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POM: maintenance and system reliability

This presentation explains the maintenance and system reliability component of Principles of Management course.

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POM: maintenance and system reliability

  1. 1. Maintenance and System Reliability K N Tayade Assistant Professor Department of Information Technology Government College of Engineering, Amravati Principles of Management- Unit-IV
  2. 2. Introduction A combination of actions carried out to keep or restore any asset (Machine, Material –equipment or building) to a satisfactory operating status can be considered as maintenance activity. The objective of maintenance is to keep all components of an operational system in an optimum operating condition.
  3. 3. Objectives of Maintenance a. To maximize the availability and reliability of all assets, to obtain the maximum possible return on investment. b. To extend the life of assets by minimizing wear and tear and deterioration. c. To ensure operational readiness of all equipment required for emergency use at all times, such as standby units, fire fighting and rescue units. d. To ensure the safety of personnel using facilities.
  4. 4. Responsibilities of Maintenance Department Keeping in view the trend towards increased mechanization, computerization and automation, there will be a new level of responsibilities for , and increased dependence upon the maintainer, since: a. Plant output capacities are raised, making downtime very costly. b. Dependence on control systems can produce total disruption of output when one machine fails. c. The possibilities for operator’s intervention to compensate for machine errors or failures have decreased. The requisites for the maintenance department include: a. Requirement for new skills in repair of computer-controlled systems. b. Need for improved multidisciplinary working. c. Requirement for a system approach to maintain.
  5. 5. Failure Analysis Failure analysis plays a vital role in taking decisions pertaining to maintenance planning and control. It helps to identify the nature and occurrence of failure. It is useful in designing and ensuring reliable performance. The bath-tub curve is typical of all operating mechanisms-including the human body with a relatively high, but falling, mortality rate at the initial stage of life, slow but relatively stable rate over the time span, followed by a rapidly rising mortality rate over the later period. Every engineer knows that new equipment is initially at a higher risk of failure, ie. it is less reliable until, after successive minor breakdowns, vulnerable and/or damaged components are replaced or repaired.
  6. 6. Bath Tub Curve
  7. 7. The Maintenance System The objective of the maintenance system is to ensure performance of the operation system at minimum total maintenance cost. The reliability of an operation system is measured in terms of probability of its satisfactory operation for a certain period under specified conditions. The maintenance system is needed to protect the operation system from deviations, in accepted standards, in the quality of output or in the cost and time to produce the same.
  8. 8. Types of Maintenance Planned maintenance Unplanned maintenance Preventive maintenance Corrective maintenance Emergency maintenance Running maintena nce Shutdown maintenance Break- down maintena nce
  9. 9. Types of Maintenance 1. Planned Maintenance: Maintenance work organized and carried out with forethought, control and records. a. Preventive Maintenance: This type of maintenance is used in those cases where deterioration and failure pattern of an item can be described with probability distribution. The routine inspections and servicing are designed to detect potential failure conditions and suggest action. a1. Running Maintenance: Maintenance which can be done when the item is in service. a2. Shutdown Maintenance: Maintenance which is carried out when the item is out of service. Time-based Preventive Maintenance: This maintenance is effective when the failure of any item of an equipment is time dependent and the item is expected to wear out within the life of the equipment. Condition Based Maintenance: It is a corrective maintenance based on condition monitoring , where continuous checks are made to determine the health of an item and to expose incipient faults.
  10. 10. Types of Maintenance Corrective Maintenance or repair: This is carried out to restore an item to the acceptable standard where replacement is not advisable. Breakdown Maintenance: Maintenance work implemented only when facilities or equipment fail to operate and are then repaired at a considerable cost. Unplanned Maintenance /Emergency Maintenance: This type of Maintenance should be an exception rather than the rule.
