CH17
4
1 Transparency Masters to accompany Heizer/Render – Principles of Operations Management, 5e, and Operations Management, 7e © 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 07458 17-1 Operations Operations Management Management Maintenance and Reliability Maintenance and Reliability Chapter 17 Chapter 17 Transparency Masters to accompany Heizer/Render – Principles of Operations Management, 5e, and Operations Management, 7e © 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 07458 17-2 ♦ All activities involved in keeping a system’s equipment working ♦ Objective: Maintain system capability & minimize total costs © 1995 Corel Corp. Maintenance Management Maintenance Management Transparency Masters to accompany Heizer/Render – Principles of Operations Management, 5e, and Operations Management, 7e © 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 07458 17-3 Maintenance & Reliability Maintenance & Reliability Procedures Procedures ♦ Clean and lubricate ♦ Monitor and adjust ♦ Minor repair ♦ Computerized records Maintenance Procedures © 1995 Corel Corp. Transparency Masters to accompany Heizer/Render – Principles of Operations Management, 5e, and Operations Management, 7e © 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 07458 17-4 Tactics for Tactics for Reliability and Maintenance Reliability and Maintenance ♦ Reliability Tactics ♦ improving individual components ♦ providing redundancy ♦ Maintenance Tactics ♦ implementing preventive maintenance ♦ increasing repair capabilities Transparency Masters to accompany Heizer/Render – Principles of Operations Management, 5e, and Operations Management, 7e © 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 07458 17-5 Reliability of Reliability of Components in Series Components in Series Components in a system are in series if the performance of the entire system depends on all of the components functioning properly. The components need not be physically wired sequentially for the system to be in series. However, all parts must function for the system to function A B Transparency Masters to accompany Heizer/Render – Principles of Operations Management, 5e, and Operations Management, 7e © 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 07458 17-6 Component A Works well Fail 60% 40% Works well Fail 50% for b 50% for b
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CH17
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1
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-1
Operations Operations ManagementManagement
Maintenance and ReliabilityMaintenance and ReliabilityChapter 17Chapter 17
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-2
♦ All activities involved in keeping a system’s equipment working
♦ Objective: Maintain system capability & minimize total costs
© 1995 Corel Corp.
Maintenance ManagementMaintenance Management
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-3
Maintenance & Reliability Maintenance & Reliability ProceduresProcedures
♦Clean and lubricate♦Monitor and adjust♦Minor repair♦Computerized records
Maintenance Procedures
© 1995 Corel Corp.
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-4
Tactics forTactics forReliability and MaintenanceReliability and Maintenance
♦ Reliability Tactics♦ improving individual components♦ providing redundancy
♦ Maintenance Tactics♦ implementing preventive maintenance♦ increasing repair capabilities
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-5
Reliability ofReliability ofComponents in SeriesComponents in Series
Components in a system are in series if the performance of the entire system depends on all of the components functioning properly. The components need not be physically wired sequentially for the system to be in series. However, all parts must function for the system to function
A B
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-6
Component A
Works well
Fail
60%
40%
Works well
Fail
50% for b
50% for b
2
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-7
Reliability ofReliability ofComponents in SeriesComponents in Series
R = R1 * R2 * R3 * ...
1 2 3 ………
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-8
♦ Parallel Reliability♦ Another word for a backup system is a redundant or a parallel system. If a set of components is in
parallel, as opposed to being in series, the system can function if a give component in the system fails
parallel Reliability
AA
BB
Parallel ReliabilityParallel Reliability
Probability of individual
component working 60%
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-9
Component A
Works well
Fail (but still has chance)
60%
40%
Fail
Works well
40% for b
60% for b
Probability of first component working
Probability of needing second component
Probability of second component working
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-10
Providing RedundancyProviding Redundancy
Probability of first
component working
Probability of second component working
+
Probability of needing second component
* = P(R)
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-11
♦ Reliability♦ Probability that an item will function for a given time
♦ Mean time between failures (MTBF)♦ Average time between failures of a repairable item
♦ Failure rate♦ Reciprocal of MTBF
Evaluating MaintenanceEvaluating Maintenance
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-12
Failure Rate (%)Failure Rate (%)
Number of failuresFR(%) = * 100%
Number of units tested
3
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-13
Lifetime Failure RatesLifetime Failure Rates
Infantmortality
andimproper use
failure
“normal” failure Wearoutfailure
Failurerate
LifetimeTransparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-14
Failures Per Operating HourFailures Per Operating Hour
Number of FailuresFR(n) =
Operating Time
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-15
Mean Time Between FailuresMean Time Between Failures
1MTBF =
FR(N)
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-16
♦ How much preventive & breakdown maintenance♦ Who performs maintenance
♦ Centralized, decentralized, operator etc.♦ Contract or in-house
♦ When to replace or repair♦ How much to replace
♦ Individual or group replacement
Maintenance DecisionsMaintenance Decisions
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-17
A Computerized Maintenance SystemA Computerized Maintenance System
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-18
Maintenance Commitment
Cost
Preventive Maintenance CostTotTotal Maintenance Cost
Breakdown Cost
Optimal
Maintenance CostsMaintenance CostsTraditional ViewTraditional View
4
Transparency Masters to accompany Heizer/Render –Principles of Operations Management, 5e, and Operations Management, 7e
© 2004 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745817-19
Maintenance CostsMaintenance CostsFull Cost ViewFull Cost View
Maintenance Commitment
Cost
Optimal
Total costs
Full cost of breakdowns
Preventive maintenance costs
Preventive Maintenance CostTotTotal Maintenance Cost
Breakdown Cost
Optimal
