modern maintenance management indosat
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MAINTENANCE MANAGEMENT 1
COMMON MAINTENANCE PROBLEM
Insufficient proactive maintenanceFrequent problem repetitionErroneous maintenance workSound maintenance practice not
institutionalizedUnnecessary and conservative PMSketchy rationale for PM actionsMaintenance program lacks of trace abilityBlind acceptance of OEM inputs
MAINTENANCE MANAGEMENT 3
MODERN MAINTENANCE MANAGEMENT
FUNDAMENTAL CONCEPT OF MAINTENANCE 4
MODERN MAINTENANCE MANAGEMENT
MAINTENANCE MANAGEMENT 5
MAINTENANCE MANAGEMENT 6
MODERN MAINTENANCE MANAGEMENT
Repair to reliability focus
THE CHARACTERISTICS Repair Focused Reliability Focused Fix it Improve it Firefight Predict, Plan, Schedule Manage defects Eliminate Defects Reduce Maintenance Cost Increase Uptime Program of the month Continuous Improvement Believe failures are inevitable Believe failures are exceptional Give priority to breakdowns Give priority to eliminating failures Many failures Few failures Low level of planned work High level of planned work High level of rework Low levels of rework Poor reliability High reliability High maintenance costs Low maintenance cost Short term plans Long term plans Become non-profitable Attract new investments
MAINTENANCE MANAGEMENTDefinition of maintenance
All activities subjected to technical systems to retain or restore the
functional capabilities of the technical system
Modern maintenance management utilizes effective maintenance
techniques to:
integrate all maintenance activities such as, preventive maintenance,
predictive and corrective maintenance
define maintenance action
define maintenance plan and schedules to achieve minimum
maintenance cost.
MAINTENANCE MANAGEMENT 9
MAINTENANCE MANAGEMENTMaintenance concept
The development of maintenance concept is the central activity
of maintenance support planning.
The maintenance concept :
defines criteria for maintenance activities
defines resources allowable at each of the specified
maintenance level
MAINTENANCE MANAGEMENT 10
MAINTENANCE MANAGEMENTThe maintenance concept serves two purposes:
provide the basis for establishment of maintainability design
requirements
provide the basis for the establishment of maintenance support
requirements in terms of :
MAINTENANCE MANAGEMENT 11
MAINTENANCE MANAGEMENT task to be performed
frequency of maintenance
maintenance down time
personnel numbers and skill level
test and support equipment
tools
repair parts
facilities
information
MAINTENANCE MANAGEMENT 12
MAINTENANCE MANAGEMENTExample :
if the maintenance policy is that no external test equipment is
allowable for organizational level maintenance, one design
implication is that built-in test features must be incorporated
If the corrective maintenance policy is no repair at the
organizational level except to replace failed items, then the
design implication is the use of modular design to the maximum
extent feasible
MAINTENANCE MANAGEMENT 13
MAINTENANCE MANAGEMENT
If the operator or repairman at the organizational level must
monitor, calibrate and adjust his equipment, then adequate training
and technical manuals must be provided along with necessary
calibration and alignment equipment and tools which are not built
into the prime equipment
MAINTENANCE MANAGEMENT 14
MAINTENANCE MANAGEMENT
COVERAGE OF THE MAINTENANCE CONCEPT
A. OPERATIONAL STATES
1. Inactive Period
2. Scheduled Downtime Period
3. Operational Demand Period
Stand-by
Alert
Reaction
Mission
Deactivation
MAINTENANCE MANAGEMENT 15
MAINTENANCE MANAGEMENTB.MAINTENANCE ACTIVITIES
1. Preventive Maintenance
Service $ Replacement
Inspection
2. Corrective Maintenance
§ Detection
§ Diagnosis
§ Correction
§ Verification
3. Maintenance Level
§ Organizational
MAINTENANCE MANAGEMENT 16
MAINTENANCE MANAGEMENT § Intermediate
§ Depot
C. RESOURCES
1. Personnel
§ Operator
§ Maintenance Technician
2. Equipment
§ Prime
§ Support
3. Facilities
4. Repair Parts and Supplies
MAINTENANCE MANAGEMENT 17
MAINTENANCE MANAGEMENT 5. Information ( Publications and Data )
D.EFFECTIVENESS
1. Downtime
§ Detection time
§ Diagnostic time
§ Correction time
§ Verification time
2. Reliability
3. Availability or Operational Readiness
MAINTENANCE MANAGEMENT 18
MAINTENANCE MANAGEMENTBASIC MAINTENANCE POLICIES
“HARD-TIME" "ON-CONDITION" COND. MONITORINGPREVENT ANTICIPATE MAX. ANTICIPATE REMEDY
MAINTENANCE MANAGEMENT 19
MAINTENANCE
CORRECTIVEMAINTENANCE
PREDICTIVEMAINTENANCE
CONDITION BASEDMAINTENANCE
PERIODIC MAINTENANCE
PREVENTIVEMAINTENANCE
PREVENTIVE MAINTENANCE
What is ?Preventive maintenance is the performance of
inspection and or servicing task that has been preplanned for accomplishment at specific point in time to retain the functional capabilities of operating system
Corrective maintenance is the performance of unplanned maintenance task to restore the functional capabilities of failed or malfunctioning equipment
MAINTENANCE OUTAGE OR BREAKDOWN MAINTENANCE ???
