Chapter 10: Maintenance Operations and Control

1
Chapter 10 Maintenance Operations and Control

• Overview
• Maintenance control cycle
• Maintenance work order system
• Record keeping
• Structure of maintenance control
• Effective maintenance program

2
Maintenance Operations and Control

• Controlling maintenance means coordinating the
  demand for maintenance and the available
  resources to achieve a desired level of
  effectiveness and efficiency
• Component of a maintenance operation and control
  systems
• Maintenance demand (what work? when?)
• Maintenance resources(who?what materials
  tools?)
• Procedures and means of coordinating,
  scheduling, dispatching, and executing the work
• Performance and quality standards
• Feedback, monitoring and control
• Work order system is the vehicle for planning and
  controlling maintenance work

3
Maintenance Control Cycle

• Objectives
• Availability
• Quality level

• Analyze sample
• Trend analysis
• Performance measures
• Downtime trend

4
Maintenance Work Order System

• Work order is a form in which written
  instructions are detailed for work to be carried
  out and it must be filled out for all jobs
• The objective of the work order system provide
  means for
• Request the work to be performed
• Screening the requested work by operation
• Assign qualified workers and method to the job
• Improve planning and scheduling of maintenance
• Maintaining and controlling the maintenance work
• Improve overall maintenance works
• Responsibility scheduling and planning persons

5
Maintenance Work Order System

• Requirements of work order
• All information needed for planning, scheduling
• clarity and ease of use
• Two types of work order
• Blanket small routine, repetitive jobs
• special work order for individual jobs
• Utilization of work order
• Work request form
• Planning document, a monitoring and control tool
• Work allocation chart, history record,

6
Design of the Work Order

• Contents
• Planning and scheduling information Inventory
  number, unit description, and site Person or
  department requesting the work Work description
  and time standards Job specifications and code
  number Priority and date work is
  required Trades required Spare parts and
  materials required Special tool
  required Safety procedures Technical
  information (drawing and manuals)

7
Design of the Work Order

• Control information Actual time
  taken Cost codes for trades Downtime
  or time work finished Causes and consequences
  of failure
• Example of a typical work order (included)
• General guidelines
• All maintenance department must have a work order
  for planning and executing their maintenance work
• Work order must be numbered and at least three
  copies are needed for maintenance control
• Work order requests can be initiated by any
  persons and must be screened by the maintenance
  planner or coordinator

8
Work Order System Flow
Work request receive and screened Work order
planned and prepared (4 copies), copy 1 filed in
open work file
Workers perform job, completes job and posts
needed information on work order
9
Record Keeping

• Job card (report)
• The job report form (job card) is a statement
  recording the work done and the condition of the
  equipment
• A job card can be issued to each employee
  participating on each job
• Reported information Repair
  time Costs Downtime
• Equipment history record
• a document records information about all work
  done on a particular facility/ equipment

10
Record Keeping

• Recorded information Equipment
  specifications and location Inspections,
  repairs, servicing, and adjustments
  done Breakdowns, failures, their causes and
  corrective actions under taken Work done on
  the equipment, component repaired or replaced,
  condition of wear and tear, erosion,
  etc. Measurements or readings taken, clearance,
  results of tests and inspections Failure
  time and the time lost to carry out repairs

11
Structure of Maintenance Control
Work order coordination and planning
Work orders
Feedback
Feedback
Work order processing
Feedback
work
Work order execution
12
Work Order Coordination and Planning

• Coordinate function plans, maintenance requests
• Four decision functions
• Preventive maintenance planning Monitor PM
  plan Generate PM work orders PM
  planning ? fixed advanced work orders
• Corrective maintenance classification Priorit
  ize corrective maintenance work
  orders Corrective maintenance classification
  ? emergency postponable work orders

13
Work Order Coordination and Planning

• Adaptive maintenance acceptance Smooth the
  maintenance works control chart Adaptive
  maintenance acceptance ? internal external
  work
• Maintenance capacity adjustment evaluate
  the current resources meet demand?
• Structure of work order coordination

14
Work Order Processing
15
Information Feedback and Corrective Action

• Information feedback and corrective action
  Collect data Analyze information Formul
  ate corrective actions
• The course of actions and decisions is aimed at
  improving Work control Cost
  control Quality control Plant
  condition control

16
Work Control

• Monitor work status work performance gtltstandards
• Reports performance report and backlog report
• Corrective actions for downtrend backlog
• Reduce contract maintenance
• Consider transfer between departments
• Downsize maintenance workforce
• Corrective actions for increasing trend backlog
• Increase contract maintenance
• Consider transfer between departments
• Schedule cost-effective overtime
• Increase maintenance workforce

17
Work Control

• Control total backlog control charts
• Center-line average CLA
• Upper control limit UCL
• Lower control limit LCL
• For a normal distribution relative range W
  R/?, where R range of sample Xmax Xmin
  ? standard deviation of normal
  distribution
• the estimator of ? is
• when the backlog is outside the limits, an
  investigation is taken to determine the causes ?
  corrective action

18
Cost Control

• Maintenance cost
• Direct cost labor, spares, materials, equipment,
  tool
• Operation shutdown cost due to failure
• Cost of quality product out of specifications
• Redundancy cost due to equipment backups
• Equipment deterioration cost due to lack of
  proper maintenance
• Cost of over-maintaining
• Cost information work order
• Cost reports will indicate the most needed cost
  reduction programs

19
Cost Control

• Cost reduction programs areas
• Use of alternative materials
• Modifying inspection procedures
• Revising maintenance procedures (adjustments in
  crew size, methods)
• Re-designing material-handling procedures and
  workshop layout

20
Quality Control

• Maintenance Quality
• Monthly report on the percentage of repeat jobs
  and product rejects ? investigate the machine ?
  causes of quality problems ? corrective actions (
  modify maintenance policy, training workforce)

21
Plant Condition Control

• Requirement recorded failures and repairs of
  critical and major equipment ? work order,
  equipment history file
• If downtime is excessive or the equipment
  availability and readiness is low ? corrective
  actions reliability improvement program, planned
  maintenance program

22
Effective Maintenance Program

• Objectives improve plant availability, reduce
  cost, and improve equipment reliability and
  product quality
• Planned Maintenance Program
• Convert most of the maintenance works into
  scheduled maintenance
• Tasks inspection, servicing of jobs,
  condition-based maintenance
• All activities are preplanned material planning
  and stocking

23
Effective Maintenance Program

• Emergency Maintenance Program
• Should minimize and lt10 total maintenance works
• Handling emergency maintenance two
  approaches Add to regular schedule ?reserve
  10-15 capacity Estimate the amount of
  emergency?skilled workers
• Reliability Improvement Program
• Critical equipment history files ? MTBF
  ?frequency of emergency maintenance n/MTBF, n
  operation hours
• Another approach reliability-centered
  maintenance program (RCM) restore gtltbring to new

24
Effective Maintenance Program

• Equipment Management Program
• Total Production Maintenance (TPM) ? equipment
  management ? improve product quality ? improve
  OEE
• Causes of equipment losses Failure Set
  up and adjustments Idling and minor
  stoppages Reduced speed Process
  defects Reduced yield

25
Effective Maintenance Program

• Cost Reduction Program
• Use engineering method approaches study how the
  work is being performed ? develop a better way
• Simplify and eliminate unnecessary steps
• Considered areas Alternative material and
  spare parts Alternative method for inspection
  and overhaul Alternative equipment and
  tools Alternative procedures for planning and
  scheduling Alternative job time standards
• Training and Employee Motivation Program
• on-the-job and off-the-job training ? upgrade,
  update