Maintenance Organization
-
Upload
umi-nabilah -
Category
Documents
-
view
632 -
download
78
description
Transcript of Maintenance Organization
SYLLABUS
• Maintenance Organization• Maintenance Strategies• System Approach to maintenance• Maintenance Planning and Scheduling• Computer Maintenance Management System
Maintenance Management Management characterises the process
of leading and directing all or part of an organization, often a business one, through the deployment and manipulation of resources (human, financial, material, intellectual or intangible).
The objectives of the MMS
• Optimize the use of available funds, personnel, and facilities and equipment through effective maintenance management methods.
• Provide accurate data for maintenance and construction program decision making.
• Enable preparation of Service maintenance and construction budget requests using systematic and standardized procedures.
• Monitor and document corrective actions, project expenditures, and accomplishments.
Objective and benefit of maintenance management
The main objectives of having maintenance management are to make sure a business doesn't stop producing, and if it does, to rectify the situation in the safest and most expedient way possible.
In addition, improperly maintained equipment can lead to safety hazards, employee abuse and misuse of machines that will lead to increased overhead costs and potential liability.
Costs of new equipment must be budgeted. Maintenance factors are part of the calculations done to consider return on investment when comparing costs and risks.
Maintenance• All actions necessary for retaining an
item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification• Increase availability of a system• Keep system’s equipment in working
order
Purpose of Maintenance• Attempt to maximize performance of
production equipment efficiently and regularly• Prevent breakdown or failures• Minimize production loss from
failures• Increase reliability of the operating
systems
Principle Objectives in Maintenance
• To achieve product quality and customer satisfaction through adjusted and serviced equipment
• Maximize useful life of equipment• Keep equipment safe and prevent safety hazards• Minimize frequency and severity of interruptions• Maximize production capacity – through high utilization
of facility• Must be consistent with the goals of production (cost,
quality, delivery, safety)• Must be comprehensive and include specific
responsibilities
Maintenance Process Description of the object condition-
The most important element in this area is the maintenance notification. This is used to describe the condition of the technical object or to report a malfunction at a technical object and request the damage is repaired.
Execution of maintenance tasks-The most important element in this area is the maintenance order. This is used to plan the execution of maintenance activities in detail, monitor the progress of work and settle the costs of maintenance tasks.
Completion of maintenance tasks-The most important element in this area is the maintenance history. This is used for long-term saving of the most important maintenance data. This data can be called up for evaluation at any time.
IMPACT OF POOR MAINTENANCE
MAINTENANCE
ORGANIZATION
Type of maintenance organization
• The selection of a particular type of system will largely depend upon the main structure of an industry. Maintenance organization can be of the following types:• Decentralized• Centralized
DECENTRALIZED DECENTRALIZED In large size plants located at different places, inter unit
communication is difficult.
The decentralized type of organization is best suited, which means that the maintenance organization works under the direct control of a chief engineer in-charge of production.
Under this type of organization, better coordination between production and maintenance groups is possible because of a common head of organization.
The advantages of such type of organization are:
•Speedy decisions due to better line of communication under single control.•Maintenance and production people understand each other’s problems better because of their common goals.•Better training at the workers’ level can be arranged.
CENTRALIZED• In a small factory where communication between
the departments is freer, the centralized type of maintenance organization is preferred, which is placed under a chief maintenance engineer/manager.
• The total responsibility of the maintenance function for the entire factory lies with the chief maintenance engineer.
• Under this type of organization, the responsibilities and accountability of work must be properly specified for production as well as maintenance personnel to successfully meet the project goals.
• If this is not taken care of, one department may blame other for any shortfall.
Role/responsibility of Maintenance Organization
Maintenance Organization are responsible for : the safe and efficient operation of fixed and rotational
equipment under their span of control. ensuring that all systems of work are carried out safely in
accordance with regulatory and company policies and procedures.
ensuring that all replacement components are available and that all personnel under their management are competent.
