University of the Southern

Caribbean

Operations Management

Maintenance and Reliability


Presented by Group 2



Purpose

Identify
Reliability functions or
activities
Role of maintenance in
reliability
Concepts for managing
reliability

Outline
Introduction
Reliability functions
Role of maintenance
Approaches to
reliability management
Summary


It is not the strongest, nor the most
intelligent that survives. It is the one that is
the most adaptable to change.

Reliability and maintenance are tools in the
manufacturing survival tool kit!
- Al Poling



Introduction
Survival in a Global Market
Nolan and Heap define Inherent Reliability as:
"the level of reliability achieved with an effective
maintenance program. This level is established by the design
of each item and the manufacturing processes that
produced it. "
Reliability functions
Key functional players
Design and development engineers
Production and quality assurance
personnel
Test and evaluation personnel
Supply chain and item managers
Sustaining (in-service) engineers
Field and warehouse maintainers
Reliability Tactics

Improving individual components
Providing redundancy
Reduced single point of failure
Enhances operational Quality

Reliability The Big Picture




Meaningful definition:

Technology
Development
Production &
Deployment
Operations & Support
Reliability Functions
System Development
& Demonstration
Concept
Refinement
Reliability by the book=R(t)=
1
e
t
MTBF
Reliability by the book=R(t)=
1
e
t
MTBF
1
e
t
MTBF
e
t
MTBF
t
MTBF
Overall
Equipment
Effectiveness
=
Availability
X
Performance
Rate
Quality
Rate
X
In other words, we tie $ directly
Empowerment Reliability Scorecard
Asset Management
Prevention
Education/Training Design for Reliability RAM Modeling OEE
Performance Mgmt.
Multi-skilling
Operator Driven Reliability
Teamwork
Roles & Responsibilities
Org. Structure
Vision & Mission
People
Mgmt. of Change
Contractor Mgmt.
T/A or S/D Mgmt.
Materials Mgmt.
Standardization
Failure Investigation
Mtce. Work Mgmt.
Process
Reliability Centered Mtce.
Risk Based Inspection
Life Cycle Costing
CMMS/Data Mgmt.
PdM/Cond. Monitoring
Basic PM
Critical Equipment Ranking
Tools/Methods
Customer
Training Hrs/Emp.
Learning & Growth
PM Compliance
Internal Business Process
Mtce $ as % RAV
Financial
Measurement
Total Plant Reliability

Best Practice Working Partially Working Not Working/Absent
Reliability Consulting benchmarks customers to identify strengths,
recognize improvement opportunities and deliver actionable roadmap
Overall System Reliability
In The Fault Tree Analysis Guide a system is defined as:
"A composite of equipment, skills, and techniques capable of
performing or supporting an operational role, or both. A
complete system includes all equipment, related facilities,
material, software, services, and personnel required for its
operation and support to the degree that it can be
considered self-sufficient in its intended operational
environment."
Role of maintenance in
reliability

Primary Roles
Prevent
Support the updating of maintenance processes
Conduct preventive and predictive maintenance
Communicate with operators and engineers
Restore
Diagnose failure
Take appropriate action on deficient items
Quality Assurance for maintenance
Report
Failure ID & categorization
Record failure and maintenance data
Initiate deficiency reports/warranty actions
Requires
Trained and skilled maintainers
Interface with engineering & supply
Restore Report
Prevent
Role of maintenance
Prevent failures
Restore Report
PREVENT


Support the updating of maintenance processes and schedules
Support engineers as they periodically update maintenance
processes and schedules based on RCM analysis
Work with engineers, as requested, to assess impact of
operational changes or environmental influences
Conduct Preventive and Predictive Maintenance
Maintain the embedded health management capabilities
Conduct PM and PdM tasks as planned to reduce total maintenance
Communicate with operators and engineers
Establish dialogue with operators and engineers to eliminate
failures
Ensure operators and engineers understand the current reliability
state




Support process updates
PM and Pd.M.
Communicate with Ops &
Eng.
Role of maintenance
Restore failed items
Diagnose failure
Locate & isolate failed items
Skilled maintainers use approved troubleshooting equipment and
procedures
Take appropriate action on deficient items
Skilled maintainers use approved maintenance equipment, materials and
procedures
Reduce repeat failures (Is item under warranty? Is it a bad actor?)
QA/PA for maintenance processes and materials
Ensure maintainers use qualified materials and processes
Establish a Quality Assurance program for maintenance
Analyze quality escapes and no fault found events for trends and
corrective actions
Prevent Report
RESTORE
Diagnose failure
Appropriate action on item
Maintenance QA/PA
Approaches to reliability
management
Techniques for Enhancing
Maintenance

Simulation: evaluates the impact of various policies
Expert systems: mimic human logic and helps isolate various plant
faults
Automated sensors: warn about failing machine

