Project on Maintenance Methodology & Systems in Manufacturing for subject of Operations Research which covers
Functions and Performance Standards:
Failure Situations
RCM
Manufacturing processes
• Casting
• Moulding
• Forming
• Machining
• Joining
• Rapid manufacturing
• Other trades
Mattingly "AI & Prompt Design: The Basics of Prompt Design"
Maintenance Methodology & Systems in Manufacturing : Operations Reserch
1. Maintanace Methodology &
Systems in Manufacturing
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2. Maintenance Methodology
• The dictionary defines maintenance as:
“The work of keeping something in proper
condition; upkeep.”
• Maintenance is performed to keep equipment
and systems running efficiently for at least
design life of the components.
• Types of maintenance : Proactive and reactive
4. MAJOR MAINTAINENCE METHODS:
• Every facility that produces a consumer product has some
requirement for maintenance or upkeep of their machinery.
• Depending upon the product and, to some extent, the size
of the
• facility, this maintenance activity may be continuous in
nature or periodic.
• Some maintenance activities may consume a significant
portion of the facility expenses and manpower.
• Facility maintenance activities generally fall into three
categories: Breakdown, Preventive, and Predictive.
• Each category has particular costs associated and specific
benefits.
5. Reactive Maintenance(Breakdown Maintenance)
SYSTEM
• Response to
Equipment
Malfunctions
CHARACTERISTIS
• Inefficient
maintenance
department.
• Unpredictable
Equipment
operation
• All maintenance
work unplanned
• Example: Light Bulb
replacement
RESULTS
• Steady degradation
of equipment
performance.
MAINTENANCE
DEPARTMENT
RESPONSIBILITY
• Respond to
emergencies
• Get production back
on line
6. Reactive Maintenance
• Reactive Maintenance can
be described as responding
to an event after it has
happened.
• Generally categorize by
profession.
Locksmith
Plumbing
Services
Glazing
Carpentry
Services
Electrical
Roofing
Small
Building
Works
7.
8. Advantages of Reactive Maintenance (Breakdown Maintenance):
• Low cost.
• Less staff.
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9. Disadvantages of Reactive Maintenance :
• Increased cost due to unplanned downtime of
equipment.
• Increased labour cost, especially if overtime is
needed.
• Cost involved with repair or replacement of
equipment.
• Possible secondary equipment or process damage
from equipment failure.
• Inefficient use of staff resources.
10. Preventive Maintenance
• Advancement on a breakdown
maintenance program is a preventive
program.
• It involves scheduling a regular
outage, usually on an annual basis,
where the entire machine train or plant
is shutdown, or removed from
production, for careful inspection and
routine replacement of specific parts.
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11. Preventive Maintenance
• This method has the highest cost for replacement parts
because the facility may have a separate program or
department with the sole purpose of maintaining an
inventory of spare parts and scheduling outage activity.
• Maintenance costs are reduced because the "annual outage"
or "turn around" is usually scheduled for a period when the
product demand is low.
• Additional cost savings are realized because manpower and
any heavy equipment are scheduled.
12. Advantages:
• Cost effective in many capital-intensive processes.
• Flexibility allows for the adjustment of maintenance
periodicity.
• Increased component life cycle.
• Energy savings.
• Reduced equipment or process failure.
• Estimated 12% to 18% cost savings over reactive
maintenance program.
13. Disadvantages:
• Catastrophic failures still likely to
occur.
• Labour intensive.
• Includes performance of unneeded
maintenance.
• Potential for incidental damage to
components in conducting unneeded
maintenance.
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14. Reliability - Centered Maintenance:
• The Changing World of Maintenance
• Since the 1930's, the evolution of
maintenance can be traced through
three generations. RCM is rapidly
becoming a cornerstone of the third
generation, but this generation can
only be viewed in perspective in the
light of the first and second
Generations.
15. The First Generation:
• The First Generation covers the period up to
World War II. In those days industry was not
very highly mechanized, so downtime did
not matter much. This meant that the
prevention of equipment failure was not a
very high priority in the minds of most
managers. At the same time, most
equipment was simple and much of it was
over-designed. This made it reliable and easy
to repair. As a result, there was no need for
systematic maintenance of any sort beyond
simple cleaning, servicing and lubrication
routines. The need for skills was also lower
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than it is today.
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16. The Second Generation:
• Things changed dramatically during World War II.
Wartime pressures increased the demand for goods
of all kinds while the supply of industrial manpower
dropped sharply. This led to increased
mechanization.
• The cost of maintenance also started to rise sharply
relative to other operating costs. This led to the
growth of maintenance planning and control
systems. These have helped greatly to bring
maintenance under control, and are now an
established part of the practice of maintenance.
• Finally, the amount of capital tied up in fixed assets
together with a sharp increase in the cost of that
capital led people to start seeking ways in which they
could maximize the life of the assets.
17. The Third Generation:
• Since the mid-seventies, the process of change in
industry has gathered even greater momentum. The
changes can be classified under the headings of new
expectations, new research and new techniques.
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18. RCM - The seven basic questions:
• The RCM process entails asking seven questions about the asset or
system under review:
• What are the functions and associated performance standards of the
asset in its present operating context?
• In what ways does it fail to fulfill its functions?
• What causes each functional failure?
• What happens when each failure occurs?
• In what way does each failure matter?
• What can be done to predict or prevent each failure?
• What should be done if a suitable proactive task cannot be found?
20. The RCM process does this at two levels:
• First, by identifying what
circumstances amount to a failed
state.
• Second, by asking what events can
cause the asset to get into a failed
state.
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21. Failure Situations
• Failure Modes:
• Failure Effects:
• What evidence that the failure has occurred
• In what ways it poses a threat to safety or the
environment
• In what ways it affects production or
operations
• What physical damage is caused by the failure
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• What must be done to repair the failure.
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22. Failure Consequences:
• A great strength of RCM is that it recognizes that the
consequences of failures are far more important than
their technical characteristics.
• The RCM process classifies these consequences into
four groups:
• Hidden failure consequences: .
• Safety and environmental consequences:
• Operational consequences:
• Non-operational consequences:
23. Failure management techniques
• Proactive tasks:
• These are tasks undertaken before a failure occurs, in order to
prevent the item from getting into a failed state. They embrace
what is traditionally known as 'predictive' and 'preventive'
maintenance, although we will see that RCM uses the terms
scheduled restoration scheduled discard and on-condition
maintenance.
• Default actions:
• These deal with the failed state, and are chosen when it is not
possible to identify an effective proactive task. Default actions
include failure-finding, redesign and run-to-failure.
26. Systems in Manufacturing
• Production machines and tools
• Material handling and work positioning devices
• Computer system
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27. Manufacturing Process
• Process or continuous production:
• Mass production:
• Batch production:
• Jobbing production:
• Just-in-Time (JIT)
• Computer integrated