Maintenance Plant Managers must also operate within a cost effective environment.
Maintenance Coststhe costs associated with
keeping an item in good condition by regularly checking it and repairing it when necessary
Source of Maintenance Cost
Down time (production loss) Overhead Losses of output Delayed shipment Scrap and rework
Types of Maintenance Costs
Cost to replace or repair Labor Hand tools, power tools and
equipment Spare parts
Who will do maintenance?
• In-house•Out-source
Decision to out-source
• Lack of expertise• Too hazardous• No experience• Bound by contract• Top management policy
Maintenance Costs
Figure 17.4 (a)
Total costs
Breakdown maintenance costs
Cos
ts
Maintenance commitment
Traditional View
Preventive maintenance costs
Optimal point (lowestcost maintenance policy)
Figure 17.4 (b)
Cos
ts
Maintenance commitment
Full Cost View
Optimal point (lowestcost maintenance policy)
Total costs
Full cost of breakdowns
Preventive maintenance costs
Maintenance Cost
Example
The record of computer breakdown for Company PCK for the past 20 months is shown below.
# of breakdown # of months breakdown occurs0123
4862
Total 20
• Each time computer breakdown – estimated loss is RM300
• Contract preventive maintenance by company DK – RM200 per month
• Should PCK contract out preventive maintenance to DK?
SolutionStep 1Calculate expected number of breakdown (based on past
records) if the company continue without service contract.Step 2Compute expected breakdown cost per month with no
preventive maintenance contractStep 3Compute the cost of preventive maintenanceStep 4• Compare the two options and select the one which cost less
Solution
# of breakdown Frequency
0123
4/20 = 0.28/20 = 0.46/20 = 0.32/20 = 0.1
Step 1
Expected # of breakdowns = (# of breakdown) x (frequency)
= (0)(0.2)+(1)(0.4)+(2)(0.3)+(3)(0.1)
= 1.3 breakdown per month
Step 2Expected breakdown cost = (expected # of breakdown) x (cost per breakdown)= (1.3) x (300)= RM390 per month
Solution
Solution
Step 3 Calculate Preventive Maintenance Cost
= cost of expected breakdown + cost of service contract
= (1 breakdown per month x 300) + RM220 per month
= RM520 per month
Step 4 Compare
Less expensive to suffer breakdown without service contract.
Breakdown = RM390
Service contract = RM520
Therefore, continue present policy.
Need to consider
• Customer service• Loss of production• Loss of customer goodwill, reputation• Machine life• Availability of spare parts and expertise • Safety to the user / customer• Environmental problem (pollutant discharge
etc.)
Maintenance Cost Example
Should the firm contract for maintenance on their printers?
Number of Breakdowns
Number of Months That Breakdowns Occurred
0 2
1 8
2 6
3 4Total : 20Average cost of breakdown = $300
Maintenance Cost Example1. Compute the expected number of
breakdownsNumber of
BreakdownsFrequency Number of
BreakdownsFrequency
0 2/20 = .1 2 6/20 = .31 8/20 = .4 3 4/20 = .2
∑ Number of breakdowns
Expected number of breakdowns
Corresponding frequency= x
= (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2)= 1.6 breakdowns per month
Maintenance Cost Example
2. Compute the expected breakdown cost per month with no preventive maintenance
Expected breakdown cost
Expected number of breakdowns
Cost per breakdown= x
= (1.6)($300)= $480 per month
Maintenance Cost Example3. Compute the cost of preventive
maintenance
Preventive maintenance cost
Cost of expected breakdowns if service contract signed
Cost of service contract
=+
= (1 breakdown/month)($300) + $150/month= $450 per month
Hire the service firm; it is less expensive
Increasing Repair Capabilities
1. Well-trained personnel2. Adequate resources3. Ability to establish repair plan and priorities4. Ability and authority to do material
planning5. Ability to identify the cause of breakdowns6. Ability to design ways to extend MTBF
How Maintenance is Performed
Figure 17.5
Operator(autonomous maintenance)
Maintenance department
Manufacturer’s field service
Depot service(return equipment)
Increasing Operator Ownership Increasing Complexity
Preventive maintenance costs less and is faster the more we move to the left
Competence is higher as we move to the right
Cost and Budget Control System
• Cost management and budget control is often one of the trickiest parts of the project management process.
