Article

Operations Management : Maintenance and Reliability
Copy Write: Managemen tfile - Quality

Maintenance ( maintenance ) are all activities related to maintaining equipment in decent condition system works . A good maintenance system will eliminate the variability of the system . Maintenance strategy ( maintenance ) is :

1 . Implement and improve preventive maintenance

2 . Improving the ability or speed of improvement

Reliability ( reliability ) is the opportunity of a machine component or product will work well for a certain time under certain conditions . Tactics reliability are :

1 . Increasing individual components

2 . provide redundancy

The purpose of the maintenance and reliability of the system is the ability to maintain and control costs . Maintenance and Reliability Strategy requires that both employee engagement and good procedures .

A. MAINTENANCE
To measure the success of maintenance management , then there are two elements that must be determined in advance , ie the involvement of employees and maintenance procedures .

Factor in maintenance employees can be seen from the information that employees , its expertise , compensation received as a motivation factor and the power amplifier synergy that needs to be done . In an effort to improve the mastery of information and expertise in relation
with maintenance activities , the management can take a few things:

• Exchange of information . Through the creation of a favorable climate , such as the presence of data bank ( bank procedure ) that contains data and procedures for the maintenance of all types of machines in the manufacturing system .

• Training expertise . For employees who do not have the expected expertise , the company may choose to submit to a training center offering training or directly trained in the company through on the job training .

The maintenance procedure for machines , factor to consider is the cleaning and lubrication . Cleanup is intended to prevent corrosion , dirt and congestion due to the activities carried out routinely . While lubrication aims to prevent friction material directly engine , cool the engine heat on certain conditions , and extend engine life .

The next procedure is monitoring and adjustment . The monitor must be carried out continuously with a fixed schedule . Good monitor system will be able to make the necessary adjustments .

The benefits of the activity of maintenance (maintenance ) , among others :

1 . Continuous improvement . This activity becomes an important study in operations management , both manufacturing and services , especially factories that use rotating machines and operating at all times .

2 . Increasing capacity . With the continuous improvement , then there is no tone rework / re- process , so the capacity will be increased .

3 . Reduce inventory . Because there should be no piles of raw materials should be prepared to do a re- production .

4 . Lower operating costs . Due to increased capacity coupled with low inventory , it will automatically result in lower operating costs . No need the storage of raw materials and does not need any additional costs due to rework process .

5 . Higher productivity . If operating costs are lower, then the productivity of the formula is the output / input will be obtained that productivity will be larger ( with constant output records ) . Surely productivity will be greater if the output is greater .

6 . Improving the quality . Will create a cost advantage , meaning that the same quality is good, the price can be set to be less expensive .

There are two types of maintenance strategies : preventive maintenance and breakdown maintenance .

( I) Preventive Maintenance ( Preventive Maintenance )

A preventive maintenance plan that includes routine inspection , maintenance , and keeping the facilities in good condition weeks to prevent failure . A high initial failure rate , known as early mortality rate ( infant mortality ) , which may occur in many products . which
referred to his own premature death rate is the failure rate in the early life of a product or process .

The results of the defect / failure will lead to additional costs of having to be processed back and bigger risk is the lack of consumer confidence in the company due to product failure . Additional production costs incurred causing swelling ( no minimum ) . If production costs increase , then the price of the goods to be high .

And planned periodic maintenance is required in the production facilities , if it will not cause damage " Critical Units " because :

• Damage to the facility will cause the cessation of all activities of the production process .
• Damage to the facility will affect the quality of the product .
• Investments invested in the facility is large enough .
• Damage to the facility will endanger workers, health and safety.

Preventive maintenance can overcome the damage that occurs suddenly . This is because preventive maintenance can detect and capture signals when a system will be damaged as well as determining when a system requires service ( repair ) .

With good reporting techniques , the company can keep the archive process , machine , or individual equipment . Such archives can provide a profile that contains both types of maintenance needed or when maintenance is needed . Equipment maintenance history is a very important part for a preventive maintenance system , as well as records of the time and cost
improvement . Records like these also provide similar information about the family as well as suppliers of equipment .