PREVENTIVE MAINTENANCE
Why? ?
PREVENTIVE MAINTENANCE
PREVENTFAILURE
DETECT ONSETOF FAILURE
DISCOVER AHIDDEN FAILURE
PREVENTIVE MAINTENANCE
Task categories
PREVENTIVEMAINTENANCE
TIMEDIRECTED
CONDITIONDIRECTED
FAILUREFINDING
RUN TOFAILURE
PREVENTIVE MAINTENANCE
Task categories
Aimed directly at failure prevention or retardation Task and periodicity are preset Safe life limit or economic life limit Action is known to directly prevent failure Task action requires some form of intrusion
TIMEDIRECTED
PREVENTIVE MAINTENANCE
Task categories
Measuring parameters related with incipient failure condition overtime Can identify measurable parameter related to
failure Specify value of parameter related to failure Task is non intrusive to equipment
CONDITIONDIRECTED
PREVENTIVE MAINTENANCE
Task categories
Uncover the hidden failure at prescheduled check Complex system with redundancy or back-up Economic driven, in lieu of td or cd task
FAILUREFINDING
PREVENTIVE MAINTENANCE
Task categories
Allow the equipment to operate until it fails ( no preventive maintenance action ever taken ) No pm task effective and applicable Available pm task option is too expensive Failure effect is not essential (safety or economic )
RUN TOFAILURE
MAINTENANCE MANAGEMENTPREVENTIVE VS CORRECTIVE
PREVENTIVE MAINTENANCE :
§ ACTION BEFORE FUNCTIONAL FAILURE
§ PREVENT FUNCTIONAL FAILURE
CORRECTIVE MAINTEANCE :
§ ACTION AFTER FUNCTIONAL FAILURE
§ RESTORE FUNCTIONAL FAILURE
CRITERION : FUNCTIONAL FAILURE DEFINITION
RECORDING: DOWN-TIME, COST, MANHOURS, INTERVAL
MAINTENANCE MANAGEMENT 27
MAINTENANCE MANAGEMENTEXAMPLES OF MAINTENANCE POLICIES
1. PREVENTIVE MAINTENANCE ACTION WILL BE PERFORMED ONLY DURING
SCHEDULED DOWNTIME
2. NO MAINTENANCE WILL BE PEFORMED DURING MISSION TIME
3. DURING OPERATIONAL PERIOD, MAINTENANCE WILL BE LIMITED TO
ORGANIZATIONAL REPAIRMAN
4. REPAIRS AT THE ORGANIZATIONAL LEVEL WILL BE MADE BY REPLACEMENT ONLY
5. MAINTENANCE BY OPERATOR WILL BE LIMITED TO SIMPLE DETECTION AND
ROUTINE DIAGNOSTIC TO REPLACE A FAILED MODULE. NO DETAIL TEST AND REPAIR
SKILL WILL BE REQUIRED
MAINTENANCE MANAGEMENT 28
MAINTENANCE MANAGEMENT 1. SYSTEM AVAILABILITY WILL BE AT LEAST 0.XXX 2. REPAIR PART WILL BE CARRIED AT ORGANIZATIONAL LEVEL 3. MTTR WILL NOT EXCEED "X" MINUTES 4. MODULES WHOSE REPLACEMENT COST IS MORE THAN "Y: DOLLARS WILL BE
DESIGNED FOR REPAIR 5. MAINTENANCE BY ORGANIZATIONAL REPAIRMEN WILL BE LIMITED TO SIMPLE VISUAL CHECK, INSPECTION, CLEANING, SERVICING, ADJUSTMENT
MAINTENANCE MANAGEMENT 29
MAINTENANCE MANAGEMENTLEVELS OF MAINTENANCE
LEVELS OF MAINTENANCE MIGHT BE DEVIDED INTO THREE CATEGORIES:
§ ORGANIZATIONAL MAINTENANCE
§ INTERMEDIATE MAINTENANCE
§ DEPOT MAINTENANCE
A. ORGANIZATIONAL MAINTENANCE
ORGANIZATIONAL MAINTENANCE IS THAT MAINTENANCE NORMALLY
AUTHORIZED FOR, PERFORMED BY, AND RESPOSIBILITY OF, A USING
ORGANIZATION ON EUIPMENT IN ITS POSSESSION.
