MAINTENACE and RELIABILITY TACTICS

The objective of reliability and maintenance is to maintain the capability of the system while
controlling cost. System maybe design and maintained to reach expected performance and quality
standards.
Reliability –the probability that a machine will part or product will function properly for given length o f time
Maintenance – it includes all the activities involved in keeping system’s equipment in working order.
Four Tactics in reliability and Performance
1.) Improving individual components.
2.) Providing redundancy
3.) Implementing or improving preventive maintenance
4.) Increasing repair capabilities

RELIABILITY
The probability that a machine will part or product will function properly for given length o f time,
known as reliability.
“Systems are composed of a series of individual related components, each performing a specific job.
If any one of these components fails to perform,the overall system can fail.
Providing Redundancy

It is provided if one component fails and the system has recourse to another. To compute
redundancy:
(Probability of first component) + [(Probability of second component) x
(Probability of needing second component)]

Maintenance- encompasses all those activities that relate to keeping facilities and equipment in good
working order and making necessary repairs when breakdowns occur, so that the system can performed as
intended.
Maintenance Activities are organized into two categories:
1. Buildings and grounds
2. Equipment Maintenance

Introduction
The goal of maintenance is to keep the production system in good working order at minimal cost.
There are several reasons for wanting to keep equipment and machines in good operating condition such as:
1. Avoid production Cost
2. not add to production cost
3. Maintain high quality

When breakdowns occur, there are a number of adverse consequences:

1. Production capacity is reduced, and orders are delayed.
2. There is no Production, but overhead continues, increasing the cost per unit.
3. There are Quality Issues; product maybe damaged
4. There are safety issues; employees maybe injured.

Decision Makers have two options with respect to maintenance:

One is Reactive/Breakdown Maintenance

Second, Proactive/ Preventive Maintenance

Breakdown Maintenance- it is t deal with breakdowns or other problems when they occur
Preventive maintenance – It is to reduced breakdowns through a program of lubrication, adjustments,
cleaning, inspection, and replacement of worn products.

PREVENTIVE MAINTENANCE
The goal of preventive maintenance is to reduce the incidence of breakdowns or failure in the plant
or equipment to avoids the associated cost.

Those costs include:

1. Idle workers
2. schedule disruptions
 3. Injuries
4. damage to other equipment, products or facilities
5. and repairs

Preventive Maintenance is Periodic; It can be scheduled according to the availability of maintenance

personnel, but Managers Usually schedule preventive maintenance using some combination of the following:
1. The result of planned inspections that reveal a need for maintenance
2. According to the calendar
3. After a predetermined number of operating hours.

An important issue in preventive maintenance is the frequency of preventive maintenance. Determining

the amount of preventive maintenance to use is a function of the expected frequency of breakdowns, the
cost of breakdown (including actual repair costs, as well as potential damage or injury, lost of production and
so on.

Term related to preventive maintenance

PREDICTIVE MAINTENANCE - it is an attempt to determine when to perform preventive maintenance

activities. It is based on historical records and analysis of technical data when a piece of equipment or part is
about to fail.

Predictive Preventive Breakdown

Maintenance Maintenance maintenance

BREAKDOWN PROGRAMS
The risks of a breakdown can be greatly reduced by an effective preventive maintenance programs.
Nonetheless, occasional breakdown still occur. Even firms with good preventive practices have some need
for breakdown program.

Some major approaches used to deal with breakdowns are the following:
1. Stand by or Back up Equipment
2. Inventories of spare parts that can be installed as needed.
3. operators
4. Repair people who are well trained and readily available to diagnose and correct problems with
equipment.

To summarize, preventive maintenance is appropriate when:

1. there is low variability in breakdown time
2. a sensing system provides data that suggest the need for maintenance
3. breakdown time is expensive

Increasing Repair Capabilities

A good maintenance facility implies many attributes. These include
1. well-trained personnel
2. adequate resources
3. ability to establish a repair plan and priorities
4. ability and authority to do material planning
5. ability to identify the cause of breakdowns
6. ability to design ways to extend MTBF

The operation manager must determine where on the continuum each type of
maintenance will be performed.

Manufacturer’s
Maintenance Depot
Operation
Department service
field service
 Preventive maintenance costs less and faster the more we move to the left, but
competence is higher the more we move to the right.

SIMULATION TECHNIQUE
This can be used to evaluate the impact of various maintenance policies prior to implementing the
policy. Many companies used computerized simulation model to decide if and when to shutdown a whole
plant for maintenance activities.
Cost analysis of the simulation can be computed as:
Simulated machine breakdown cost = (Total hours of breakdown) x
(lost per hour of downtime)
Total maintenance cost of the current system = Service cost + Breakdown cost

EXPERT SYSTEM APPLIED To MAINTENANCE

The used of expert system is proving beneficial in maintenance system. Experts are the assisting
maintenance personnel personal in isolating and repairing various faults in machinery and equipment.

Ways to evaluate reliability and maintenance:

1.) units produced
2.) dollar invested
3.) standard hours to do the job
4.) measures of machine utilization
5.) measures of emergency maintenance hours against preventive hours shown.