Maintenance Planning and Control : Modeling and Analysis

1. Maintenance Planning and Control : Modeling and Analysis • Slides on chapter 1

2. Lecture 1 OBJECTIVE 1. 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

3. 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

4. MAINTENANCE BS 3811 : 1964 defines Maintenance as : Work undertaken in order to keep or restore every facility to an acceptable working condition/standard.

5. Maintenance Versus Organization Objectives The objectives and goals of an organization depends on the organization state of mind and type of business. Some objectives are Meet or exceed customer satisfaction Maximizing profit, Meet set targets Meet set safety standard, Zero product defect Does Maintenance affect these goals?

6. In any organization Maintenance is the backbone of all successful enterprises and contributes to: Costs Meet Set Targets Improve Utilization Improve Equipment Improve Product Quality Reduce Performance

7. 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

9. 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.

10. 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

12. Maintenance Planning activities Planning activities generally include the following : 1. Maintenance philosophy 2. Maintenance load forecasting 3. Maintenance capacity 4. Maintenance organization 5. Maintenance scheduling.

13. 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

15. 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.

17. Maintenance Scheduling Maintenance 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.

18. Maintenance Capacity Planning Maintenance 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.

19. 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

21. Organizing Activities 1. Job Design 2. Standard Time 3. Project Management

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

23. 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

24. 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

25. Control activities Control is an essential part of Scientific management. control as applied to maintenance includes: 1. Work control 2. Inventory control 3. Cost control 4. Quality control

26. 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.

27. 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.

28. 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

29. 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.

30. 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

31. Quality Control In 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.

32. Managing For Quality and Training Managing 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.

33. 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.

34. 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.

35. Maintenance Terms Condition-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.

36. Maintenance Terms Corrective 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

37. 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.

38. 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.

39. Maintenance Terms Inspection: 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

40. Maintenance Terms Maintenance: 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.

41. Maintenance Terms Maintenance 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

42. Maintenance Terms Overhaul: 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.

43. 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.

44. 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.

45. Maintenance Terms Shut 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.

46. 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

47. 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.