MAINTENANCE MANAGEMENT 30
MAINTENANCE MANAGEMENTIT INCLUDES :
§ INSPECTING
§ SERVICING
§ CLEANING
§ LUBRICATING
§ ADJUSTING
§ REPLACEMENT OF PARTS, MINOR ASSEMBLIES, SUB ASSEMBLIES
ACTIVITIES PERFORMED BY EQUIPMENT OPERATOR AND ORGANIZATIONAL
REPAIRMAN FORWARD REMOVED ITEMS FOR REPAIR TO HIGHER LEVEL
MAINTENANCE MANAGEMENT 31
MAINTENANCE MANAGEMENT B. INTERMEDIATE MAINTENANCE
THIS LEVEL OF MAINTENANCE IS LIMITED TO THE REPAIR OF
UNSERVICEABLE ASSEMBLIES IN SUPPPORT OF USING ORGANIZATION ON A
RETURN-TO-USER BASIS
CHARACTERISTICS :
§ FURNISHES SUPPLIES AND SERVICES TO THE USER
§ ORGANIZED AS SEMIFIXED OR PERMANENT SHOP
§ SERVES LOWER LEVELS WITHIN A DESIGNATED GEOGRAPHICAL AREA
MAINTENANCE MANAGEMENT 32
MAINTENANCE MANAGEMENT C. DEPOT MAINTENANCE
DEPOT MAINTENANCE IS THE CENTRAL MAINTENANCE FACILITIES AND ACTIVITIES OF THE COMPANY WHICH, THROUGH OVERHAUL OF ECONOMICALLY REPAIRABLE MATERIEL, AUGMENTS THE PROCUREMENT PROGRAM IN SATISFYING OVERALL COMPANY REQUIREMENT
CHARACTERISTICS: § SERVES LARGE GEOGRAPHICAL AREA § MOST COMPLETE FACILITIES § PERFORM SERVICES THAT ARE BEYOND THE CAPABILITIES OF LOWER
LEVEL § PROVIDE MAJOR SUPPLY BASIS
MAINTENANCE MANAGEMENT 33
MAINTENANCE MANAGEMENTDESIGN-FAULT DETECTION
IN A CORRECTIVE MAINTENANCE, ACTIVITIES MIGHT BE DEVIDED INTO THE
FOLLOWING SEQUENTIAL TIME PHASES
§ DETECTION TIME (FAULT RECOGNITION)
§ DIAGNOSTIC TIME (FAULT LOCATION & ISOLATION )
§ CORRECTION TIME (REPLACE OR REPAIR )
§ VERIFICATION TIME (TEST AND ALIGN)
DETECTION (AND DIAGNOSTIC) TIME USUALLY CONTRIBUTES SIGNIFICANT
AMOUNT OF TIME TO THE EQUIPMENT DOWN TIME
SO, IT HAS TO BE MINIMIZED !!!
