Operations Management, Maintenance and Reliability

Flashcards on Operations Management, Maintenance and Reliability.

Maintenance

Activities involved in keeping a system's equipment in working order.

Reliability

The probability that a machine part or product will function properly for a specified time under stated conditions.

Corrective Maintenance

Maintenance that is reactive, occurring after a breakdown. Also known as Breakdown Maintenance.

Preventive Maintenance

Maintenance that involves performing frequent maintenance and inspection to assure that system never fails.

Scheduled Maintenance

Maintenance is done as needed based on asset conditions.

Preventive Costs

Costs related to efforts such as training staff to avoid disruptive mistakes.

Detection Costs

Costs related to hiring experts to inspect a process, find the source of a problem, and resolve it.

Failure Rate

The frequency with which a system or component in a product fails.

Mean Time Between Failures (MTBF)

A measure of reliability, where a longer MTBF indicates a lower failure rate and higher system reliability.

Series System

A system where all components or subsystems must function for the entire system to work; failure of any component leads to system failure.

Redundancy

The use of backup components or additional components to ensure that a system has resources available if one component fails.

Parallel System

A system where components are arranged in parallel, such that the system works as long as at least one of the components works.

Total Productive Maintenance (TPM)

A system of maintenance that integrates the entire organization, from management to the shop floor, to maintain and improve equipment.

Autonomous Maintenance

A TPM pillar where operators are responsible for basic maintenance tasks, freeing up maintenance personnel for more complex tasks.

Overall Equipment Effectiveness (OEE)

A metric to measure how effectively a manufacturing operation is utilized. It is calculated by multiplying availability, performance, and quality.

Availability

The proportion of time a machine is available to run during its scheduled production time.

Performance

The speed at which a machine runs as a percentage of its designed speed.

Quality

The percentage of good units produced compared to the total units started.

Root Cause Analysis (RCA)

A method of problem-solving used for identifying the root causes of faults or problems.

Condition Monitoring

Using sensors and data analysis to monitor the condition of equipment and predict potential failures.

Mean Time To Repair (MTTR)

The average time required to repair a failed component or piece of equipment.

Life Cycle Cost (LCC)

The total cost of owning an asset over its entire life, including purchase, operation, maintenance, and disposal costs.

Fishbone Diagram (Ishikawa Diagram)

A visual tool that helps in identifying, isolating, and rectifying the causes of problems.

Affinity Diagram

A technique used to organize ideas into common themes or groups.

Pareto Chart

A chart that contains both a line and a bar graph, where individual values are represented in descending order by bars, and the cumulative total is represented by the line.

Scatter Diagram

A statistical chart showing plotted points that illustrate the functional relationship between two sets of data.

Histogram

A graphic summary of variation in a set of data.

Quality Inspection

The process of observing a product or service to identify and record any departure from specified quality standards.

ISO 9000

A set of international standards on quality management and quality assurance developed to help companies effectively document the quality system elements needed to maintain an efficient quality system.

Six Sigma

A quality management framework that combines management and statistical tools to reduce defects and minimize variability in processes.

DMAIC (Define, Measure, Analyze, Improve, Control)

A structured approach to process improvement that includes the phases of Define, Measure, Analyze, Improve, and Control.

DMADV (Define, Measure, Analyze, Design, Verify)

A methodology used to create a defect-free process using five phases: Define, Measure, Analyze, Design, and Verify.