Optimization of preventive maintenance to reduce maintenance costs and increase equipment...
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Transcript of Optimization of preventive maintenance to reduce maintenance costs and increase equipment...
What is preventive maintenance?
· Overview of the types of preventive
maintenance
· Identifying ideal preventive maintenance
· A practical approach to optimise equipment
availability
· Techniques for optimisation
Maintenance
All activities that maintain facilities and
equipment in good working order so that
a system can perform as designed to
achieve production/services
To keep production systems in good working
order at minimal cost.
Reactive Maintenance:
Breakdown maintenance
Reactive approach; dealing with breakdowns or
problems when they occur
Proactive Maintenance:
Preventive maintenance
Proactive approach; reducing breakdowns through
a program of lubrication, adjustment, cleaning,
inspection, and replacement of worn parts
Production capacity is reduced
Orders are delayed
No production
Overhead continues
Cost per unit increases
Quality issues
Product may be damaged
Safety issues
Injury to employees
Injury to customers
Preventive maintenance: goal is to reduce the
incidence of breakdowns or failures in the plant or
equipment to avoid the associated costs
Preventive maintenance is periodic
Result of planned inspections
According to calendar
After predetermined number of hours
All actions are prevent to failure
Predictive maintenance
An attempt to determine when best to perform
preventive maintenance activities
Total productive maintenance
JIT approach where all stakeholders perform
preventive maintenance on the machines they operate
Time based
Counter based
Predictive maintenance online
maintenance oil
analysis,Thermogrpahy & vibration
anaylsis etc.
Breakdown and
repair cost
Optimum Amount of
preventive maintenance
Co
st
Total Cost
Preventive
maintenance cost
Frequency of breakdown
If the average cost of a breakdown is $1,000, and
the cost of preventative maintenance is $1,250 per
month, should we use preventive maintenance?
Number of breakdowns 0 1 2 3
Frequency of occurrence .20 .30 .40 .10
Number of
Breakdowns
Frequency of
Occurrence
Expected number of
Breakdowns
0
1
2
3
.20
.30
.40
.10
1.00
0
.30
.80
.30
1.40
Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400
Preventive maintenance = $1250
PM results in savings of $150 per month
Normally PM duration and frequency are
evaluated by following manner
OEM recommendations
Past expereicne
Both have additional ideal time to have better
PM in the mind of 100 % equipment availability
even some of equipments/facilities not
required
IDEAL PM CALCULATION SUMMARY
SI.NO EQUIPMENT PM FREQUENCY PM DURATION EQUIPMENT CATEGORY REQUIRED EA
1 EQP A M+ Q 10 NON CRITICAL 50.00
2 EQP B M+ Q 18 MEDIUM CRITICAL 85.00
3 EQP C M+ Q 10 CRITICAL 85.00
4 EQP D BI AN + ANNUAL 36 NON CRITICAL 50.00
5 EQP E W+M+Q 18 CRITICAL 85.00
6 EQP F W+M+Q 18 CRITICAL 85.00
7 EQP G W+M+Q 18 NON CRITICAL 85.00
Differentiation between critical & non critical
equipment's PM Plan
PM Strategy based on essential
PM frequency based on equipment
performance
Including weekly inspection /predictive
approach for critical & most critical
equipments
PRACTICAL APPROACH PM CALCULATION ANALYSIS VS IDEAL
SI.NO EQUIPMENT PM FREQUENCY PM DURATION EQUIPMENT CATEGORY REQUIRED EA Current EA BD hrs
1 EQP A M+ Q 10 NON CRITICAL 50% 100% 0
2 EQP B M+ Q 18 MEDIUM CRITICAL 85% 65% 252
3 EQP C M+ Q 10 CRITICAL 85% 75% 180
4 EQP D BI AN + ANNUAL 36 NON CRITICAL 50% 100% 0
5 EQP E W+M+Q 18 CRITICAL 85% 65% 252
6 EQP F W+M+Q 18 CRITICAL 85% 65% 252
7 EQP G W+M+Q 18 NON CRITICAL 85% 100% 0
Optimization based on analysis
SI.NO EQUIPMENT PM FREQUENCY PM DURATION EQUIPMENT CATEGORY REQUIRED EA Current EA BD hrs
1 EQP A Q 6 NON CRITICAL 50% 99% 2
2 EQP B W+M+ Q 26 MEDIUM CRITICAL 85% 86% 100.8
PM increase on
EQ B 8 hr
BD reduces on
EQ B 151.2
EQUIP B BD ANALYSIS ( TRANSFER ARM,RUBBER GUIDE & PNEUMATIC CYLINDERS)
SI.NO EQUIP E BD ANALYSIS BD hrs % Reason
1 RUBBER GUIDE 138.6 0.55
2 TRANSFER ARM FAILURES 63 0.25 due to nature of operations /services
damages occurs every 144 hrs
3 PNEUMATIC CYLINDERS 50.4 0.2
RUBBER GUIDE TRANSFER ARM FAILURES PNEUMATIC CYLINDERS
1 2 3
BD hrs 138.6 63 50.4
0
20
40
60
80
100
120
140
160
BD
hrs
BD hrs analysis on EQ B
BD hrs 138 63 50
Percent 55.0 25.1 19.9
EQUIP B BD ANALYSIS
PNEU
MAT
IC C
YLIN
DERS
TRAN
SFER
ARM
FAI
LURE
S
RUBB
ER GUI
DE
250
200
150
100
50
0
100
80
60
40
20
0
BD
hrs
Pe
rce
nt
Pareto Chart of EQUIP B BD ANALYSIS
PNEUM
ATI
C C
YLIN
DER
S
T RANSF
E R A
RM F
AIL
URES
RUBBE
R GUID
E
150
100
50
0
PNE U
MATIC
CYLI
NDERS
T RAN
SFE
R A R
M F
AIL
URES
RUBB
ER
GUID
E
150
100
50
0
count = 6
EQUIP B BD ANALYSIS
BD
hrs
count = 8
count = 14
RUBBER GUIDE
TRANSFER ARM FAILURES
PNEUMATIC CYLINDERS
EQUIP B BD ANALYSIS
Pareto Chart of EQUIP B BD ANALYSIS by count
Thank you
Interaction on Implementation