MAINTENANCE MANAGEMENT 34
MAINTENANCE MANAGEMENTA FAULT IS ASSUMED TO EXIST UPON THE OCCURRENCE OF ONE OF THE FOLLOWING EVENTS: § DEGRADATION OF PERFORMANCE § CRITICAL FAILURE § CATASTROPHIC FAILURE FAULT DETECTION PROCESS
MAINTENANCE MANAGEMENT 35
PARAMETER
STANDARD
SENSOR COMPARATOR INDICATOR DISPLAY
ALARM
MAINTENANCE MANAGEMENTFAULT DETECTION STRATEGIES:
§ AUTOMATIC MONITORING WITH ALARM INDICATION
§ AUTOMATIC FAULT INDICATION WITH ALARM FOR CRITICAL
PARAMETER
§ PERIODIC TEST AND INSPECTION BY MAINTENANCE PERSONNEL
§ PERIODIC SELF-TEST AND CALIBRATION BY THE OPERATOR
§ ABNORMAL OPERATION NOTED BY OPERATOR
MAINTENANCE MANAGEMENT 36
MAINTENANCE MANAGEMENTCOST ANALYSIS
ONE OF THE MOST COMPREHENSIVE TOOL FOR COMPARING TWO OR MORE DESIGN
ALTERNATIVES (OR VENDORS) IS THE SYSTEM LIFE CYCLE COST
MODELING
AELCC = PC + OC + RC + SC
AELCC = ANNUAL EQUIVALENT LIFE CYCLE COST
PC = ANNUAL EQUIVALENT POPULATION COST
RC = ANNUAL REPAIR FACILITY COST
OC = ANNUAL OPERATING COST
SC = ANNUAL SHORTAGE PENALTY COST
MAINTENANCE MANAGEMENT 37
MAINTENANCE MANAGEMENTPC = CiN
Ci = annual equivalent cost per unit n = retirement age
P = acquisition cost per unit i = interrest rate
F = estimated salvage value of a unit
B = book value of a unit at the end of n year
L = estimated life of the unit
N = number of unit in the population
MAINTENANCE MANAGEMENT 38
L
FPnPB
i
iB
i
iiPC
nn
n
i
1)1(1)1(
)1(
MAINTENANCE MANAGEMENTOC = (EC + LC + PMC + Other) N
Where: EC = annual cost of energy LC = annual cost of operating labor PMC = annual cost of preventive maintenance
RC = CrM
Where: Cr= annual fixed and variable repair cost per repair channel
M = number of repair channelSC= Cs[E(S)]
MAINTENANCE MANAGEMENT 39
D
jjDNjPSE
1)()(
MAINTENANCE MANAGEMENTTHE STEADY STATE PROBABILITY OF n FAILED UNIT IS
Pn= P0Cn , for n =1, 2,………….N
Where:
IF n = 0,1,2…………..M
IF n = M, M+ 1, M+2 …………….N
MAINTENANCE MANAGEMENT 40
n
n nnN
NC
!)!(
!
n
Mnn MMnN
NC
!)!(
!
MAINTENANCE MANAGEMENTAND THE PROBABILIY THAT NO ITEM FAILED, P0
EXAMPLE:SUPPOSE YOU NEED TO DEPLOY 15 IDENTICAL BASE TRANSCEIVER STATION, BUT YOU HAVE NO CONTROL OVER SYSTEM DESIGN (MTBF AND MTTR), BUT CAN ONLY CHOOSE THE NUMBER OF UNIT TO PROCURE, THE RETIREMENT AGE, NUMBER OF REPAIR CHANNELASSUME THE NUMBER TO PROCURE IS 19, REPAIR CHANNEL IS 3 AND THE RETIREMENT AGE IS 4 YEARS
MAINTENANCE MANAGEMENT 41
1
00
N
nnCP
MAINTENANCE MANAGEMENTPARAMETER VALUE
Unit Acquisition Cost $52,000Unit Design Life 6 yearsSalvage value at end of design life $7000Unit Operating cost- energy $500- operating labor $450 - preventive maintenance $400 - other $400 Annual repair channel cost $45,000Annual shortage cost $73,000Annual interrest rate 10 %MTBF 300 jamMTTR 50 jamRETIREMENT AGE 4 YEARS
MAINTENANCE MANAGEMENT 42
MAINTENANCE MANAGEMENTANNUAL EQUIVALENT POPULATION COST
ANNUAL OPERATING COSTOC= ( $500 + $450 + $400 + $400)(19) = $ 33,250
ANNUAL REPAIR FACILITY COSTRC = $45,000 (3) = $ 135,000
MAINTENANCE MANAGEMENT 43
616,221$)19(664,11$
664,11$1)10.1(
10.0000,22$
1)10.1(
)10.1(1.0000,52$
000,22$6
000,7$000,,52$4000,52$
44
4
PC
C
B
i
MAINTENANCE MANAGEMENTANNUAL SHORTAGE
(/) = 1/6 = 0.1667
COMPUTING Cn FOR n = 0,1,..3 (n M )
MAINTENANCE MANAGEMENT 44
1665.3)!1(!18
)1667.0(!19
1)!0(!19
)1667.0(!19
1
1
0
0
C
C
COMPUTING Cn FOR n = 4, 5, ……19
MAINTENANCE MANAGEMENTCOMPUTING Cn FOR n = 4, 5, ……19
MAINTENANCE MANAGEMENT 45
0000.0)!3()!3(!0
)1667.0(!19
....
