Introduction to
Equipment
Maintenance
Lecture 1
MEG 531
–
Delivering Reliability and maintenance excellence that the power of the
Redefining Maintenance
• Few companies address the significant synergies of lean
combination of lean manufacturing and lean
maintenance
• The best approach is to focus on lean maintenance and
reliability improvements simultaneously
• When equipment does what it needs to do when it needs to
do it, plant out and profitability is maximized
• No organization wants its production systems or
processes to break down, to produce poor quality
products or to operate inefficiently. Unfortunately, no physical asset operate flawlessly forever
Maintenance –
• Performing sustaining levels of maintenance is a
fundamental requirement of long term survivability of all
that will assure the loss of the ability to compete in today's
maintenance operations minimizes waste, as well as
• In most organizations, breakdowns are the norm. Quality
and Productivity losses are high. Scheduled
shipments are
missed.
Redefining Delivering
• Maintenance is too often blamed for all
problems • Majority of work is done on a
reactive basis
plants
Reliability
• Ignoring this requirement is a guarantee that the plant will
incur unacceptably, ever increasing higher operating cost
world market.
• Maintenance excellence is a subset of reliability excellence.
Achieving high reliability in manufacturing and
minimizes cost.
Maintenance –
sold. Specifically, changes such
• lower production unit cost
Redefining
Delivering Reliability
as:
maintenance as part of the total
• By redefining the role of
plant reliability program
provides the infrastructure, processes, and employee involvement that result in
improved throughout and lower
total cost goods
• reduced maintenance cost, • better process stability
Lower Production Unit Cost
Production unit cost is one of the most critical variables impacting an organization's profitability
Calculated simply as the sum of all manufacturing cost divide by the production volume.
Improved asset reliability reduces unit the numerator and increases the denominator
Reduced
Maintenance Costs
• Improved reliability results in lower maintenance sots. If the
assets are not breaking down, a greater
percentage of maintenance work can be
performed in a planned and scheduled manner,
which enables the work to be at least twice as
efficient. Reducing these loses also result in
• Fewer spare parts
• Less overtime
• Fewer contractors
• It is not unusual for an organization to experience as much as
a 50 percent reduction in maintenance cost as a result of
moving from a reactive style of management to a proactive
approach.
constantly failing. This inevitably results in • When reliability is improved, process process
capability is increased.
Better Process
Stability
• Equipment breakdowns inevitable result in
process upsets.
• It is difficult to have a stable, optimized
process when the production equipment is
problems with final product quality. variability is reduced, and statistical
• This results in the capability to have a more stable predictable manufacturing process
If routing maintenance is continually
the future value of the asset - taking
the capital value from the future
Extended Equipment Life
organizations spend an excessive
amount of capital funds to replace
equipment that failed far earlier than it
should have.
defered due to production demands or
resource limitation, the organization is in
fact mortgaging
Many
and spending it today
• Organizations that take a proactive
condition in knowing the condition of
their assets. The need for parts is
much
Reduced
Maintenance
Spare Parts
Inventory
• All organizations require some level
of spare parts inventory to ensure the
right parts will be available when
needed.
• Reactive organizations typically find
themselves carrying a large quantity
of inventory because they cannot
predict
when the parts will be
needed
approach to reliability place a high
more predictable
Reduced Overtime
• Most tractive organizations have a large
percentage of the workforce spread across all
operating shifts "just in case" a failure occurs. In
this case equipment is in control, not
management.
• Large amounts of overtime are
experienced.
• For proactive organizations, fewer resources are
waiting for breakdowns to occur because
equipment condition is known and early
warning signs of distress are heeded.
They
tend to
develop
a sense
of ownership- in the
In proactive organizations, it is realized that basic
equipment care is one of the most critical elements
affecting equipment reliability
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In most appearance of the
cases, this equipment and its
Emphasis is placed on is done by personnel operating performance
routing cleaning,
improved reliability – the discipline to
root causes of problems – result in
Improved Employee
Safety
improved employee safety
This Photo by Unknown author is licensed under CC BY-NC-ND.
• Several Studies have indicated that asset
reliability and employee safety are
closely correlated
• The same behaviours that result in
follow procedures, attention to detail,
and the perseverance needed to find the
harzardous substances appropria
Reduced Risk of
containing harzadous chemical
Environmental
Issues
substances must be maintained
• Federal and state environmental
regulations require organizations
to dispose
This Photo by Unknown author is licensed under CC BY-SA.
tely
• Equipment failures in many
chemical processes can result in
releases of harzadous
substances to the environment.
• The integrity of equipment
Self-Directed Work
Teams: A
Competitive
Advantage
• An increasing number of
companies are adopting the
Toyota Production System
(lean manufacturing) and are
involving their employees in
the daily operation and
management
• Team members have free,
direct access to information
that allows them to plan,
control, and improve their operations. In short,
employess that comprise work team manage
themselved
Self-Directed Work Teams: A
Competitive Advantage
• The concept of self-directed teams is growing varies from a corporation's misdirected
effort to reduce salaried headcount,
to geniune efforts to empower the workforce. • The
benefits include
o Improved quality, productivity, and service o Greater Flexibility
o Reduced Operating Costs
o Faster response to technological change o Fewer and
simpler job classifications o Better response to workers
values
o Increased employee commitment to the organization
o Ability to attract and retain the best people