Post on 04-Jun-2018
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KULIAH PEMELIHARAAN PERKAKASPRESISI
INTRODUCTION TOMAINTENANCE
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Operators less able to do repairs themselvesMachine and product failure can have effect on companys operation and
profitability
Idle workers, facilityLosses due to breakdown
INTRODUCTION
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Failure inability to produce work in appropriatemanner
Equipment / machine failure on production floor worn out bearing, pump, pressure leaks, broken shaft,
overheated machine etc.Equipment failure in office failure of power supply,air-conditioned system, computer network, photocopy
machine Vehicle failure brake, transmission, engine, coolingsystem
FAILURE
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HospitalRestaurants
Transport companiesBanks
Hotels and resortsShopping malls / retail
Gas station
MAINTENANCE IN SERVICEINDUSTRY
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Electronic Automotive
PetrochemicalsRefineryFurnitureCeramics
Food and beverages
MAINTENANCE IN MANUFACTURING COMPANIES
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All actions necessary for retaining an item, or restoring to it, a serviceablecondition, include servicing, repair, modification, overhaul, inspection and
condition verification
Increase availability of a systemKeep systems equipment in working order
MAINTENANCE
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Why do we need maintenance? What are the costs of doing maintenance?
What are the costs of not doing maintenance?
What are the benefits of maintenance?How can maintenance increase profitability of company?
QUESTION?
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Attempt to maximize performance of production equipment efficiently andregularly
Prevent breakdown or failures
Minimize production loss from failuresIncrease reliability of the operating systems
PURPOSE OF MAINTENANCE
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To achieve product quality and customer satisfactionthrough adjusted and serviced equipment
Maximize useful life of equipmentKeep equipment safe and prevent safety hazardsMinimize frequency and severity of interruptions
Maximize production capacity through high utilizationof facility
PRINCIPLE OBJECTIVES IN MAINTENANCE
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Lack of management attention to maintenanceLittle participation by accounting in analyzing and
reporting costsDifficulties in applying quantitative analysis
Difficulties in obtaining time and cost estimates for
maintenance worksDifficulties in measuring performance
PROBLEMS IN MAINTENANCE
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Cost to replace or repairLosses of outputDelayed shipmentScrap and rework
MAINTENANCE COSTS
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Maintenance may be classified into four categories:(some authors prefer three categories- scheduled and preventive
maintenances are merged)
Corrective or Breakdown maintenanceScheduled maintenance
Preventive maintenancePredictive (Condition-based) maintenance
TYPES OF
MAINTENANCE
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Corrective or Breakdown maintenance implies thatrepairs are made after the equipment is failed and can
not perform its normal function anymore
Quite justified in small factories where:
Down times are non-critical and repair costs are less than othertype of maintenance
Financial justification for scheduling are not felt
CORRECTIVE ORBREAKDOWN
MAINTENANCE
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Breakdown generally occurs inappropriate times leading topoor and hurried maintenance
Excessive delay in production & reduces output
Faster plant deteriorationIncreases chances of accidents and less safety for both workers and machinesMore spoilt materials
Direct loss of profitCan not be employed for equipments regulated by statutory
provisions e.g. cranes, lift and hoists etc
DISADVANTAGES OFCORRECTIVE
MAINTENANCE
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Scheduled maintenance is a stitch-in-time procedure andincorporates
inspection
lubricationrepair and overhaul of equipments
If neglected can result in breakdownGenerally followed for:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks etc.
SCHEDULED
MAINTENANCE
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Principle Prevention is better than cure Procedure - Stitch-in-time
Itlocates weak spots of machinery and equipments
provides them periodic/scheduled inspections and minor
repairs to reduce the danger of unanticipated breakdowns
PREVENTIVEMAINTENANCE
(PM)
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CANDIDATES FOR PREVENTIVE MAINTENANCE
Mean Time Between Failure (MTBF)
Frequency of FailureGood candidateshave more normal
distribution withlow variability
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Advantages:Reduces break down and thereby down time
Lass odd-time repair and reduces over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipments and spare parts
Better product quality and fewer reworks and scrapsIncreases plant life
Increases chances to get production incentive bonus
ADVANTAGES OF
PM
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In predictive maintenance, machinery conditions areperiodically monitored and this enables the
maintenance crews to take timely actions, such asmachine adjustment, repair or overhaul
It makes use of human sense and other sensitive
instruments, such asaudio gauge, vibration analyzer, amplitude meter, pressure,
temperature and resistance strain gauges etc.
PREDICTIVE(CONDITION-
BASED)MAINTENANCE
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Unusual sounds coming out of a rotating equipment predicts a trouble An excessively hot electric cable predicts a trouble
Simple hand touch can point out many unusual equipment conditions andthus predicts a trouble
PREDICTIVEMAINTENANCE
(CONTD.)
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MAINTENANCE COSTS
MaintenanceCommitment
Cost
Breakdown Cost
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MAINTENANCE COSTS
MaintenanceCommitment
Cost
PM Cost
Breakdown Cost
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MAINTENANCE COSTS
MaintenanceCommitment
Cost
PM Cost
Breakdown Cost
Total Maintenance Cost
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MAINTENANCE COSTS
MaintenanceCommitment
Cost
PM Cost
Total Maintenance Cost
Breakdown Cost
Optimal
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Problem: A factory has 200 machines and the maintenance engineer
supervises the repair crews who repair malfunctioning machines. The maintenance policy is to repair the broken down machineand bring back in production within 2 hours on the average. Ifaverage breakdown rate is 3.5 machines/hour and each repair
crew can repair 0.25 machine per hour on the average. How manyrepair crews are required ?
DETERMINING THESIZE OF REPAIR
CREWS
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The formula for average repair rate ( ) is1
ts = ---------- or = + 1/ ts -
Where = repair rate = arrival rate of malfunctioning machines
ts = average time arrivals in the system
Required average repair rate = 3.5 + 1 / 2 = 4 machines / hour
No. of Crews = machines/hour a crew can repair= 4 0.25 = 16 repair crews required
SOLUTION
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Thanks...
BARELWALA_CHINTAN2004@YAHOO.CO.IN