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CHAPTER 11

MAINTENANCE
CHAPTER OUTLINE:

Introduction to maintenance
Importance of maintenance
Types of maintenance
INTRODUCTION

Def: all the activities involved in keeping an


operating system (machines, robots, automations,
tools, equipment or instruments) in good working
order. (Heizer and Render, 2011)

Maintenance also can be defined as activities


relating to keeping the entire production /
operations system facilities or specific equipment
in the system in operating condition.

It is concerned with avoiding or minimizing


downtime or to avoid undesirable results due to
system failure.
Downtime refers to work stoppage or production
interference resulting from machine failure or
breakdown. (Roaimah Omar, 1999).

Regular maintenance will enhance the reliability of


machines.

Reliability is the probability that a machine will


function properly for a specified time under stated
conditions. (Heizer and Render, 2011)
IMPORTANCE OF MAINTENANCE

Can avoid work stoppage and ensure that the loss of


production time and cost are minimized.
To keep the entire production system running
smoothly with minimum interruption.

To reduce production cost such as idle labor cost and


overtime cost.

To ensure that the entire workplace is a safe place to


work for its employees.

To establish a competitive edge and to enhance good


customer service.

To avoid delays in production schedules and deliveries,


thus the companies can meet customers demand.
TYPES OF MAINTENANCE
1) Breakdown maintenance

Breakdown maintenance is when an equipment


malfunctions or damaged and immediate repairs
are needed to put it back to working condition.

Includes repairs, replacement of parts, or even


renovate to ensure the machines is put back in
operating condition.

Breakdown maintenance occurs when equipment


fails and must be repaired on emergency basis
and restored back to working conditions.
2) Preventive maintenance

It involves performing routine inspections and servicing and


keeping facilities in good repair. These activities are
intended to build a system that will find potential failures
and make changes or repairs that will prevent failure.

Preventive maintenance is much more than just keeping


machinery and equipment running. (Heizer and Render,
2011)

The main objectives:


1) To reduce the frequency and severity of interruptions to
production caused by machine malfunctions.

2) To detect potential failures in the plant or equipment to


avoid the associated costs (e.g: loss of output, injuries,
damage to other equipment or products) and make changes
or repairs to prevent failure.
FORMULA:

Expected cost for breakdown


=
Expected no of breakdown x cost of each
breakdown

Expected cost for preventive maintenance


=
Cost of preventive maintenance
+
(cost of breakdown x average no of breakdown)
Comparing preventive and breakdown
maintenance costs.

EXAMPLE 1
- THE END -

THANK YOU.