Supplement 15

Maintenance

McGraw-Hill/Irwin

Copyright 2009 by The McGraw-Hill Companies, Inc. All Rights Reserved.

Supplement 15: Learning Objectives

You should be able to:
Explain the importance of maintenance in production systems
Describe the range of maintenance activities
Discuss preventive maintenance and the key issues associated
with it
Discuss breakdown maintenance and the key issues associated
with it
State how the Pareto phenomenon pertains to maintenance
decisions

15S-2

Maintenance
Maintenance
All activities that maintain facilities and equipment in
good working order so that a system can perform as
intended
Maintenance activity categories:
Buildings and grounds
Equipment maintenance

15S-3

Maintenance Goals
The goal of maintenance is to keep the production
system in good working order at minimal cost
Reasons for wanting to keep equipment and machines
in good operating condition:

Avoid production or service disruptions

Not add to production or service costs
Maintain high quality
Avoid missed delivery dates

15S-4

Breakdown Consequences
Operations capacity is reduced, and orders are delayed
There is no output, but overhead continues, increasing
the cost per unit
There are quality issues
output may be damaged

There are safety issues

employees or customers may be injured

15S-5

Maintenance Options
Reactive:
Breakdown maintenance
Dealing with breakdowns or problems when they occur

Proactive:
Preventive maintenance
Reducing breakdowns through a program of lubrication,
adjustment, cleaning, inspection, and replacement of
worn parts

15S-6

Total Maintenance Cost

15S-7

Preventive Maintenance
The goal of preventive maintenance is to reduce the
incidence of breakdown or failures in the plant or
equipment to avoid the associated costs

Loss of output
Idle workers
Schedule disruption
Injuries
Damange to other equipment, products, or facilities
Repairs

15S-8

Preventive Maintenance Schedule

It is periodic
It is scheduled according to the availability of
maintenance personnel and to avoid interference with
operating schedules
Maintenance is scheduled using some combination of
The result of planned inspections that reveal a need for
maintenance
According to the calendar (passage of time)
After a predetermined number of operating hours

15S-9

Preventive Maintenance: Frequency

The goal is to strike a balance between the cost
of preventive maintenance and the cost of
breakdown
The amount of preventive maintenance,
therefore, is a function of the expected
frequency of breakdown, the cost of breakdown,
and the cost of preventive maintenance

15S-10

Frequency: Example 1
The frequency of breakdown of a machine per month is $1,000 and
the cost of preventive maintenance is $1,250 per month. If
preventive maintenance is performed, the probability of a machine
breakdown is negligible. Should the manager use preventive
maintenance, or would it be cheaper to repair the machine when it
breaks down?
Number of breakdowns
Frequency of occurrences

.20

.30

.40

.10

15S-11

Frequency: Example 1
Number of breakdowns
Frequency of occurrences

.20

.30

.40

.10

Expected number
0(.20) 1(.30) 2(.40) 3(.10) 1.4
of breakdowns

Expected benefit of
Expected cost of Cost of preventive

preventive maintenanc e
breakdown
maintenanc e
1.4($1,000 ) - $1,250
$150

15S-12

Frequency: Example 2
Suppose the average time before breakdown is normally distributed
with a mean of 3 weeks and a standard deviation of .60 weeks. If
breakdown cost average $1,000 and preventive maintenance costs
$250, what is the optimal maintenance interval?

Preventive cost
$250

.25
Breakdown cost $1,000
Find the number of standard deviations from the mean represented
by an area under the normal curve of .25
Using the standard normal table, it is -0.67
Use this value to determine the maintenance interval

Mean z (standard deviation) 3 (-.67)(.60) 2.598 weeks

15S-13

Maintenance Approaches
Predictive maintenance
An attempt to determine when best to perform preventive
maintenance activities
Ideally, preventive maintenance will be performed just prior to
a breakdown or failure because this will result in the longest
possible use of facilities or equipment without a breakdown

Total productive maintenance

JIT approach where workers perform preventive maintenance on
the machines they operate

15S-14

Maintenance Problems
Maintenance problems are sometimes designed
into products:
Poor design
Designer have accorded other aspects of design
greater importance
Cost
Appearance is more important than maintenance
activities

15S-15