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Preventive Maintenance

The document discusses preventive maintenance (PM), which includes periodically inspecting equipment to prevent failures. It describes two types of PM: time-based and predictive. The benefits of PM are also outlined, such as reducing costs, extending equipment life, and minimizing downtime. A manufacturing game is described that simulates operations, maintenance, and spare parts management. Players make decisions about PM and see the effects on metrics like revenue, costs, and uptime. Teams using reactive maintenance strategies have initial low costs but then costs rise as defects increase, while preventive maintenance teams have higher initial costs but outperform over time. PM makes economic sense when the cost is less than not performing PM.

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Dwi Achmad Satrio
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96 views4 pages

Preventive Maintenance

The document discusses preventive maintenance (PM), which includes periodically inspecting equipment to prevent failures. It describes two types of PM: time-based and predictive. The benefits of PM are also outlined, such as reducing costs, extending equipment life, and minimizing downtime. A manufacturing game is described that simulates operations, maintenance, and spare parts management. Players make decisions about PM and see the effects on metrics like revenue, costs, and uptime. Teams using reactive maintenance strategies have initial low costs but then costs rise as defects increase, while preventive maintenance teams have higher initial costs but outperform over time. PM makes economic sense when the cost is less than not performing PM.

Uploaded by

Dwi Achmad Satrio
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Preventive Maintenance (PM):

(Time-based or run-based)
Periodically inspecting, servicing,
cleaning, or replacing parts to prevent
sudden failure
(Predictive) On-line monitoring
of equipment in order to use
important/expensive parts to the limit of
their serviceable life

Benefits of Preventive
Maintenance
...the cost of breakdown
maintenance is usually much greater
than preventive maintenance. 1
Preventive maintenance...
Keeps equipment in good
condition to prevent large problems
Extends the useful life of
equipment
Finds small problems before
they become big ones
Is an excellent training tool for
technicians
Helps eliminate rework/scrap
and reduces process variability
Keeps equipment safer
Parts stocking levels can be
optimized
Greatly reduces unplanned
downtime

The Manufacturing Game


Similar to the Beer Game
Simulates a typical plant
with three roles: Operations
Manager
Maintenance Manager
Spare Parts Stores Manager
Each round, participants
make decisions such as:
Which equipment to take down
for PMs
How to allocate maintenance
resources
How many spare parts to order
Revenue, cost, output,
uptime, inventory are recorded

The Manufacturing Game


Results
Teams who follow a cost-
minimization strategy (reactive
maintenance policies) are able to
keep costs low for a while.
However, as defects build up they
find their uptime falling and costs
rising.
Teams who follow a
preventive maintenance strategy
initially find higher costs and
reduced uptime as equipment is
taken offline for planned
maintenance. Soon, however,
these teams begin to greatly
outperform teams following a
cost-minimization strategy.
When Does PM Make
Sense?
PM makes sense when the
cost of doing PM is less than the cost
of NOT doing PM.
PM makes sense if CDoingPM < CNotDoingPM

CDoingPM = f(hours of not running


equipment, loss in employee morale from
doing PM instead of real work, materials
and man-hours consumed in PM, potential
for making things worse, etc.)
CNotDoingPM = f(cost of losing/reworking
a failed batch (unless PM makes no
difference in preventing the failure),
materials
and man-hours spent repairing equipment,
loss of
equipment lifetime, loss in employee morale
from NOT doing PM, reduced employee
familiarity with equipment, etc.)

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