Presentation Transcript
Slide 1:William J. Stevenson Operations Management 8th edition
Slide 2:CHAPTER 14s Maintenance McGraw-Hill/Irwin Operations Management, Eighth Edition, by William J. Stevenson
Copyright © 2005 by The McGraw-Hill Companies, Inc. All rights reserved.
Introduction :Introduction Maintenance
All activities that maintain facilities and equipment in good working order so that a system can perform as intended
Breakdown maintenance
Reactive approach; dealing with breakdowns or problems when they occur
Preventive maintenance
Proactive approach; reducing breakdowns through a program of lubrication, adjustment, cleaning, inspection, and replacement of worn parts
Maintenance Reasons :Reasons for keeping equipment running
Avoid production disruptions
Not add to production costs
Maintain high quality
Avoid missed delivery dates Maintenance Reasons
Breakdown Consequences :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 Breakdown Consequences
Total Maintenance Cost :Total Maintenance Cost Table 14S.1
Preventive Maintenance :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 Preventive Maintenance
Example S-1 :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? Example S-1
Example S-1 Solution :Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400
Preventive maintenance = $1250
PM results in savings of $150 per month Example S-1 Solution
Predictive Maintenance :Predictive Maintenance Predictive maintenance
An attempt to determine when best to perform preventive maintenance activities
Total productive maintenance
JIT approach where workers perform preventive maintenance on the machines they operate
Breakdown Programs :Breakdown Programs Standby or backup equipment that can be quickly pressed into service
Inventories of spare parts that can be installed as needed
Operators who are able to perform minor repairs
Repair people who are well trained and readily available to diagnose and correct problems with equipment
Replacement :Replacement Trade-off decisions
Cost of replacement vs cost of continued maintenance
New equipment with new features vs maintenance
Installation of new equipment may cause disruptions
Training costs of employees on new equipment
Forecasts for demand on equipment may require new equipment capacity
When is it time for replacement?