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Module 4 Maintenance Management

Module 4 Machinery Maintenance. Universidad Europea de Madrid.
by

Jorge Asiain

on 22 June 2017

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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
Section 8.5.1.1. Control plan - Control plan review and update criteria and linked to the PFMEA updates.
Section 8.5.1.4. Verification after shutdown - The necessary actions after the shutdown period should be anticipated in the PFMEA, control plans, and maintenance instructions, as appropiate.
Section 8.5.1.5.
Total productive maintenance
- Strengthens the requirements for equipment maintenance and overall practive management of the Total Productive Maintenance (TPM).

TPM is a system for maintaining and improving the integrity of production and quality systems through machines, equipment, processes, and employees that add value to the manufacturing process. TPM should be fully integrated within the manufacturing processes and any necessary support processes.
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.
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
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.
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

Maintenance Budget =
Total annual labour cost +
Spare parts & materials +
Services +
Maintenance department overheads +
Company overheads
TECHNICIANS
Qualifications:

EN 15628:2014 (Annex A)
EQF Level 4/5 (RQF/HND/HNC)
2 years experienced

Qualifications:

EN 15628:2014 (Annex B)
EQF Level 4/5 (HNC/HND)
2/3 years experienced

SUPERVISOR
PLANNER
RELIABILITY / MAINTENANCE ENGINEER
Qualifications:

EN 15628:2014 (Annex B)
EQF Level 6 (BEng)
2 years experienced

CMRP/CRE/CRL

MAINTENANCE CLERK
TRAINING COORDINATOR
Budget and cost.
Planning and quality.
Staff and contracts.
MAINTENANCE MANAGER
Qualifications:

EN 15628:2014 (Annex C)
EQF Level 6/7 (BEng/MEng)
5 years experienced

CMRP/CRE/CRL

STOREROOM
Centralized
Descentralized
Shared
Consigment
LOCALITATION
per Equipment
per Spare Part Family
Floating
Random
Section 8.7.1.4. Control of reworked product - the risk analysis and customer approval requirements are interrelated; FMEAs should identify and address risks related to each possible rework of the characteristics stated in the control plan.
Section 9.1.1.2. Identification of statistical tools - the use of statictical tools from DFMEA, PFMEA, and the APQP process.
Section 10.2.3. Problem solving.
Section 10.2.4. Error-proofing.
Section 10.3.1. Continual improvemen - supplemental - Uso of TPM, Lean, Six Sigma, and other manufacturing excellende programs or methodologies.
Full transcript