Expert systems
Computers help users identify problems and select course of action
Automated sensors
Warn when production machinery is about to fail or is becoming
damaged
The goals are to avoid failures and perform preventive maintenance
before machines are damaged


2011 Pearson Education, Inc. publishing as
Prentice Hall

Computerized Maintenance
System
Flexibility
Planning
Reporting

Autonomous Maintenance

Emphasis on employee empowerment

Employees predict failures, prevent breakdowns,
and prolong equipment life

Total Productive Maintenance (TPM)
Combines the concepts of:
Total Quality Management (TQM)

Preventive Maintenance concepts
Designing machines that are reliable, easy to operate, and easy to
maintain

Emphasizing total cost of ownership when purchasing machines

Utilizing the best practices of operators, maintenance departments and
depot service
Training for autonomous maintenance, in partnership with maintenance
personnel

2011 Pearson Education,
Inc. publishing as Prentice
Hall
2011 Pearson
Education, Inc.
publishing as Prentice
Hall
Maintenance Strategy
Comparison
Maintenance
Strategy Advantages Disadvantages
Resources/
Technology
Required
Application
Example
Breakdown No prior
work
required
Disruption of
production,
injury or death
May need
labor/parts
at odd
hours
Office copier
Preventive Work can
be
scheduled
Labor cost,
may replace
healthy
components
Need to
obtain
labor/parts
for repairs
Plant
relamping,
Machine
lubrication
Predictive Impending
failures can
be detected
& work
scheduled
Labor costs,
costs for
detection
equipment and
services
Vibration, IR
analysis
equipment
or
purchased
services
Vibration
and oil
analysis of a
large
gearbox
18
C
o
s
t
s

Total Cost
Lost Revenue
Maintenance
Cost
100% Mechanical Availability
Profit Optimization
19
Path to First Quartile
High Mechanical Availability
and Low Cost
Low Mechanical Availability
and High Cost
<95
95
95
96
96
97
97
98
>98
1 1.4 >10
Maintenance Cost, % (US $/PRV)
M
e
c
h
a
n
i
c
a
l

A
v
a
i
l
a
b
i
l
i
t
y
,

%

Not Sustainable
E
f
f
e
c
t
i
v
e
n
e
s
s

Efficiency and Cost
Industry Leaders
Facility
Sustainable


Summary


Reliability functions involve numerous activities across various functional
areas.

As the first observer of failures maintenance plays a key role - prevent,
restore, and report

Focus on design improvements

Practice preventive maintenance

Give employees ownership of their equipment

Build and maintain systems that drive out variability and inspire customer
satisfaction

Kececioglu D. (2003) -Maintainability, Availability, and Operational Readiness Engineering Handbook.DE Stech
Publications, Inc, Electronic books

Hayes, T. (1997), The Learning Organization: fashionable fad or path to progress?
www.globasearchbusiness.com

Gallimore K. F. and Penlesky, R.J. (1988) A framework for developing
maintenance strategies, Production and Inventory Management Journal, First Quarter, pp.16 -21.


LBNL 2005. Planning and Reporting for Operations & Maintenance in Federal Energy Saving Performance Contracts.
Lawrence Berkeley National Laboratory, Berkeley, California. Available at: http://ateam.lbl.gov/mv/.

Heizer, J., & Render, B. (2014). Maitenance and Reliability -Chapter 17 PowerPoint presentation. Retrieved from
https://ttuscmy.sharepoint.com/personal/ramellas_usc_edu_tt/_layouts/15/guestaccess.aspx?guestaccesstoken=
%2bfnjUOIuVrxiFSuSESugxgNcoozS9bwjSkGFWb7jjTs%3d&docid=038e4aa394a3846b0b05cc9486e596cf4


Industrial Energy Efficient Training/Dupont Sustainable Solutions. Retrieved from
https://www.youtube.com/watch?v=-fSWkLSLL48&list=PLK4m93-HTw3BYAwegKlwhzdL6zUI2kn4m&index=3

O&M Best Practices Guide, Release 3.0, Chap 5: Types of maintenance Program. Retrieved from
http://www1.eere.energy.gov/femp/pdfs/om_5.pdf



References
Group Members Roles
Team Leader Adrian Cabralis,

To Liaise with the members as to the status of the work within the team
To ensure that required resources are in the correct place at the right time
To schedule task and ensure that one task is not holding up others tasks and to re-schedule resources to tasks where
necessary
To communicate with other memebers of the team

Design/Scribe Onika Blandin:

Structural; give shape and voice to the work.
Proofreading look at the syntax (spelling, punctuation and grammatical side of the work)
Checks for sense, clarity, grammatical and mechanical accuracy, and conformance,
focus on the structure and flow of the work as a whole.

Research of the body

Beckles, Kurnisha Sherwana
Bishop, Raynelle Renysce To provide applicable and relevant, input.
Browne, Kenwin Leon To communicate with other members of the team
Charles, La Tricia Christien
Onika Blandin
Adrian Cabralis,