Maintenance Planning - In Depth Notes

Overview of Maintenance Planning

  • Course: ME542: Maintenance Planning
  • Instructor: Ahmad Sayed Saif-Eddine
  • Contact: A7mad.saif@hotmail.com

Agenda

  • Quick Review
  • Types of Maintenance Actions
  • Implementing Preventive Maintenance
  • References

Types of Maintenance Actions

  1. Types of Maintenance Actions
    • Maintenance Actions fall into several categories:
      • Corrective Maintenance
      • Preventive Maintenance
      • Predictive Maintenance
      • Immediate and Deferred Actions
      • Predetermined, Condition-based, Opportunistic Maintenance
      • Clock-based (Calendar, Age, Usage)
      • Usage-based Maintenance
      • Condition Monitoring & Inspection
      • Functional Test
      • Cleaning, Adjustment, Calibration, Lubrication, Replacement, Refurbishment

Corrective Maintenance

  • Definition: Reactive approach to repair equipment after failure.
  • Advantages:
    • Low initial investment
    • Requires less specialized staff
  • Disadvantages:
    • Increased costs due to unplanned downtime
    • Higher labor costs, especially overtime
    • Cost for repairs or replacements
    • Risk of secondary damage to equipment or processes
    • Inefficient use of resources

Preventive Maintenance

  • Definition: Scheduled maintenance aimed at preventing breakdowns.
  • Advantages:
    • Cost-effectiveness in capital-intensive processes
    • Flexible adjustment of maintenance schedule
    • Extends the lifecycle of components
    • Energy savings
    • Reduced chances of equipment/process failures
    • Estimated 12-18% cost savings compared to Reactive Maintenance
  • Disadvantages:
    • Risk of catastrophic failures still exists
    • Labor-intensive process
    • Possibility of performing unnecessary maintenance
    • Potential damage from unnecessary maintenance actions

Predictive Maintenance

  • Definition: Maintenance based on predicting when maintenance should be performed.
  • Advantages:
    • Increases operational life and availability of components
    • Allows for timely corrective actions
    • Reduces equipment downtime
    • Lower parts and labor costs
    • Improves product quality and worker safety
    • Energy savings
    • Estimated 8-12% cost savings over Preventive Maintenance
  • Disadvantages:
    • Higher investment in diagnostic tools
    • Increased training requirements for staff
    • Management may not realize potential savings

Implementing Preventive Maintenance

  • Cost Analysis:
    • Full cost of breakdowns vs. preventive maintenance costs.
    • Aim for an optimal point where overall maintenance costs are minimized.

Case Study: Farlen & Halikman

  • Context: A CPA firm relying on high-speed printers for payroll.
  • Observations:
    • Breakdown Statistics over 20 months:
      • 0 Breakdowns: 2 months
      • 1 Breakdown: 8 months
      • 2 Breakdowns: 6 months
      • 3 Breakdowns: 4 months
  • Impact of Breakdowns: Approximately $300 loss for each breakdown in production.
  • Prevention Option: Buying preventive maintenance service for $150 per month, with an average of one breakdown/month still expected.

References

  1. M. Ben-Daya, U. Kumar, and D.N. P. Murthy, “Introduction to Maintenance Engineering,” Wiley, 2016.
  2. S.A. Kumar & N. Suresh, “Production and Operations Management,” 2nd ed., New Age International Publishers, 2008.
  3. J. Heizer, B. Render & C. Munson, “Operations Management: Sustainability and Supply Chain Management,” 12th ed., Pearson, 2017.

Conclusion

  • Understanding the types and planning of maintenance is critical to enhancing operational efficiency and reducing costs. Proper implementation of preventive actions can lead to significant long-term benefits.