All entries for Monday 10 June 2013

June 10, 2013

Redifining maintenance

Many organizations utilize maintenance approaches such as TPM, RCM and PM. However, some organizations started to look for radical improvements to support production and operations. This was achieved by following an approach known as preventing maintenance. Although this is developed by equipment manufacturers, some companies that has world wide production and others that require optimum operations and asset availability work along sides with their suppliers to develop this function. This focuses on increasing components reliability and expected life. A typical example is in the automotive industry, some older cars require a check every 5,000KM while new designed cars can go up to 30,000KM.

This provides the asset user with more space for utilization leading to more effective operations and lower total cost of ownership. This can be worked on by a company provided products or by developing suppliers of core business assets.

This maintenance prevention approach is applicable to my job. One of the most maintenance demanding components is the motion system hydraulic servo-actuators. It would be very beneficial for the department operations to work with the simulator manufacturer in developing an electrical servo-actuators. Some design techniques such as NPD and DFSS can be incorporated as well. achieving this goal can reduce maintenance tasks by around 35% leading to a lower ownership cost and more availability of the device.

Maintenance method selection

Continuing on the previous blog, to have a successful maintenance management a maintenance strategy is needed to support in achieving the organizational goal. Based on this strategy, a maintenance method can be selected based on "Best Fit".

Maintenance methods differ in their approaches and goals, hence, to use a method that can optimize maintenance tasks in an effort to achieve the organizational goals, there has to be a direct link to the maintenance strategy.

In my work for instance, The maintenance strategy can be to increase the reliability of the flight simulators. This might require computerized maintenance management even if the availability is reduced, having a downtime with pilots time being wasted it can be more costly to flight operations than having an extra hour on the device for thorough maintenance. It would be useful to create a matrix which shows the link between the department strategy and RCM strategy. by doing this as a workshop with the department management suitability can be ensured.

Creating the maintenance strategy

There is a simple concept to understand about maintenance, equipment are maintained to support production or utilization of the equipment. Therefore, the maintenance strategy should be part of the production strategy and to act as a support for acheiving the overall business strategy. A very effective means is strategic planning and especially by using Hoshin Kanri to deploy a detailed plan on what maintenance has to do for the company to achieve its vision.

The use of hoshin kanri can help in planning to show what is the gap in cureent maintenance performance and accordingly create a maintenance strategy that can overcome this gap and raise the overall organizational performance.

In my department, we work on maintaining flight simulators to support training pilots. Therefore, the maintenance strategy should be derived from the flight operations strategy. It also has to be working towards acheiving the organizational vision. This approach will help us address the gap in flight training department performance and create a maintenance strategy among other functions to close the gap and optimize the performance.

June 2013

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  • Good point, you dont have to consider it while using the decision tree as the available data is limi… by Ahmed Alali on this entry
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