Preventive Maintenance Principles SPL 7.2 Scott Couzens, LFM ’06 Scott Hiroshige, LFM ‘06 Presentation for: Summer 2004 i Erik Smith, LFM ’03 – Intel Corporation ESD.60 – Lean/Six Sigma Systems MIT Leaders for Manufacturing Program (LFM) These materials were developed as part of MIT's ESD.60 course on "Lean/Six Sigma Systems." In some cases, the materials were produced by the lead instructor, Joel Cutcher-Gershenfeld, and in some cases by student teams working with LFM alumni/ae. Where the materials were developed by student teams, additional nputs from the faculty and from the technical instructor, Chris Musso, are reflected in some of the text or in an appendix
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Preventive Maintenance Principles
SPL 7.2 Scott Couzens, LFM ’06 Scott Hiroshige, LFM ‘06
Presentation for:
Summer 2004
i
Erik Smith, LFM ’03 – Intel Corporation
ESD.60 – Lean/Six Sigma Systems MIT Leaders for Manufacturing Program (LFM)
These materials were developed as part of MIT's ESD.60 course on "Lean/Six Sigma Systems." In some cases, the materials were produced by the lead instructor, Joel Cutcher-Gershenfeld, and in some cases by student teams
working with LFM alumni/ae. Where the materials were developed by student teams, additional nputs from the faculty and from the technical instructor, Chris Musso, are reflected in some of the text or in an appendix
¾ “…the cost of breakdown maintenance is usually much greater than preventive maintenance.” 1
¾ Preventive maintenance… ¾ Keeps equipment in good condition to prevent large problems ¾ Extends the useful life of equipment ¾ Finds small problems before they become big ones ¾ Is an excellent training tool for technicians ¾ Helps eliminate rework/scrap and reduces process variability ¾ Keeps equipment safer ¾ Parts stocking levels can be optimized ¾ Greatly reduces unplanned downtime
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9/04 --LFM Students] – ESD.60 Lean Six Sigma Systems, LFM, MIT
Part I: Introduction Part II: Concepts Part III: Application Part IV: Disconnects Part V: Conclusion
¾ Similar to the Beer Game ¾ Simulates a typical plant with three roles: ¾ Operations Manager ¾ Maintenance Manager ¾ Spare Parts Stores Manager
¾ Each round, participants make decisions such as: ¾ Which equipment to take down for PMs ¾ How to allocate maintenance resources ¾ How many spare parts to order
¾ Revenue, cost, output, uptime, inventory are recorded
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9/04 --LFM Students] – ESD.60 Lean Six Sigma Systems, LFM, MIT
Part I: Introduction Part II: Concepts Part III: Application Part IV: Disconnects Part V: Conclusion
Source: Business Dynam cs: Systems Thinking and Modeling for a Complex World, Sterman, John D., 2000.
¾ Teams who follow a cost-minimization strategy (reactive maintenance policies) are able to keep costs low for a
uptime falling and costs rising. ¾ 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.
i
9/04 --LFM Students] – ESD.60 Lean Six Sigma Systems, LFM, MIT
Part I: Introduction Part II: Concepts Part III: Application Part IV: Disconnects Part V: Conclusion
while. However, as defects build up they find their
Source: Business Dynam cs: Systems Thinking and Modeling for a Complex World, Sterman, John D., 2000.