Introduction to maintenance Importance of maintenance Types of maintenance INTRODUCTION
Def: all the activities involved in keeping an
operating system (machines, robots, automations, tools, equipment or instruments) in good working order. (Heizer and Render, 2011)
Maintenance also can be defined as activities
relating to keeping the entire production / operations system facilities or specific equipment in the system in operating condition.
It is concerned with avoiding or minimizing
downtime or to avoid undesirable results due to system failure. Downtime refers to work stoppage or production interference resulting from machine failure or breakdown. (Roaimah Omar, 1999).
Regular maintenance will enhance the reliability of
machines.
Reliability is the probability that a machine will
function properly for a specified time under stated conditions. (Heizer and Render, 2011) IMPORTANCE OF MAINTENANCE
Can avoid work stoppage and ensure that the loss of
production time and cost are minimized. To keep the entire production system running smoothly with minimum interruption.
To reduce production cost such as idle labor cost and
overtime cost.
To ensure that the entire workplace is a safe place to
work for its employees.
To establish a competitive edge and to enhance good
customer service.
To avoid delays in production schedules and deliveries,
thus the companies can meet customers demand. TYPES OF MAINTENANCE 1) Breakdown maintenance
Breakdown maintenance is when an equipment
malfunctions or damaged and immediate repairs are needed to put it back to working condition.
Includes repairs, replacement of parts, or even
renovate to ensure the machines is put back in operating condition.
Breakdown maintenance occurs when equipment
fails and must be repaired on emergency basis and restored back to working conditions. 2) Preventive maintenance
It involves performing routine inspections and servicing and
keeping facilities in good repair. These activities are intended to build a system that will find potential failures and make changes or repairs that will prevent failure.
Preventive maintenance is much more than just keeping
machinery and equipment running. (Heizer and Render, 2011)
The main objectives:
1) To reduce the frequency and severity of interruptions to production caused by machine malfunctions.
2) To detect potential failures in the plant or equipment to
avoid the associated costs (e.g: loss of output, injuries, damage to other equipment or products) and make changes or repairs to prevent failure. FORMULA:
Expected cost for breakdown
= Expected no of breakdown x cost of each breakdown
Expected cost for preventive maintenance
= Cost of preventive maintenance + (cost of breakdown x average no of breakdown) Comparing preventive and breakdown maintenance costs.