( II ) Damage Maintenance / Repair

Maintenance is the maintenance of direct damage that occurs when equipment fails and must be repaired in an emergency or priority basis .

There are several factors that can cause damage to production machinery , namely :

• Selection of design is not appropriate
• Skills operator and maintenance personnel who do not support the production machine pegoperasian
• Failure to basic maintenance , such as cleaning and lubrication
• Condition of machinery or equipment that is worn due to friction , and
• Error keeping the engine operating conditions at the time of operation

Damage caused some of the above , will result in :

1 . Operating inefficiencies , because they have to perform reprocessing .
2 . Bad reputation , due to changes in the way consumers view the products .
3 . The low profitability , due to reduced consumer demand in the long term .
4 . Loss of customers who switch to another product , because the product failed .
5 . The decline in the quality of the product , because the product failed .
6 . Employees become dissatisfied , because it produces a product that failed .
7 . The advantage of being lower due to reduced demand .

It is therefore necessary to improve the ability to repair . Enlarge or improve facilities maintenance can make the system work faster . A good maintenance facility requires the following six features : well-trained personnel , sufficient resources , capabilities
to establish an improvement plan and priorities , ability and authority to do material planning , ability to identify the cause of the damage, the ability to design a way to extend the mean time between failures ( mean time of failure ) .

B. RELIABILITY

Maintenance will cause reliability , and reliability will lead to efficiency and increase productivity . To manage each component , the techniques used are :

Increasing individual components

To measure reliability in a system in which each component or individual may only have its own level of reliability , system reliability calculation method used ( Rs ) is very simple . This calculation is trying to find a product of the reliability of the individual as follows :

Rs = R1 x R2 x R3 x ... x Rn ..... ( 1 )

Assuming that the reliability of an individual component does not depend on the reliability of other components ( each component stands alone ) .

Reliability can also be interpreted as an opportunity to function in a specified time . The size of the reliability of the most common is the failure rate of the product (product failure rate / FR ) . The company that manufactures high-tech equipment often provide the level of data
the failure of their products .

FR ( % ) = ( number of defective units / number of units tested ) x 100 % ..... ( 2 )
or
FR ( N ) = Number of defective units / number of unit - hours of operating time ..... ( 3 )

Also use the average time between failures ( mean time between failures / MTBF ) , which is the expected time between repairs and component failure , machine , process , or product that is next .

MTBF = 1 / FR ( N ) ..... ( 4 )

Establish Redundancy

To improve the reliability of the system , the added redundancy . This technique is used to " support " component with additional components ( spare ) . This is done by placing the unit in parallel and a standard operating management tactics .

Redundancy is given to ensure that if a component fails , the system has other resources . Reliability of the resulting work is the possibility of the first component coupled with the possibility of a reserve component ( parallel component ) multiplied by the probability that work
the need for spare parts .

A manager can evaluate the effectiveness of the maintenance function .

To measure the success of maintenance management , then there are two elements that must be determined in advance , ie the involvement of employees and maintenance procedures .

Factor in maintenance employees can be seen from the information that employees , its expertise , compensation received as a motivation factor and the power amplifier synergy that needs to be done .

The maintenance procedure for machines , factor to consider is the cleaning and lubrication , and adjustment of the monitor as well .

In a contest of opinion regarding preventive maintenance in Windsor Printers , owner of the company asked , " Why should be corrected before the appliance is damaged ? " , " What if you as the director of maintenance to answer that question ? "

As described above , the periodic preventive maintenance and planned indispensable in production facilities , if it will not cause damage " Critical Units " because :

• Damage to the facility will cause the cessation of all activities of the production process .

• Damage to the facility will affect the quality of the product .

• Investments invested in the facility is large enough .

• Damage to the facility will endanger workers, health and safety.

Therefore, maintenance of the engine before damage is very important. However, the consequences of the damage should be seriously considered . Even some minor damage can lead to disaster for the future of productivity .