  11. 11. Performance Criterion for Maintenance Systems An effective Maintenance system is needed to ensure economic and smooth operation of the production system. For low or negligible preventive maintenance effort the total cost of maintenance is attributed to the cost of downtime repairs. Beyond the point of optimal preventive-maintenance effort an increasingly higher level of preventive maintenance cost is incurred for inspection, service and scheduled repairs, and so the firm would be better off waiting for a breakdown to occur.
  12. 12. The Maintenance Strategy 1. Condition Survey and Maintenance Plan. 2. Legal Responsibilities. 3. When can the work be carried out? 4. Maintenance standards. 5. Sources of Finance. 6. Value for Money. 7. Contractors.
  13. 13. TQM: Total Quality Management Quality is no longer seen as something that can be ‘added on’ or ‘inspected’ at the end of the process. A more systematic, approach is necessary to build in quality. Implementing a successful quality programme is not easy, but the rewards are great- reduced costs through less scrap, more efficient production, less wasted effort, increased competitiveness and market share. Juran defines, “ quality control is the regulatory process through which one measures actual quality performance, compare it with standards, and act on the difference”. TQM Definition: TQM means the systematic approach which integrates quality- related activities throughout the organization, including market research, research and development, operational planning for production of goods/services, procurement, production and service. TQM is a system to ensure that a product is manufactured correctly the first time and a system to prevent the occurrence of products which do not meet customer requirements accurately, the ultimate aim being to reduce costs, increase the competitiveness of products and thereby their market share.
  14. 14. TQM: Total Quality Management Quality in business is accomplished by adopting TQM. Its four principles are: 1. Customer focus 2. Strategic quality planning 3. Executive leadership 4. Quality planning, quality control and quality improvement of all key business processes.
  15. 15. TQM Components
  16. 16. TQM: Total Quality Management TQM model provides a distinctly different way of looking at the management style. It develops a participative culture where each employee can directly participate in areas and decisions concerning his work. It is organized through quality circles, on a voluntary basis, and quality improvement teams. It builds positive attitudes of employees towards quality, organization and enhances respect for each other leading to a meaningful workplace proud to be in.
  17. 17. TQM for Empowerment of People In applying TQM approach to an organization, the following six points emerge: 1. TQM approach not only provides transform of employee-employer relationship, but also focuses attention on economic development. 2. History shows that attempts at workers participation have not proved successful. 3. TQM is a win-win approach. 4. TQM assumes: Recognition of employee rights, needs, redesign of work to benefit people, Participative decision making and problem solving. 5. TQM involves everyone: Worker, Clerk, Manager and Management. 6. It builds synergies of all.
  18. 18. TQM Approach
  19. 19. Evolution of TQM Four phases of quality management 1.Quality Control(QC) Phase: QC focuses on product defect detection through post-production inspection. It is concerned with adherence to standards and sorting out rejects. 2. Quality Assurance (QA) Phase. QA recognizes that “inspection is not the answer” and that “the entire manufacturing process must be committed to meeting the quality needs of the design”. 3. Total Quality Control(TQC) Phase: TQC programmers attempt to expand the QA philosophy beyond manufacturing operations into other areas of organizational life. TQC incorporates many of the tools used in QA, but the purpose of problem analysis is to develop long-term solutions rather than respond to short-term variations. 4. Total Quality Management: The systematic analysis, preplanning and blueprinting of operations remain essential, the focus switches from a process driven by external controls through procedure compliance and enhancement to a process of habitual improvement, where control is embedded within and is driven by the culture of the organization.
  20. 20. Cost of Quality The following factors are involved in the cost of quality: 1. Language of money is easily understood. 2. It costs money to do anything. In India, money is not easy to come by. 3. Cost of quality helps to measure and reduce wasteful expenditure. 4. Total It enables one to find the most cost-effective way of doing work.
  21. 21. ISO 9000 and Quality Audit International Organization for Standardization 1.ISO 10011-1 Auditing 2.ISO 10011-2 Auditing 3.ISO 10011-3 Auditing
  22. 22. Thank You