1 17 maintenance and reliability powerpoint presentation to accompany heizer and render operations...
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1717 Maintenance and Reliability
Maintenance and Reliability
PowerPoint presentation to accompany Heizer and Render Operations Management, 10e Principles of Operations Management, 8e
PowerPoint slides by Jeff HeylAdditional content from Gerry Cook
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Outline
The Strategic Importance of Maintenance and Reliability
Reliability Improving Individual Components Providing Redundancy
Maintenance Implementing Preventive Maintenance
Total Productive Maintenance Techniques for Enhancing Maintenance
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Learning Objectives1. Describe how to improve system reliability
2. Determine system reliability
3. Determine mean time between failure (MTBF)
4. Distinguish between preventive and breakdown maintenance
5. Describe how to improve maintenance
6. Compare preventive and breakdown maintenance costs
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Orlando Utilities Commission
Maintenance of power generating plants Every year each plant is taken off-line for 1-3
weeks maintenance Every three years each plant is taken off-line
for 6-8 weeks for complete overhaul and turbine inspection
Each overhaul has 1,800 tasks and requires 72,000 labor hours
OUC performs over 12,000 maintenance tasks each year
Every day a plant is down costs OUC $110,000 Unexpected outages cost between $350,000
and $600,000 per day
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Strategic Importance of Maintenance and Reliability
Failure has far reaching effects on a firm’s Operation Reputation Profitability Dissatisfied customers Idle employees Profits becoming losses Reduced value of investment in plant and
equipment
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Maintenance and Reliability
Reliability is the probability that a machine will function properly for a specified time
Tactics to improve Reliability Improving individual components Providing redundancy
Maintenance: activities involved in keeping a system’s equipment in working order
Maintenance Tactics Implementing or improving preventive maintenance Increasing repair capability or speed
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Reliability
Improving individual components
Rs = R1 x R2 x R3 x … x Rn
where R1 = reliability of component 1R2 = reliability of component 2
and so on
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Overall System ReliabilityR
elia
bil
ity
of
the
syst
em (
per
cen
t)
Average reliability of each component (percent)
| | | | | | | | |
100 99 98 97 96
100 –
80 –
60 –
40 –
20 –
0 –
n = 10
n = 1
n = 50n = 100n = 200n = 300
n = 400Figure 17.2
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Rs
R3
.99
R2
.80
Reliability Example
R1
.90
Reliability of the process is
Rs = R1 x R2 x R3 = .90 x .80 x .99 = .713 or 71.3%
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Product Failure Rate (FR)
Basic unit of measure for reliability
FR(%) = x 100%Number of failures
Number of units tested
FR(N) =Number of failures
Number of unit-hours of operating time
Mean time between failures
MTBF =1
FR(N)
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Failure Rate Example
20 air conditioning units designed for use in NASA space shuttles operated for 1,000 hoursOne failed after 200 hours and one after 600 hours
FR(%) = (100%) = 10%2
20
FR(N) = = .000106 failure/unit hr2
20,000 - 1,200
MTBF = = 9,434 hrs1.000106
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Failure Rate Example
20 air conditioning units designed for use in NASA space shuttles operated for 1,000 hoursOne failed after 200 hours and one after 600 hours
FR(%) = (100%) = 10%2
20
FR(N) = = .000106 failure/unit hr2
20,000 - 1,200
MTBF = = 9,434 hrs1.000106
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Providing Redundancy
Provide backup components to increase reliability
+ x
Probability of first
component working
Probability of needing
second component
Probability of second
component working
(.8) + (.8) x (1 - .8)
= .8 + .16 = .96
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Redundancy ExampleA redundant process is installed to support the earlier example where Rs = .713
R1
0.90
0.90
R2
0.80
0.80
R3
0.99
= [.9 + .9(1 - .9)] x [.8 + .8(1 - .8)] x .99
= [.9 + (.9)(.1)] x [.8 + (.8)(.2)] x .99
= .99 x .96 x .99 = .94
Reliability has increased
from .713 to .94
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Maintenance
Two types of maintenance Preventive maintenance –
routine inspection and servicing to keep facilities in good repair
Breakdown maintenance – emergency or priority repairs on failed equipment
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Maintenance Costs The traditional view attempted to
balance preventive and breakdown maintenance costs
Typically this approach failed to consider the true total cost of breakdowns Inventory Employee morale Schedule unreliability
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Maintenance Costs
Total costs
Breakdown maintenance costs
Co
sts
Maintenance commitment
Traditional View
Preventive maintenance costs
Optimal point (lowestcost maintenance policy)
Co
sts
Maintenance commitment
Full Cost View
Optimal point (lowestcost maintenance policy)
Total costs
Full cost of breakdowns
Preventive maintenance costs
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Maintenance Cost ExampleShould the firm contract for maintenance on their printers?
