Professional Documents
Culture Documents
Management
by
Asitha Kulasekera
Type of machinery
Resources available
Others jobs:
Generation and distribution of power and other utilities
Providing plant protection e.g. fire
Maintaining a store of maintenance materials
House keeping cleaning equip. building, toilets, wash
rooms etc.
Pollution & noise control etc.
Running maintenance:
Conduct while machine in service (working)
Shutdown maintenance:
Conduct while M/cs are out of service/work
Usually shutdown the plant during this period
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Types of maintenance - 3
Unplanned maintenance:
Operate machine until it breaks down without maintenance
Similar to breakdown maintenance
Application
Should not apply PM to whole factory at once
Should build up section by section
e.g. one section / one type of equipment at a time
Performance measurement:
100 = 10% (. )
100 = %
Total cost
Cost
Labour & overheads
Cost of downtime
()
=
+ ()
R1 R2 R3
Time
03 phases are important in analysing item reliability
If improved reliability during the infancy failure period (R1),
Reliability during random or middle age failures would be high
Reduce failures during the old age period
Critical period is the random failure stage, where
systematic maintenance system is needed
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Repair and replacement
Issue: to decide the amount of resources for
maintenance
Large team with shorter repair time: large resource idle
time
Small team with long repair time (longer downtime)
Strategy I:
Depend on the cost of a single replacement
Probable No. of failures during a particular period (e.g. year)
Strategy 2:
Total cost is determined by the No. of components replaced
No. of first failure during the period
Strategy 3:
Total cost is determined by the No. of parts replaced at every
replacement period which have longer service life than average
No. of first failure during the period
Statistical theory
Not effective due to non-availability of standard patterns
like Normal, Poisson, Exponential, etc.
and revenues
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NPV values
Rs. 100 investment at present will be worth only [100/(1+i)n]
in n years time, if the investment could generate an
interest of i% per year
E.g.: Rs. 100 investment in this year is worth only RS. 82.64 in
02 years time, if the interest rate is 10%
I n En
N
SN In Income in year n
NPV En Expenditure in year n
N Life of equipment or number of
n 1 (1 i ) n
(1 i ) N
years been considered
SN Sale or scrap value at the end of
N years
NPV for New Equipment = 177.801 NPV for Present Equipment = 186.662
Payoff table can also used for determining the No. of spare
parts to carry for maintenance (uncertain demand)
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Example for determining No. of
standby machines - 3
Payoff table
=300 (15-5)=3000 =1500*.238+3000*.333+4500*.286=2643
where:
Bn = expected number of breakdowns for each policy
pn = probability that a breakdown will occur between
inspections when PM is performed every n periods
N = number of machines in group
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Example for determining the
frequency of maintenace-1
It costs Rs. 6,000 to perform PM on a group of four
machines . The cost of down time and repairs, if a
machine malfunctions between inspections is Rs. 8,000.
How often should the maintenance be performed
to minimise the expected cost of malfunction and
the cost of maintenance
B1 = 4(0.2) = 0.800
B2 = 4(0.2 + 0.3) + 0.8(0.2) = 2.160
B3 = 4(0.2 + 0.3 + 0.5) + 2.16(0.2) + 0.8(0.3) = 4.672
=2.160/2=1.080 =1.080*8000=8640
=6400
+6000