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JJ616 – MAINTENANCE ENGINEERING & MANAGEMENT

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zakwan zaman

on 29 December 2014

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Transcript of JJ616 – MAINTENANCE ENGINEERING & MANAGEMENT

MAINTENANCE ORGANIZATION
CHAPTER 1

MAINTENANCE ORGANIZATION
1. The role of maintenance organization
2. The types of maintenance costs


INTRODUCTION

-Process of arranging resources together to
achieve organization strategies & goals

-System that involving the interaction input
and output

-Being made up by 3 necessary & independent
components :
i) Resources
ii) Administration
iii) Work Planning & Control System

OBJECTIVES & BENEFITS OF MAINTENANCE ORGANIZATION
Heavily impacted by elements :
Type of business
Objectives
Size & structure of organization
Culture of Organization
Range of responsibility assigned to maintenance


THE ROLE OF MAINTENANCE ORGANIZATION
MAINTENANCE ORGANIZATION

LECTURER NAME’S: PUAN SHARIFAH ZAINHUDA BT SYED TAJUL ARIFFIN

JJ616 – MAINTENANCE ENGINEERING & MANAGEMENT
Organizations seek objectives :
i)profit maximization
ii)specific quality level of product
iii)minimizing cost
iv)human resource development

Principal responsibility to provide service to enable organization

to achieve objectives
Keeping assests & equipment in good condition
Perform all maintenance activities
Conserve & control the use of spare parts & material
Commissions new plants & plant expansions
Operate utilities & conserve energy


TYPES OF MAINTENANCE ORGANIZATION
Decentralized
-better coordination
-maintenance group is possible

Centralized
-Responsibilities and accountabilities of work must be properly

Partially Decentralize
-specific facilities
-specific industry
-specific set of problems and traditions


DIFFERENTIATE TYPES OF
RESPONSIBILITIES / ROLES
IN MAINTENANCE
MANAGEMENT ORGANIZATION
Unique though actual maintenance practice may be to a specific
facility, a specific industry, and a specific set of problems and traditions.
Have two general classification primary and secondary function.
The primary that demand daily work by the maintenance function.
The secondary ones assigned to the function for reasons of expediency, know-how, or precedent.


Primary functions
Maintenance of Existing Plant Equipment.
> Responsible here is simply to make necessary repairs to production machinery quickly and economically.
Maintenance of Existing Plant Buildings and Grounds.
> Additional aspects of buildings and grounds maintenance may be included in this area of responsibility.
Equipment Inspection and Lubrication.
> All equipment inspection and lubrication has been assigned to the maintenance organization or function.
Utilities Generation and Distribution.
> It can be administered either as a separate function depending on management requirement
Alteration and New Installations.
> Have a three factor generally determine to what extent this area involves the maintenance department
> Plant size: in a small plant of a one-plant company, may be type of work controlled by outside contractors.
> But for this major alteration and installation may be performed by a company-wide central engineering department.



Secondary functions
Storekeeping
Plant Protection
Waste Disposal
Salvage
Insurance Administration
Other Services


TYPES OF
MAINTENANCE COSTS
MAINTENANCE COST
It is defined as the cost that includes lost opportunities in uptime,
rate, yield and quality due to non-operating or unsatisfactorily operational equipment in addition to costs involved with equipment-related degradation of the safety of people, property and environment.

But, often it described simply as the labor and materials expenses needed to maintain equipment or items in satisfactory operational state.

SOURCES OF
MAINTENANCE COST
Among factors that associated with maintenance expediture:-
Downtime
Idle equipment or personnel due to equipment breakdown
Missed delivery dates of equipment (Including out of stock)
Transportation due to remoteness of some of the maintenance work
Overhead cost
Maintenance labor
Asset condition
Losses due to inefficient operations of machines
Capital requirement for replacement of machines.


Some of the many reasons for maintenace costing:-
Determine maintenace cost drivers
Prepare budget
Provide input in the design of new equipment, items or system.
Provide input in equipment life cycle cost studies
Control costs
Make decision concerning equipment replacement
Compare maintenance cost effectiveness to industry averages
Develop optimum preventive maintenance policies
Compare competing approaches to maintenance
Provide feedback to upper level management
Improve productivity.


TYPES OF MAINTENANCE COST
Direct cost : costs required to keep
equipment operable.

These include periodic inspection and preventive maintenance,
servicing costs, repair costs and overhaul costs.




(b) Standby costs : total cost of operating and
maintaining standby
equipment needed to be put
in operation when primary
facilities are either
undergoing a maintenance
activity or are inoperable for
some reason.

(c) Lost production cost : costs due to lost
production because
primary equipment is
down and no standby
equipment is available.

(d) Degradation cost : costs occurring in
deterioration in the
life Span of
equipment resulting
from inadequate
and/or inferior
maintenance.

COST ANALYSIS METHOD
Life cycle cost is....
> sum of all incurred during the life time of an item.
> total procurement and ownership cost.
 
Life cycle cost :
> analysis examines the effect on cost of alternative equipment designs.
> analysis involve evaluating the total cost of a product or system
over its entire life span.

Life cycle cost will consider:
the cost of developing or acquiring the assest
the cost of running
operating and maintaining
the cost of disposal.


The aim of life cycle costing:
-is to know the total cost of equipment accruing over its whole life period, which may include all costs possibly will increase the other cost starting from the specification cost

-observed that reduction in one cost possibly will increase the other cost.


The data to be input into a life cycle cost include the purchase price of the product
-mean time between failures (MTBF)
-mean time to repair (MTTR)
-average material cost of failure
-labor cost per preventive maintenance action
-laor cost per corrective maintenance action
-installation cost
-training cost
-the warranty coverage period cost of carrying spares in inventory
-shipment forecasts over the cource of the product's useful life.

Advantages can be achieved when applying the life cycle cost analysis:
It may result in selection of
equipment that has lower operating and maintenance cost resulting in reduced cost of ownership
The money saved an be used for some other works
It is excellent tool for comparing the cost of competing projects, controlling program cost, selecting among competing contractors, making decisions associated with equipment replacement, reducing total cost, and conducting planning and budgeting.

THANK YOU….
GROUP 1 PRESENTATION CHAPTER 1 JJ616

PRESENTER........
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Secondary functions
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