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Maintenance & Reliability Strategies

The document discusses the strategic importance of maintenance and reliability for organizations. It notes that system failures can negatively impact operations, reputation, profitability, customer satisfaction, employee productivity, and investment value. Effective maintenance aims to keep equipment working properly while reliability focuses on the likelihood that systems will function as intended. Key tactics for improving reliability and maintenance include enhancing individual components, adding redundancy, implementing preventive maintenance programs, and increasing repair capabilities and speed. The benefits of effective maintenance and reliability include preventing failures, prolonging equipment life, and reducing total costs.

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278 views5 pages

Maintenance & Reliability Strategies

The document discusses the strategic importance of maintenance and reliability for organizations. It notes that system failures can negatively impact operations, reputation, profitability, customer satisfaction, employee productivity, and investment value. Effective maintenance aims to keep equipment working properly while reliability focuses on the likelihood that systems will function as intended. Key tactics for improving reliability and maintenance include enhancing individual components, adding redundancy, implementing preventive maintenance programs, and increasing repair capabilities and speed. The benefits of effective maintenance and reliability include preventing failures, prolonging equipment life, and reducing total costs.

Uploaded by

brennestevez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Strategic Importance of Maintenance

and Reliability

The objective of maintenance and


reliability is to maintain the
capability of the system
Failure has far reaching effects on
a firms
Operation
Reputation
Profitability
Dissatisfied customers
Idle employees
Profits becoming losses
Reduced value of investment in
plant and equipment

Maintenance and Reliability

Maintenance is all activities


involved in keeping a systems
equipment in working order
Reliability is the probability that a
machine will function properly for
a specified time

Important Tactics

Reliability
Improving individual
components
Providing redundancy
Maintenance
Implementing or improving
preventive maintenance
Increasing repair capability or
speed

Reliability

Improving individual components


Rs = R1 x R2 x R3 x x Rn
where
R1
= reliability of
component 1
R2
= reliability of
component 2
and so on

Overall System Reliability

Reliability Example

Providing Redundancy

Product Failure Rate (FR)

Redundancy Example

Failure Rate Example

Maintenance

Two types of maintenance


Preventive maintenance
routine inspection and
servicing to keep facilities in
good repair
Breakdown maintenance
emergency or priority repairs
on failed equipment

Implementing Preventive Maintenance

Need to know when a system


requires service or is likely to fail
High initial failure rates are
known as infant mortality

Once a product settles in, MTBF


generally follows a normal
distribution
Good reporting and record
keeping can aid the decision on
when preventive maintenance
should be performed

Computerized Maintenance System

Maintenance Cost Example

Maintenance Costs

The traditional view attempted to


balance preventive and
breakdown maintenance costs
Typically this approach failed to
consider the true total cost of
breakdowns
Inventory
Employee morale
Schedule unreliability

Maintenance Costs

Employees accept responsibility


for
Observe
Check
Adjust
Clean
Notify

Increasing Repair Capabilities


1. Well-trained personnel

2. Adequate resources
3. Ability to establish repair plan and
priorities

Total Productive Maintenance (TPM)

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

Developing preventive
maintenance plans that utilize the
best practices of operators,
maintenance departments, and
depot service

Training for autonomous


maintenance so operators
maintain their own machines and
partner with maintenance
personnel

4. Ability and authority to do


material planning
5. Ability to identify the cause of
breakdowns
6. Ability to design ways to extend
MTBF

How Maintenance is Performed

Predict failures, prevent


breakdowns, prolong equipment
life

Techniques for Enhancing Maintenance

Autonomous Maintenance

Simulation
Computer analysis of
complex situations

Model maintenance
programs before they are
implemented

Warn when production


machinery is about to fail or
is becoming damaged

Physical models can also be


used

The goals are to avoid


failures and perform
preventive maintenance
before machines are
damaged

Expert systems
Computers help users
identify problems and select
course of action

Automated sensors

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