Maintenance Management

Maintenance Management

 All activities involved in keeping a system’s

equipment working

 Objective: Maintain system capability &

minimize total costs
 The Strategic Importance of
Maintenance and Reliability

 Failure has far reaching effects on a firm’s

 operation
 reputation
 profitability
 customers
 product
 employees
 profits
Maintenance Performance
Employee Maintenance
Involvement Procedures

Maintenance © 1995
Corel
Corp.
Performance

© 1995 Corel Corp.

 Good Maintenance & Reliability
Strategy
 Requires:
 Employee involvement
 Maintenance and reliability procedures

 To yield:
 Reduced inventory
 Improved quality
 Improved capacity
 Reputation for quality
 Continuous improvement
Maintenance Benefits
Lower
operating Faster, more
Reduced
costs dependable
inventory
throughput

Improved Maintenance Higher

capacity productivity

Continuous Improved
improvement quality
Tactics for Maintenance
 Reliability Tactics
 improving individual components
 providing redundancy

 Maintenance Tactics
 implementing preventive maintenance
 increasing repair capabilities
 Evaluating Maintenance
 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
Failure Rate (%)

Number of failures
FR(%) = * 100%
Number of units tested
 Maintenance Decisions
 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
 Types of Maintenance
Preventive Breakdown
 Routine inspection &  Non-routine
servicing inspection
 Prevents failures & servicing
 Bases for doing  Remedial
 Time: Every day  Basis for doing
 Usage: Every 300  Equipment failure
pieces
 Inspection: Control
chart deviations
Mean Time Between Failure and
Preventive Maintenance

Candidate for preventive

maintenance will have
distribution with low
variability
Frequency
of failure

Mean Time Between Failure

Organizing the
Maintenance Function
 Centralized maintenance department
 Does all maintenance (PM & breakdown)

 Decentralized maintenance department

 Useful if different equipment used in different
areas of company

 Contract maintenance
 Used if little equipment or expertise

 Operator ownership approach

A Computerized Maintenance System
Total Productive Maintenance
 Designing machines that are reliable, easy to
operate and easy to maintain

 Emphasizing total cost of ownership when

purchasing machines, so that service and
maintenance are included in the cost

 Developingpreventive maintenance plans that

utilize the best practices of operators,
maintenance departments, and depot services

 Training workers to operate and maintain their

own machines