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OPERATIONS MANAGEMENT
Lecture # 7:
WORLD
CLASS
RELIABILITY
EVERYTHING RIGHT,
FIRST TIME, EVERY TIME
INTRODUCTION
The results of failure can be disruptive, inconvenient,
wasteful and expensive in terms of money & human lives
Machine and product failures can have far-reaching effects
on an organizations operation, reputation and profitability,
whether it is an office or production floor
The objective of maintenance and reliability is to maintain
the capability of the system while controlling costs. A good
maintenance system drives out system variability
Maintenance includes all activities involved in keeping a
systems equipment in working order
Reliability is the probability that a machine part or product
will function properly for a specified time under stated
conditions
Interdependency of operator, machine and mechanic is a
hallmark of maintenance and reliability
RELIABILITY
Systems are composed of a series of individual
interrelated components, each performing a specific job.
If any one component fails to perform, for whatever
reason, the overall system can fail. The Chain is just as
strong as the Weakest Link
Two tactics:
Improving Individual components
Providing redundancy
Rs = R1 X R2 X R3 X . X Rn
PROVIDING REDUNDANCY
To increase reliability, Redundancy is added
This is done by use of addition Backup
components in parallel
If one component fails, an alternate
arrangement is in place
Probability of
first component
working
(0.8)
Probability of
Probability of
second component X second component
working
Not working
+ [(0.8)
(1-0.8)] = 0.96
MAINTENANCE
Two types of maintenance:
Preventive Maintenance:
A plan that involves routine inspections, servicing and
keeping facilities in good condition to prevent failure
& to keep the system working without interruptions
Breakdown Maintenance:
Remedial Maintenance that occurs when equipment
fails and must be repaired on an emergency or
priority basis
Two tactics:
Implementing or improving preventive maintenance
Increasing repair capabilities or speed
IMPLEMENTING OR IMPROVING
PREVENTIVE MAINTENANCE
Preventive Maintenance implies that we can determine
when a system will need service or repair
For some products, failure in initial stages is possible,
called Infant Mortality.
Mortality This is due to improper use by
customer mostly. So firms test products for this prior to
shipment and sometimes after sales service includes
installation and training
Equipment history and replacing parts or components
before the time specified by OEM to be maintained
Maintenance Required
Time of Maintenance
Cost of Maintenance
Inventory of spares
Emergency spares supplier
Well-Trained personnel
Adequate Resources
Ability to establish a repair plan and priorities
Ability and authority to do material planning
Ability to identify the root cause of breakdown
Ability to design ways to extend MTBF
Equipped In-house maintenance facility or external vendors
THANK YOU