Project Management. Maintenance and Reliability

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Project Management. Maintenance and Reliability

• 14 Aug 2001

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Introduction

• What Project Management
• Where Where the success or failure of a project
  will have major consequences for the company
• Why At some point every company takes on large
  and complicated projects opening a new store,
  building a plant, developing a product

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Project Management

• What is at stake?
• Large projects, outside of normal production
• Cost overruns
• Late completion penalties
• Early completion bonuses

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 Project Planning

• Project organization
• Project manager

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Project Planning

• Planning Task
• Work Breakdown Structure
• Determines gross requirements for people,
  supplies and equipment

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Work Breakdown Structure

• Level
• 1 Project
• 2 Major tasks
• 3 Subtasks
• 4 Activities

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Example

• Level
• 1 Open a new Retail Outlet
• 2 Select Location
• 2 Refurbish Location
• 3 Signage
• 4 Install new sign
• 3 Displays
• 4 Install racks
• 4 Install Mannequins

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Project Scheduling

• Sequence project activities
• Allotting time

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Gantt Chart
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Project Controlling

• Monitor resources, costs, quality, and budgets
• Use feedback to revise project plan

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PERT and CPM

• Program Evaluation and Review Technique
• Critical Path Method
• Schedule, monitor and control large projects

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PERT and CPM Framework

• Define project
• Develop relationships among activities
• Draw network connecting activities
• Assign time / cost estimates to each activity
• Compute longest time path through network the
  critical path
• Use network to plan, schedule, monitor, control
  project

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Difference Between PERT and CPM

• CPM one estimate of time
• PERT three estimates with probabilities

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PERT Symbols
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PERT Symbols
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PERT Symbols
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PERT Symbols
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Activity Time Estimates

• Optimistic Time (a)
• Most Likely Time (m)
• Pessimistic Time (b)
• Beta distribution
• Expected Time t (a 4m b) / 6
• Variance v (b a)/62

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Critical Path Analysis

• ES Earliest Start Time
• LS Latest Start Time
• EF Earliest Finish
• LF Latest Finish
• S Slack Time LS ES
• Critical Path Group of activities in the
  project that have a slack time of zero
• T total project completion time
• V total variance of activities on the critical
  path

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Project Crashing

• Crashing shorten activity time by adding
  resources
• Can be expensive may be less expensive than
  cost penalties

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PERT Advantages

• Useful at several stages, especially scheduling
  and control
• Not mathematically complex
• Graphical display show relationships
• Critical path pinpoints activities to closely
  monitor
• Documents who is responsible for each activity
• Applicable to a wide range of industries
• Monitors schedules and costs

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PERT Limitations

• Project activities clearly defined, independent,
  stable in their relationships
• Precedence relationships must be specified in
  advance
• Time estimates are subjective
• Danger of too much emphasis on critical path

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Maintenance and Reliability
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Introduction

• What maintain capability of system while
  controlling costs
• Where Where results of failure can be
  disruptive, wasteful, and expensive in dollars
  and lives
• Why breakdown idle facilities loss of
  customers

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Definitions

• Maintenance all activities involved in keeping
  a system in working order
• Reliability Probability that a machine function
  or part will function properly for a specified
  period of time under stated conditions

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Improving Individual Components

• If one component fails, entire system could fail
• Reliability is the probability of not failing
• Assuming the reliability of each component does
  not depend on the reliability of other
  components,
• Rs R1 x R2 x R3 x x Rn

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Product Failure Rate

• - FR() Number Failures / Number units tested x
  100
• FR(N) Number of failures / Operating time
• MTBF 1 / FR(N)

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Providing Redundancy

• Back up components with additional components
• Rs R1 R2 x (1 R1)

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Maintenance

• Preventative Maintenance Routine inspections,
  servicing, and keeping facilities in good repair
  to prevent failure
• Breakdown Maintenance Equipment fails and must
  be repaired

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Implementing Preventative Maintenance

• Maintenance is costly so when to maintain?
• Infant Mortality high initial failure rate
• Once past the Infant Mortality phase, determine
  MTBF
• Requires maintenance and breakdown record-keeping
• Difficult to determine full costs of breakdown

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Increasing repair capabilities

• Must decide where repairs are to be performed
• Must decide who will perform repairs
• Better to have employees perform as much as
  possible themselves

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Total Productive Maintenance TPM

• Applies TQM concepts to maintenance
• Employee involvement
• Excellent maintenance records
• Designing machines to be reliable, easy to
  operate, easy to maintain
• Emphasizing total cost of ownership when
  purchasing machines
• Developing preventative maintenance plans
• Training workers to operate and maintain machines