaul: A comprehensive examination and restoration of an equipment, or a major part thereof, to an acceptable condition.

Preventive maintenance: The maintenance carried out at predetermined intervals or intended to minimize the probability of failure or the performance degradation of equipment.

Maintenance Terms

Refurbishment:Extensive work intended to bring equipment up to acceptable functional conditions, often involving improvements.

Repair: To restore an item to an acceptable condition by the renewal, replacement or replacement of damaged or worn parts.

Maintenance Terms

Restoration: Maintenance actions intended to bring back equipment to its original conditions

Running maintenance: Maintenance which can be carried out whilst the equipment is in service.

Maintenance TermsShut down maintenance: Maintenance which can only be carried out when the equipment is out of service.

Spare stock: Items which are available for maintenance purposes or for the replacement of defective parts.

Maintenance Terms

Work order: A written instruction giving detail of work to be carried out including detail of spares, manpower, etc.

Work requisition: A document requesting work to be carried out

Maintenance Terms

Work specification: A document describing the way in which the work is to be carried out. It may define the materials, tools, time standards, and procedures.