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Module 4 Maintenance Management

Module 4 Machinery Maintenance. Universidad Europea de Madrid.
by

Jorge Asiain

on 5 November 2016

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Transcript of Module 4 Maintenance Management

Module 4 - Maintenance Management
Machinery Maintenance
Jorge Asiain, CEng
Ingeniería Industrial y Aeroespacial
Finance Management
Mistakes
Minimum cost.
Continuous maintenance.
Total availability.
Keeping service to the users at a reasonably high level.
Keeping inventory investment reasonably low.
Cost-effective purchasing.
Stock is secure.
Stock identity, quantity and location are known.
Items are available and accesible when required.
Exercise
A list of the equipment.
Define maintenance requirements (tasks and frequency).
Maintenance program (with task schedules).
Procedures defining how specific maintenance tasks are to be conducted.
Procedures governing the decommissioning of plant prior to planned maintenance.
Procedures governing the commissioning of plant following planned maintenance.
Procedures dealing with the actions required in the event of equipment malfunction.
Maintenance logs which record both the preventive and corrective maintenance work carried out.
Control of work.
Training and motivation.
Tactical decision to stay on schedule.
Administrative of personnel functions.
Job plan estimates for nonemergency work.
Work schedules by priority.
Ensure even low priority jobs are accomplished.
Maintains records, indexes, charts.
Reports on performance versus goals.
Improve the availability.
Identify and correct chronic and costly equipment problems.
Design and monitor an effective and economically justified maintenance program.
Maintain and analyze equipment data and history records.
Define training needes.
Do training programs.
Log activities.
Support management.
Keep logs.
Do reports.
1
"Economic" quantities save money.
2
Risk must be re-evaluated to reduce inventory
3
Consignment stock must cost more.
4
Software will solve the problem.
5
Putting items into inventory saves money.
KPI
Purchase orders are placed promptly and goods received effectively.
Systems
Reparables
Non-Reparables
Renewal Process
Non-Renewal Process
Homogeneous Poisson Process (HPP)
Non-Homogeneous Poisson Process
HOYLE D. Automotive quality systems handbook. Oxford: Butterworth-Heinamenn Ltd. 2000. page 359.
ISO TS 16949 - 4.9.1.1g and 4.9.1.5.
MOBLEY R.K; HIGGINS L.R; WIKOFF D.J. Maintenance engineering handbook. 7th Ed. New York: McGraw-Hill. 2008. page 1.37.
SLATER P. 5 myths of inventory reduction. Melbourne: Initiate Action. 2006.
HASTINGS N.A.J. Physical asset management. London: Springer-Verlang. 2010. page 198.
Risk Assessment for Spare Parts
NORSOK STANDARD Z-008 Risk based maintenance and consequence classification. Edition 3, June 2011. page 36.
Human Error Management
Human error is inevitable
Recognition failures.

Memory failures.

Skill-based slips.

Rule-based Mistakes.

Knowledge-based errors.

Violations – deliberate acts which violate procedures.
¡Avoid Unnecessary Preventive Maintenance!
Key Principles
Human error is both universal and inevitable.
Errors are not intrinsically bad.
You cannot change the human condition, but you can change the conditions in which humans work.
The best people can make the worst mistakes.
People cannot easily avoid those actions they did not intend to commit.
Errors are consequences, rather than causes.
Many errors fall into recurrent patterns.
Safety-significant errors can occur at all levels in the system.
Error Management is all about managing the manageable.
Maintenance Quality Management is about making good people excellent.
There is no one best way.
Effective Maintenance Quality Management aims at Continuous Reform rather than Local Fixes.
Measures I
Person Measures
Provide training in error-provoking factors.
Implement measures to reduce the number of deliberate violations.
Encourage mental rehearsal of tasks before they are performed.
Control Distractions.
Avoid Place-Losing Errors.
Team Measures
Provide teamwork training.
Workplace and Task Measures
Ensure that personnel only perform tasks when they are properly trained, skilled and qualified.
Fatigue Management.
Assign tasks appropriately.
Ensure that equipment, and tasks, are properly designed.
Enforce good housekeeping standards.
Ensure Spare Parts and Tools are managed well.
Write, and Use, Effective Maintenance Work Instructions.
Measures II
Organizational Measures
Put in place effective processes for analyzing, and learning from, past failures.
Put in place proactive processes for assessing the risk of future maintenance errors.
Asset Management
from Alexander Dunn, Assetivity Pty Ltd.
Spare Parts Management
Contracted Services Management
Staff Management
Human Error Management
Quality Management
Finance Management
Performance Management
Asset Management
Perform maintenance tasks.
Perform simple root cause analysis.
Fulfil work order templates.
Skill Matrix
ROI
&
NPV

Extended Warranties
Maintenance Services
Lease Contracts
Full transcript