Number of Breakdowns
Number of Months That Breakdowns Occurred
0 2
1 8
2 6
3 4
Total : 20Average cost of breakdown = $300
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Maintenance Cost Example
1. Compute the expected number of breakdowns
Number of Breakdowns
Frequency Number of Breakdowns
Frequency
0 2/20 = .1 2 6/20 = .3
1 8/20 = .4 3 4/20 = .2
∑ Number of breakdowns
Expected number of breakdowns
Corresponding frequency= x
= (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2)
= 1.6 breakdowns per month
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Maintenance Cost Example
2. Compute the expected breakdown cost per month with no preventive maintenance
Expected breakdown cost
Expected number of breakdowns
Cost per breakdown= x
= (1.6)($300)
= $480 per month
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Maintenance Cost Example
3. Compute the cost of preventive maintenance
Preventive maintenance cost
Cost of expected breakdowns if service contract signed
Cost of service contract
=+
= (1 breakdown/month)($300) + $150/month= $450 per month
Hire the service firm; it is less expensive
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Total Productive Maintenance (TPM)
Designing machines that are reliable, easy to operate, and easy to maintain
Emphasizing total cost of ownership when purchasing machines, so that service and maintenance are included in the cost
Developing preventive maintenance plans that utilize the best practices of operators, maintenance departments, and depot service
Training for autonomous maintenance so operators maintain their own machines and partner with maintenance personnel
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Problems With Breakdown Maintenance
“Run it till it breaks” Might be ok for low criticality
equipment or redundant systems Could be disastrous for mission-
critical plant machinery or equipment
Not permissible for systems that could imperil life or limb (like aircraft)
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Problems With Preventive Maintenance
“Fix it whether or not it is broken” Scheduled replacement or
adjustment of parts/equipment with a well-established service life
Typical example – plant relamping Sometimes misapplied
Replacing old but still good bearings Over-tightening electrical lugs in
switchgear
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Another Maintenance Strategy Predictive maintenance – Using advanced
technology to monitor equipment and predict failures Using technology to detect and predict
imminent equipment failure Visual inspection and/or scheduled
measurements of vibration, temperature, oil and water quality
Measurements are compared to a “healthy” baseline
Equipment that is trending towards failure can be scheduled for repair
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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
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In-Class Problems from the Lecture Guide Practice Problems
Problem 1:California Instruments, Inc., produces 3,000 computer chips per day. Three hundred are tested for a period of 500 operating hours each. During the test, six failed: two after 50 hours, two at 100 hours, one at 300 hours, and one at 400 hours. Find FR(%) and FR(N).
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In-Class Problems from the Lecture Guide Practice Problems
Problem 2:If 300 of these chips are used in building a mainframe computer, how many failures of the computer can be expected per month?
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In-Class Problems from the Lecture Guide Practice Problems
Problem 3: Find the reliability of this system:
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In-Class Problems from the Lecture Guide Practice Problems
Problem 4:Given the probabilities below, calculate the expected breakdown cost.Assume a cost of $10 per breakdown.
Number of Breakdowns
Daily Frequency
0 31 22 23 3