Cost and Budget Control SystemCharacteristics of a budget •A good budget is characterised by the following: · Participation: involve as many people as possible in drawing up a budget.· Comprehensiveness: embrace the whole organisation.· Standards: base it on established standards of performance.· Flexibility: allow for changing circumstances.· Feedback: constantly monitor performance.· Analysis of costs and revenues: this can be done on the basis of product lines, departments or cost centres
Why costs and budget need to be controlled?
If you budget and do not control the spending then how do you know what is received and spent.
If the receipts and spending of the receipts are not controlled then you have uncontrolled spending and since money spends faster than it is earned in most instances one would find themselves without the resources needed for the budget, the project or the results desired in the budgeting process.
Analysis effective and non-effective maintenance
An effective maintenance system includes the following elements:
• Maintenance Policy• Control of materials • Preventive Maintenance• Condition Monitoring• Work Order • Job planning• Priority and backlog control • Data recording system • Performance measurement measures or indices
MAINTENANCE AUDITS• The maintenance audit is a review of the maintenance function from within the
overall organisation taking into account all the various functions within the organisation. The purpose of a Maintenance Audit is to derive a Maintenance strategy, which aims to deliver improvements to the general maintenance function, provide clearer communications and to develop a set of Best Practices for the maintenance function.
• Maintenance Audits can prove vital to your organisation. It is very important to measure the performance of the maintenance function whether you have an existing Maintenance strategy or not. A dysfunctional maintenance function can adversely affect the following:
• Performance targets not being met due to breakdowns• Low morale of engineering personnel• Ratio of breakdown to Planned Maintenance very high• Over- purchasing and double-purchasing of Maintenance Spares• Purchasing of incorrect maintenance spares• Unnecessary Planned Maintenance• Machinery over-maintained
AIM • The aim of a maintenance audit, which is the main
consideration of this policy sector, is to determine whether the way forward is correctly defined and is being followed.
• The audit should measure the effectiveness of the normal practices and reveal whether improvements are required.
• Increasing awareness of the maintenance contribution.• From this, action plans may evolve which will sharpen up
not only the maintenance strategy, but also the way in which the maintenance operations and technologies are applied. Any changes should not be made just for the sake of change, and they should be translated into economic benefit and added value.
Audit Question
Apply KPIWhat are KPIs?•KPIs measure parameters which describe an aspect of the current state of your operation whether at departmental level or board level•They can be compared over time to indicate changes or trends•Their nature & range will vary from company to company •They will be derived from the stated Business Objectives
Maintenance impacts on: – The condition of a company's assets – The output of a company's assets
• Organizations looking to find the most effective ways of managing and improving maintenance operations discover: – in order to manage maintenance effectively first of all we need to learn how to measure it
Why Measure?• “Until you can measure something and express it in numbers, you have only the beginning of understanding”•William Thomson [Lord Kelvin (1824-1907) “You cannot manage what you cannot measure”Attributed to Bill Hewlett (1930-2001), Co-founder of Hewlett-Packard
• Maintenance Influencing Factors• External Influencing Factors• Location, Society, Culture, Labour Cost• Market Situation, Laws, Regulations• Internal Influencing Factors• Company Culture, Process Severity• Product Mix, Plant Size, Utilization Rate• Age of Plant, Criticality
CONCLUSIONS To achieve cost effective maintenance, it is necessary to implement a maintenance program using a
staged process with key steps Without clear definition of requirements, Achievements
and feedback, measurement is not possible Measurement of effectiveness through monitoring key performance indicators is only possible if each stage has been completed Without measurement, management and optimisation
is not possible