....
3224.3)!3()!3(!14
)1667.0(!19
9813.3)!3()!3(!15
)1667.0(!19
19
19
5
5
4
4
C
C
C
19
0
9390.27n
nC
MAINTENANCE MANAGEMENT
THE PROBABILITY OF NO FAILED ITEM
COMPUTING Pn FROM Pn = P0Cn
P0 = 0.0358 x 1 = 0.0358
P1 = 0.0358 x 3.1665 = 0.1134
…P6 = 0.0358 x 2.5840 = 0.0925
P19 = 0.0358 x 0.000 = 0.0000
MAINTENANCE MANAGEMENT 46
0358.09390.27
1119
0
0
n
nCP
MAINTENANCE MANAGEMENTTHE EXPECTED NUMBER OF UNIT SHORT IS
THE ANNUAL SHORTAGE COST IS
SC = Cs [E(S)]
= $73,000(1.00663) = $ 73,484
THE TOTAL SYSTEM ANNUAL EQUIVALENT COST
TC = $221,616 + $33,250 + $135,000 + $73,484 = $463,350
MAINTENANCE MANAGEMENT 47
00663.1)0000.0(15.............)0925.0(2)1189.0(1)(
)(1
15
1)4()(
SE
jPjPSED
j jjjDN
MAINTENANCE MANAGEMENT
MAINTENANCE MANAGEMENT 48
RETIREMENT AGE UNIT NUMBER,N
2 CHANNEL 3 CHANNEL 4 CHANNEL
3 19 $598,395 $465,985 $469,130
4 18 $592,920 $464,770 $465,755
4 19 $600,720 $463,350 $464,295
4 20 $610,775 $466,610 $468,755
5 19 $643,050 $480,375 $467,735
MAINTENANCE MANAGEMENTMAINTENANCE COST MODEL
WHERE, W : HOURLY RATE OF SERVICE ENGINEERH : EQUIPMENT USAGE IN HOURS PER PERIOD CONSIDEREDTP
R : SCHEDULED TIME FOR PREVENTIVE MAINTENANCE
TPT : EXPECTED TRAVEL TIME FOR PREVENTIVE MAINTENANCE
TPl : SCHEDULED PREVENTIVE MAINTENANCE INTERVAL
TCT : EXPECTETED TRAVEL TIME FOR CORRECTIVE MAINTENANCE
MAINTENANCE MANAGEMENT 49
MTBF
TMTTRWH
T
TTWHICM
CCCMCT
Pl
PT
PR
CRMC
CMPMSPIC
MAINTENANCE MANAGEMENTMTTR : MEAN TIME TO REPAIR
MTBF : MEAN TIME BETWEEN FAILURE
CM : MANUFACTURING COST OF SPARE PARTS
ICR : INVENTORY COST RATE
EXAMPLE:
CONSIDER AN ELECTRONIC EQUIPMENT WITH THE FOLLOWING PARAMETER,
CM = $ 5000 , W = $ 250/hour, H = 4000 HOURS/YEAR, ICR = 50%/YR
MTTR = 0.5 hours, MTBF = 3000 hours,TPR = 0.25 hours, TP
T = 0.5 hours
TPl = 2 months, TC
T = 1.5 hours
MAINTENANCE MANAGEMENT 50
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