This ppt may help you to get a clear picture about reliability and maintenance in Production Management. Feedback is a must!!!1 Regards. Nazneen Sheikh

1. PRODUCTION
Management
Reliability,
Maintenance

2. Group members..
 Shivani Sahu – 121
 Afzal Shaikh – 132
 Nazneen Sheikh – 137
 Raviraj Shetty - 140
 Gulmohit Singh – 148
 Yogesh Singh - 151
 Sandesh Sonawane – 154
 Lydia Thomson - 159

3. Maintenance
• Maintenance management is concerned with the
direction and organisation of resources in order to
control (improve) the availability and performance of
the industrial plants to some specified level.
• Maintenance is defined also as that function of
production management concerned with the day to day
problem of keeping the physical plant in good operating
condition

4. Plant Maintenance
• Is repairing of the machine at planned intervals so that
sudden breakdowns could be prevented and costly
downtime avoided. This work is generally done when the
shop can spare the machine for repairs, generally during
off shift hours, Sundays and holidays.
– Lubrication and Inspection are two constituents of
PM

5. OBJECTIVE
– Get equipment back into operation as quickly as
possible.
– Control cost of repairs crews.
– Control cost of the operation of repair shops.
– Control the investment in replacement spare parts.
– Control the investment in standby or backup
machines.
– Perform the appropriate amount of repairs at each
malfunction.

6. Advantages of PM
• Greater safety to workers
• Reduction in production down time
• Lesser expenditure on repairs due to fewer repetitive
and large scale repairs
• Less spare parts
• Prolongs the life of the machine
• Maintains quality and continuity of production

7. Disadvantages of PM
• High control on records and analysis, planning &
scheduling
• Monitoring of parameters like temperature, lubrication,
noise, corrosion ,leaks etc are high. The equipments to
do that also are costly.
• Optimum PM is required, hence correct judgement is
needed. Too much or too little is not good.

8. SCOPE OF MAINTENANCESCOPE OF MAINTENANCE
• Primary functions:-Primary functions:-
• Maintenance of existing plant and equipment's.
• Maintenance of existing plant buildings and grounds.
• Equipment inspection and lubrication.
• Utilities generation and distribution.
• Secondary functions:-Secondary functions:-
• Store keeping
• Plant protection including fire protection.
• Waste disposal
• Salvage.

9. Importance of maintenanceImportance of maintenance
• Dependability of services is on of the performance
measures.
• Maintenance is an important factor in quality assurance.
• It helps company by offering protection in case of lengthy
equipment
• Important for the company ‘s cost control.
• To maintain equipment in good condition.

10. Reliability
• Reliability is defined as the probability of a plant to give
satisfactory performance in a particular period of time under
specified conditions. The time between failures is called MTBF
• Availability is the percentage of time the machine will be
available for operation
• Availability = Mean Time Between failures(MTBF)
MTBF + Mean Time for Repairs(MTR)

11. Maintenance and Reliability
 The objective of maintenance and reliability isThe objective of maintenance and reliability is
to maintain the capability of the system whileto maintain the capability of the system while
controlling costscontrolling costs
 Maintenance is all activities involved inMaintenance is all activities involved in
keeping a system’s equipment in workingkeeping a system’s equipment in working
orderorder
 Reliability is the probability that a machineReliability is the probability that a machine
will function properly for a specified timewill function properly for a specified time

12. Strategic Importance of Maintenance and
Reliability
 Failure has far reaching effects on a firm’sFailure has far reaching effects on a firm’s
 OperationOperation
 ReputationReputation
 ProfitabilityProfitability
 Dissatisfied customersDissatisfied customers
 Idle employeesIdle employees
 Profits becoming lossesProfits becoming losses
 Reduced value of investment in plant andReduced value of investment in plant and
equipmentequipment

13. Maintenance Strategy
Employee InvolvementEmployee Involvement
Information sharing
Skill training
Reward system
Employee empowerment
Maintenance and ReliabilityMaintenance and Reliability
ProceduresProcedures
Clean and lubricate
Monitor and adjust
Make minor repair
Keep computerized records
ResultsResults
Reduced inventory
Improved quality
Improved capacity
Reputation for quality
Continuous improvement
Reduced variability

14. Categories
• Breakdown Maintenance ( Corrective maintenance)
• Preventive maintenance(PM)
– Lubrication & Inspection
• Predictive maintenance ( Condition monitoring)
– Is a form of PM
– by tracing the performance of the machine over its
operating life, deterioration that can occur at various
intervals of time is predicted. Early symptoms of failure
are identified and proper maintenance measures
developed.

15. • Routine maintenanceRoutine maintenance
a. Running maintenance
b. shut down maintenance
• Planned maintenancePlanned maintenance
It is an maintenance activities that are carried out
according to a predetermined schedule .also known as
scheduled maintenance or productive maintenance.

