Introduction and Course overview
by
S. O. Duffuaa
Module Outline
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Role of Maintenance in a
Company
Production and
Maintenance Relationship
Maintenance as an input
output system.
Module Outline
Maintenance costs
 Maintenance planning
 Maintenance Strategic
Planning
 Overview of the course
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Role of Maintenance
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Predictable Plant Capacity
Efficient Energy Use
Maintenance and Availability
Maintenance and Quality
Maintenance and Equipment Life Time
Maintenance and Energy Use
Maintenance and Economy
Role of Maintenance
Organizations’ Objectives include:
 Meet or exceed customer satisfaction
 Maximizing profit
 Meet deliveries
 Meet set targets
 Meet set safety standard
 Zero product defect
Does Maintenance affect these goals?
Maintenance is the backbone of all
successful enterprises and contributes
to:
Improve Product Quality
 Reduce Costs
 Meet Set Targets
 Improve Utilization
 Improve Equipment Performance
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Primary Input
Primary Output
Production/
Service
Product Quality
Production
Capacity
Quality
Demand for
Maintenance
Equipment Condition
Maintenance
Figure 1: Dependency between production/Service and
maintenance.
Maintenance Costs
1. DIRECT COSTS
– Cost of Periodic Inspection
– Service Cost
– Repair Cost, Overhaul Cost
2. STAND-BY COSTS
– Cost of Operating and Maintaining a
Standby Unit
Maintenance Costs.
3. LOST PRODUCTION COSTS :
– Cost due to Equipment down time.
4. DEGRADATION COST
– Cost occurring due to deterioration of the
life span of equipment due to no
maintenance or inadequate maintenance.
V ariations in
Maintenance
Demand
PLANNING
ORGANIZING
Job Design
Standards
Maintenance Philosophy
INPUT
Facilities
Labor
Maintenance Load Forecasting
Maintenance Capacity
Maintenance Organization
Maintenance Scheduling
Maintenance
Process
Equipment
Spares
Management
Work Measurement
Project Management
MONITOR
OUTPUT
Operational
Machines
&
Equipment
* Scheduling
FEEDBACK
CONTROL
Work control
Material control
Inventory control
Cost control
Managing for quality
Maintenance Planning
activities
Planning activities generally include the
following :
 1. Maintenance philosophy
 2. Maintenance load forecasting
 3. Maintenance capacity
 4. Maintenance organization
 5. Maintenance scheduling.
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Maintenance Strategies
1.Breakdown Maintenance (Run To
Failure)
2. Fault Finding (FF)
3. Time directed Preventive
Maintenance(TD)
4. Condition Based Maintenance (CBD)
5. Design Modification (DM)
6. Replacement Instead of Maintenance
7. Planned Replacement (Car Fleet)
8. Opportunity Maintenance
Maintenance an Internal Part of an
Organization
Growing
Maintenance Expectations
Higher plant availability and reliability
Greater safety
Better product quality
Higher plant availability
No damage to the environment
Longer equipment life
Longer equipment life
Greater cost effectiveness
Fix it when it broke Lower costs
1940
1950
1960
1970
1980
1990
2000
Production System, Maintenance
System & Operations System
Relationship
Availability Performance
Conceptual Presentation
Of Availability Performance
Maintenance Strategies
Strategic Planning in Maintenance
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Vision
Mission
Objectives
Measures/ balanced scored card
Strategies
Implementation
Targets or goals
Action plans
Vision
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“Where you want to be”
To be an Award winning department
at the international level.
Mission “ Why you exist?”
– Keep plant equipment and assets well
configured, safe to operate with the
maximum availability maintained with
minimum cost.
Objectives
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“ What to pursue to achieve mission
and objectives.”
Recruit and maintain the best
technical staff.
Adopt effective and proactive
maintenance strategies using latest
knowledge and technology.
Avail the needed spare parts at the
minimum cost.
Measures
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MTBF for reliability
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Availability
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Costs
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Employee learning
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Utilization
Strategies
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TPM
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Intelligent maintenance.
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Reliability Centered Maintenance
(RCM)
Course Overview
May15-18, 2005
Sunday
May, 15
8:00- 12:00
Overview of
Maintenance Strategies
Monday
May, 16
RCM Methodology &
Tools
Tuesday
May,17
RCM STEPS
Wednesday
May,18
RCM Implementation
12:00- 1:00
Lunch
Day
1:00-3:00
Introduction to RCM
RCM Tools
RCM Steps with example
Case Study