Maintenance Engineering

Assoc. Prof. Dr. Somkiat Tangjitsitcharoen

HW2

Autonomous Maintenance
and
Preventive Maintenance

by

Mr. Atjanon Benjamasutin

5031467021

Atajnon Benjamasutin 5031467021

 Autonomous Maintenance
It is an operator skill development program that
- Allows problems to be identified and solved quickly.
- Stop accelerated deterioration of plant and equipment.
- Stop deterioration related failures.
- Stabilize equipment conditions.

To implement it we have to first improve human resources , plant and equipment
and last improve corporate culture. We can divided the implementation into 5 steps.

1. Step 0 ( Education - Machine Function )

- Introduce machine component sheets to help us understanding how equipment works
and what can cause it to fail.
- It should initially be hand drawn and let by and experienced engineer.
One point lesson
- Tool to communicate improvements , capture ideas , share knowledge and for effective
training.
- 3 types of One Point Lesson namely 1. Basic Knowledge 2. Improvement Idea 3.
Downtime Problem
- It should also initially be hand drawn , take only 5 mins to teach and be verified by
engineer.
- 80 % Drawing and 10% Words.
- Use bottom sheet as a training record.

2. Step 1 ( Initial clean and inspect )

- Clean and inspection fault finding sheet
- Machine , Date , Completed by

3. Step 2 ( Eliminate Contamination by Machine Mapping )

- Group exercise with experienced engineer/maintainer as a leader
- Use in conjunction with Tags.
- Identify sources of contamination.
- Make in more specific to reduce inspection/cleaning time , make essential access
easier.
- To simplify equipment operations.

4. Step 3 ( Develop Provisional Standards Cleaning , Lubrication and Inspection )

5. Step 4 ( Finalize standards and Train )

- In the training we should include component sheets , one point lessons , standards
and work instruction sheet.

Preventive maintenance or Scheduled Maintenance

It is a daily maintenance including cleaning , inspection , oiling and re-tightening.
It is designed to retain the healthy condition of equipment and prevent failure through

Atajnon Benjamasutin 5031467021

 the deterioration. Like human life , we keep our life longer by preventive medicine and
machineʼs life can be prolonged by doing preventive maintenance.

Repairs VS Preventive Maintenance (PM)

Cost ($)

Minimum Total Maintenance Cost

Total Maintenance Cost

Preventive Maintenance Cost

Breakdown and repair cost

Degree of PM

Trade off between Repairs and PM

Repairs Preventive Maintenance

Activities are reactive Regularly scheduled inspection are

performed

Breakdowns occur when machine is in PM are performed BEFORE machine

use. fails.

Standby machines can speed repairs. PM is usually performed during idle.

At minimum level of PM , breakdown cost is very high and decreasing when level of PM
is higher finally at some point we reach the minimum total maintenance cost.

Repair Program
Objective is to get equipment back into operation as quickly as possible and also
control cost of repairs crews , the operation of repair shops.
- Control the investment in replacement spare parts / standby or backup machines.

Atajnon Benjamasutin 5031467021

Cost
Total cost of
repairs
Minimum Total
cost of repairs Cost of repairs
crew shops
spare parts etc.

Cost of
interruptions to
production

Speed of making repairs

Example

Determine the size of repair crews ??

Sewing machine breakdown at average rate of 12 / hour
Average repair time is 0.75 hours
Malfunction should be out of production no more than 2 hours.
How many sewing machine repair specialists needed?
( Assume breakdown rate is Poisson distributed and repair times are exponentially
distributed. )

1. Compute necessary average service rate ( entire crew )

Average service rate is 12.5 machines/hour

2. Compute implied average service rate per repair crew

0.75 is repair time per machine per specialist

Average service rate per repair crew is 1.333 machines per hour

3. Compute no. of repair crew

= 9.375 or 10 crews

Atajnon Benjamasutin 5031467021

Advantages of letting workers repair their own machines
- Greater variety may make job more satisfying.
- Increase flexibility.
- Operate machines more carefully.

Reasons for a PM program

- Reduce the frequency and severity of interruptions due to malfunctions.
- Extend useful life of machine.
- Reduce the total cost of maintenance.
- Provide a safe working environment.

PM database requirements
- Detailed record history must be maintained on each machine
includes dates and frequency of breakdowns, descriptions of malfunction and cost of
repairs.
- Machine spec/checklists for PM inspection.
- Computer database or kept in plastic pocket on a machine.

Decision analysis in PM ( 3 decisions )

1. Number of spare parts to carry
2. How often to perform PM on a group of machines
3. Planning and controlling a large-scale PM project.

Determine the frequency of performing PM.

1. Compute expected no. of breakdowns for each PM policy.
2. Compute breakdown cost , PM cost , total cost for each PM policy.
3. Identify policy that minimizes the total cost/unit of time.

Formula

Bn is expected no. of breakdown each PM policy.

pn is probability that breakdown will occur between PM inspections when perform every
n periods.
N = no. of machines in group.

Atajnon Benjamasutin 5031467021

Example

6000$ to perform PM on group of fours machines.

8000$ is cost of down time and repairs if machine malfunctions between PM inspection.

Machine Breakdown history

Weeks Probability that machine will
between PM malfunction

1 0.2

2 0.3

3 0.5

B1 = 4(0.2) = 0.8
B2 = 4(0.2+0.3) + 0.8(0.2) = 2.16
B3 = 4(0.2+0.3+0.5) + 2.16(0.2) + 0.8(0.3) = 4.672

PM every n No. of No. of BDs Cost of Weekly Total

weeks breakdown per wk. breakdown cost of PM weekly
(A) (B) C = (B/A) ($8000xC) ($6000/A) cost

1 0.8 0.8 $6,400 $6,000 $12,400

2 2.16 1.08 $8,640 $3,000 $11,640

3 4.672 1.557 $12,456 $2,000 $14,456

We can see that PM every 2 weeks is the best solution to minimize the cost.

Atajnon Benjamasutin 5031467021