16. IMPACT OF POOR MAINTENANCEIMPACT OF POOR MAINTENANCE
• Production capacity
• Production costs
• Product and service quality
• Employee or customer safety
• Customer satisfaction

17. IMPORTANT TACTICSIMPORTANT TACTICS
 ReliabilityReliability
1.1. Improving individual componentsImproving individual components
2.2. Providing redundancyProviding redundancy
 MaintenanceMaintenance
1.1. Implementing or improving preventiveImplementing or improving preventive
maintenancemaintenance
2.2. Increasing repair capability or speedIncreasing repair capability or speed

18. IMPLEMENTING PREVENTIVE MAINTENANCEIMPLEMENTING PREVENTIVE MAINTENANCE
 Need to know when a system requires serviceNeed to know when a system requires service
or is likely to failor is likely to fail
 High initial failure rates are known as infantHigh initial failure rates are known as infant
mortalitymortality
 Once a product settles in, MTBF generallyOnce a product settles in, MTBF generally
follows a normal distributionfollows a normal distribution
 Good reporting and record keeping can aid theGood reporting and record keeping can aid the
decision on when preventive maintenancedecision on when preventive maintenance
should be performedshould be performed

19. Computerized Maintenance System
Output ReportsOutput Reports
Inventory and
purchasing reports
Equipment
parts list
Equipment
history reports
Cost analysis
(Actual vs. standard)
Work orders
– Preventive
maintenance
– Scheduled
downtime
– Emergency
maintenance
Data entry
– Work requests
– Purchase
requests
– Time reporting
– Contract work
Data FilesData Files
Personnel data
with skills,
wages, etc.
Equipment file
with parts list
Maintenance
and work order
schedule
Inventory of
spare parts
Repair
history file

20. Maintenance Costs
 The traditional view attempted to balanceThe traditional view attempted to balance
preventive and breakdown maintenance costspreventive and breakdown maintenance costs
 Typically this approach failed to consider theTypically this approach failed to consider the
true total cost of breakdownstrue total cost of breakdowns
 InventoryInventory
 Employee moraleEmployee morale
 Schedule unreliabilitySchedule unreliability

21. Increasing Repair Capabilities
1.1. Well-trained personnelWell-trained personnel
2.2. Adequate resourcesAdequate resources
3.3. Ability to establish repair plan and prioritiesAbility to establish repair plan and priorities
4.4. Ability and authority to do material planningAbility and authority to do material planning
5.5. Ability to identify the cause of breakdownsAbility to identify the cause of breakdowns
6.6. Ability to design ways to extend MTBFAbility to design ways to extend MTBF

22. How Maintenance is Performed
OperatorOperator MaintenanceMaintenance
departmentdepartment
Manufacturer’sManufacturer’s
field servicefield service
Depot serviceDepot service
(return equipment)(return equipment)
Preventive
maintenance costs less and
is faster the more we move to the left
Competence is higher as we
move to the right

23. Total Productive Maintenance (TPM)
 Designing machines that are reliable, easy toDesigning machines that are reliable, easy to
operate, and easy to maintainoperate, and easy to maintain
 Emphasizing total cost of ownership whenEmphasizing total cost of ownership when
purchasing machines, so that service andpurchasing machines, so that service and
maintenance are included in the costmaintenance are included in the cost
 Developing preventive maintenance plansDeveloping preventive maintenance plans
that utilize the best practices of operators,that utilize the best practices of operators,
maintenance departments, and depot servicemaintenance departments, and depot service
 Training workers to operate and maintain theirTraining workers to operate and maintain their
own machinesown machines

24. Establishing Maintenance Policies
 SimulationSimulation
 Computer analysis of complex situationsComputer analysis of complex situations
 Model maintenance programs before theyModel maintenance programs before they
are implementedare implemented
 Physical models can also be usedPhysical models can also be used
 Expert systemsExpert systems
 Computers help users identify problemsComputers help users identify problems
and select course of actionand select course of action

25. What is system reliability?
 Also known as product reliability.
 When components or parts are combined into a larger
system, such as a machine or a product, the combined
reliability of all the components or parts form the basis
for system reliability.

26. Knowing how to calculate system reliability
• When critical components interact during the operation
of the product or system, the reliability of the product or
system is determined by computing the product of the
reliabilities of all the interacting critical components.

27. Calculation.
• If a product or system has ‘n’ critical components each
with reliability CR1, CR2,….. CRN, then the product or
system reliability SR= CR1*CR2*……CRN (this is known as
multiplication law of probability).
• 10 critical points, each having a reliability of 0.99, the
reliability of that product would be (0.99)10 = 0.904. 100
critical components, each having a reliability of 0.99,
system reliability would be (0.99)100 = 0.366.

28. Fault tree analysis: a systematic and stylized
deductive process.
 An undesired event is defined.
 The event is resolved into its immediate causes.
 This resolution of events continues until basic
causes are identified
 A logical diagram called a fault tree is constructed
showing the logical event relationships

29. Benefits of Constructing a Fault Tree
 Explicitly shows all the different relationships that are
necessary to result in the top event
 A thorough understanding is obtained of the logic and
basic causes leading to the top event
 Is a tangible record of the systematic analysis of the
logic and basic causes leading to the top event

30. Why FTA is carried out ?
 To exhaustively identify the causes of a failure
 To identify weaknesses in a system
 To assess a proposed design for its reliability or safety
 To identify effects of human errors
 To prioritize contributors to failure
 To identify effective upgrades to a system
 To quantify the failure probability

31. Role of FTA in System Safety Analysis
 FTA is used to resolve the causes of system failure
 FTA is used to quantify system failure probability
 FTA is used to evaluate potential upgrades to a system
 FTA is used to optimize resources in assuring system
safety
 FTA is used to resolve causes of an incident

32. The Thought Process in FTA
 FTA is backward looking
 The end result is the analysis starting point
 The end result is then traced back one step at a time to
its immediate causes
 The relationships of the causes, or events, are shown
with logic symbols
 This backward tracing process continues until the basic
causes are identified
 FTA systematizes and codifies the process

33. Thank you for your patient listening.. ! 