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Maintenance Strategies Course Overview

This document provides an overview of a course on maintenance strategies and reliability centered maintenance (RCM). It includes the following key points: - The course will cover topics such as the role of maintenance in organizations, maintenance costs, planning, and strategic planning. - Maintenance is important for meeting organizational objectives like customer satisfaction, profits, and safety standards. It impacts factors such as production capacity, equipment condition, and quality. - The document outlines maintenance strategies like breakdown, preventative time-directed, condition-based, and strategic planning approaches. - It provides a conceptual view of the relationships between production, maintenance, and operations systems and how they influence availability performance.

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Enas Al-khawaldeh
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14 views25 pages

Maintenance Strategies Course Overview

This document provides an overview of a course on maintenance strategies and reliability centered maintenance (RCM). It includes the following key points: - The course will cover topics such as the role of maintenance in organizations, maintenance costs, planning, and strategic planning. - Maintenance is important for meeting organizational objectives like customer satisfaction, profits, and safety standards. It impacts factors such as production capacity, equipment condition, and quality. - The document outlines maintenance strategies like breakdown, preventative time-directed, condition-based, and strategic planning approaches. - It provides a conceptual view of the relationships between production, maintenance, and operations systems and how they influence availability performance.

Uploaded by

Enas Al-khawaldeh
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

Introduction and Course overview

by S. O. Duffuaa

Module Outline

Role of Maintenance in a Company Production and Maintenance Relationship Maintenance as an input output system.

Module Outline
Maintenance costs Maintenance planning Maintenance Strategic Planning Overview of the course

Role of Maintenance

Predictable Plant Capacity Efficient Energy Use Maintenance and Availability Maintenance and Quality Maintenance and Equipment Life Time Maintenance and Energy Use Maintenance and Economy

Role of Maintenance
Organizations Objectives include: Meet or exceed customer satisfaction Maximizing profit Meet deliveries Meet set targets Meet set safety standard Zero product defect Does Maintenance affect these goals?

Maintenance is the backbone of all successful enterprises and contributes to:


Improve Product Quality Reduce Costs Meet Set Targets Improve Utilization Improve Equipment Performance

Primary Input Production/ Service

Primary Output

Product Quality

Production Capacity

Quality

Demand for Maintenance

Equipment Condition

Maintenance

Figure 1: Dependency between production/Service and maintenance.

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

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.

V ariations in Maintenance Demand

PLANNING
M aintenance Philosophy

ORGANIZING
Job Design Standards Work Measurement

INPUT
Facilities Labor Equipment Spares Management

Maintenance Load Forecasting Maintenance Capacity Maintenance Organization Maintenance Scheduling

OUTPUT
Operational Machines & Equipment

Maintenance Process

Project Management

MONITOR

* Scheduling

FEEDBACK CONTROL
Work control Material control Inventory control Cost control Managing for quality

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.

Maintenance Strategies
[Link] 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

Maintenance an Internal Part of an Organization

Growing Maintenance Expectations


Higher plant availability and reliability Greater safety Better product quality Higher plant availability No damage to the environment Longer equipment life Greater cost effectiveness
1970 1980 1990 2000

Longer equipment life


Fix it when it broke Lower costs
1940 1950 1960

Production System, Maintenance System & Operations System Relationship

Availability Performance

Conceptual Presentation Of Availability Performance

Maintenance Strategies

Strategic Planning in Maintenance


Vision Mission Objectives Measures/ balanced scored card Strategies Implementation


Targets or goals Action plans

Vision

Where you want to be To be an Award winning department at the international level. Mission Why you exist?
Keep plant equipment and assets well configured, safe to operate with the maximum availability maintained with minimum cost.

Objectives

What to pursue to achieve mission and objectives.


Recruit and maintain the best technical staff. Adopt effective and proactive maintenance strategies using latest knowledge and technology. Avail the needed spare parts at the minimum cost.

Measures

MTBF for reliability


Availability Costs Employee learning Utilization

Strategies

TPM
Intelligent maintenance. Reliability Centered Maintenance (RCM)

Course Overview
May15-18, 2005
Day
Sunday May, 15

8:00- 12:00
Overview of Maintenance Strategies RCM Methodology & Tools

12:00- 1:00

1:00-3:00 Introduction to RCM

Monday May, 16

Lunch

RCM Tools

Tuesday May,17 Wednesday May,18

RCM STEPS

RCM Steps with example

RCM Implementation

Case Study

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