Chapter 14:Advances in Maintenance Concepts

1
Chapter 14Advances in Maintenance Concepts

• Overview
• Design for Maintainability
• Reliability-centered Maintenance
• Total Productive Maintenance (TPM)
• Benchmarking Maintenance
• Maintenance Process Reengineering

2
Design for Maintainability

• Maintainability MTTR

3
Design for Maintainability

• Design for maintainability aim at reducing
• Frequency of required repairs
• Duration of repair time
• Total maintenance intervention time
• Including the PM tasks
• Maintenance prevention
• Maintenance prevention
• Built-in diagnostics
• Ease in disassembly and reassembly
• Ease and speed in setups and changeovers

4
Design for Maintainability

• Expert systems built-in
• Ease in cleaning, inspection, lubrication,
  adjustment, and component replacement
• Clean operation, without excessive oil or debris
  scatter
• Protection against dirt in sensitive mechanisms
• Energy efficient, environmental friendly and safe
• Adaptable to several plant locations or
  environments
• Foolproofing, ease to follow the correct
  procedures than incorrect ones
• High reliability and precision
• Ease in initial startup

5
Reliability-Centered Maintenance

• Time-based overhauls of complex equipment reduce
  a little frequency of failure and uneconomical
• RCM is a logical methodology use the failure
  mode effect and criticality analysis (FMECA)
  tool for maintenance of complex equipment
• Methodology
• Select the most important equipment systems
• Define the expected performance or function of
  equipment? what constitutes a function failure

6
Reliability-Centered Maintenance

• Identify the root causes of the functional
  failure
• Determine the effect in a sequence of events in
  terms of safety, production, environment, or a
  hidden effect
• Calculate the criticality of the effect of that
  failure
• Use RCM logic diagram to select the most
  appropriate maintenance tactic to prevent the
  failure
• Determine the specific action to prevent
  functional failure and its scheduling frequency
• If no preventive task is appropriate, determine
  whether it can be run to failure if a redesign is
  warranted, or if there is a test to determine the
  failure

7
Reliability-Centered Maintenance

• RCM ensures correct PM actions eliminate
  inefficient PM
• RCM outputs list of maintenance actions,
  schedules, responsibilities
• RCM favors condition-based maintenance
• Simplified RCM logic tree diagram

Combination? Redesign?
n
Is failure easy spotted?
Safety or Environmental Risk?
Defect a gradual loss of function?
Prevention through Scheduled overhauls/replacemen
t?
y
n
y
Nofailure finding test
No Production risk?
Yes condition-based maintenance
Yes Time-based maintenance
8
Total Productive Maintenance

• Total Productive Maintenance (TPM) is a
  management approach to maintenance that focuses
  on involving all employees in an organization in
  equipment improvement
• Objectives
• Maximize overall equipment effectiveness
  availability, process efficiency, and product
  quality
• Take a systematic approach to reliability,
  maintainability, life cycle costs
• Involve operations, material management,
  maintenance, engineering, an administration in
  equipment management

9
Total Productive Maintenance

• Involve all levels of management and workers
• Improve equipment performance through small group
  activities and team performance
• TPM activities Equipment operators ? autonomous
  maintenance
• Employee empowerment operations ?maintenance
  skill transfer
• Equipment management identify major losses
• Breakdowns, setup and adjustment downtime ?
  Availability
• Idling and minor stoppages, reduced speed ?
  Efficiency
• Process defects, reduced yield ? Product quality

10
Total Productive Maintenance

• TPM performance measureOEEavailability
  performance efficiency quality rate
• Availability (loading timedowntime)/loading
  time)
• Performance efficiency (theoretical cycle time
  amount processed)/operating time
• Quality rate (amount processed defective
  amount) amount processed
• OEE (theoretical cycle timeamount
  processedquality rate)/loading time
• Steps for implement TPM
• Decision to introduce TPM

11
Total Productive Maintenance

• Launch an educational campaign to introduce TPM
• Create organizational to promote TPM
• Establish basic TPM policies
• Formulate a master plan for TPM development
• Hold TPM kick-off
• Improve effectiveness of each equipment
• Develop an autonomous maintenance program
• Develop a scheduled maintenance program
• Conduct training to improve operation and
  maintenance skills
• Develop an effective management program
• Perfect TPM implementation and raise TPM levels

12
Benchmarking Maintenance

• Benchmarking is a continuous improvement
  methodology metrics and process to achieve the
  metrics
• Areas for selection as benchmarking exercise
• Long-range planning and improvement initiatives
• Organization and manpower planning
• Work planning, scheduling and control
• Purchasing, stores, and inventory control
• Preventive and predictive maintenance
• Performance measures and statistics
• Information management and systems
• Reliability engineering
• Maintenance/production interface and
  communication
• Management and administrative processes

13
Maintenance Process Reengineering

• Reengineering the maintenance process use
  several techniques ?understand the current
  process, costs, components ? set
  the vision and performance targets for the new
  process
• Technique 1 Process analysis
• Set the process boundaries
• Map the core process flow through each step and
  responsibility
• Determine inputs, outputs and other performance
  measurements
• Identify the key suppliers, customers, and
  managers

14
Maintenance Process Reengineering

• ?Benefit identify sources of inefficiencies
• Technique 2 Activity-based costing
• Determine the key activities in maintenance
  process (emergency work, corrective work,
  planning and scheduling, PM development and
  execution, safety and security, outsourcing,
  skills training, procurement, inventory
  management, major overhaul, data and performance
  management)
• Determine the activity cost and performance
• Determine the cost driver or output of the
  activity
• Trace this activity cost to the cost objectives
• Evaluate the cost effectiveness and efficiency by
  matching the activity cost to the process
  objectives