Syllabus

MAINTENANCE
IT 341 Download a hardcopy of this file

INSTRUCTOR:         Dr. Tomas Velasco, C.Q.E.
                                    112C Engineering Building D
                                    Carbondale, IL 62901-6603
         ( (618) 453-7842
         - VELASCO@engr.siu.edu
         : Http://www.siu.edu/~VELASCO

TEXT:                     TEXTBOOKS
                                                · Maintenance Management by Lawrence Mann, Jr. Lexington Books.
                                 AUDIOVISUALS
                                    · Against all Odds: Inside Statistics Series, 1988

CLASS:                    Spring Semester 1999
                                   Tuesday-Thursday
                                   2:00 pm. - 3:15 pm.
                                   EGR A 219

OBJECTIVE:
The purpose of this course is to provide the student with a comprehensive coverage of the management of maintenance operations from basic principles and practices to state-of-the-art concepts and applications, emphasizing in specific operations in manufacturing environments. Upon completion of the course, students should be able to demonstrate their understanding and ability to apply the essential management functions in managing a maintenance organization

REQUIREMENTS:
Major emphasis will be placed on reading and understanding the material from the class, suggested books and reference material prior to class, and in homework assigned. I do require class attendance.

GRADES:

·4 Examinations, each of which counts 15% of your grade.

·Homework and Quizzes which counts 20% of your grade.

·Final examination which counts 20% of your grade.

STANDARDS:
Letter grades are assigned based on the total number of points accumulated. ·A : 90% and higher

·B : 80% - 89.99%

·C : 70% - 79.99%

·D : 60% - 69.99%

·F : Less than 60%

GRADING POLICY:
Missed examinations and assignments have a 10% penalty per day, imposed when turned in, unless an appropriate, prior excuse is provided to the instructor. The missed examination must be completed on the make-up date set by the instructor.

ACADEMIC CONDUCT:
Cheating on examinations, submitting work of other students as your own, or plagiarism in any form will result in penalties ranging from an F on the assignment to expulsion from the university, depending on the seriousness of the offense.

OFFICE HOURS:
11:00 to 11:45 a.m. on Monday, Wednesday & Friday; 10:00 a.m. to 12:00 p.m. on Tuesday & Thursday; other hours by appointment.

EQUIPMENT AND SOFTWARE:
Hand-held calculator and any computer-based spreadsheet. Excel is available in all the P.C. laboratories in Engineering including Industrial Technology labs. and College of Engineering labs.

MINIMUM STUDENT COMPETENCIES:
I. Introduction

          1. Know the major problem areas associated with maintenance management.
          2. Understand how that improved maintenance results in lower costs and improved profit.
          3. Know that the typical maintenance productivity rate is only 35-40%.

II. Organizing for Maintenance Operations

1. Understand the three types of maintenance: normal, emergency, and preventive.
2. Identify the nine key features of an effective maintenance system.
3. Know the steps required to design and implement an effective maintenance management information system (MMIS).
4. Understand the need for and general contents of the maintenance annual report.
5. Know the general duties of the Maintenance Engineer.
6. Explain the need for a maintenance management manual. What are some typical contents?
7. Explain the four basic maintenance organizational plans: central, area, departmental, and combined.
8. Know the factors to be considered in determining the type of organizational plan to use. III. Maintenance Paperwork Control

1. Explain the need for a work order system.
2. Know the major elements required on a work order.
3. Explain the use of minor work-order forms and maintenance logs.
4. Know, in a general manner, the routing of a work order.
5. Explain work order priorities. Know that narrative terms are usually more effective than numeric priorities.
6. Explain the function of the maintenance clerk-coordinator.

IV. Maintenance Planning and Scheduling 1. Know what engineering the work order means.
2. Explain some required qualifications of both the maintenance planner and the maintenance scheduler.
3. Explain the purpose and four parts of maintenance standards.
4. Explain the function of maintenance scheduling. Describe some of the considerations that are involved in its preparation.
5. Know the importance of maintenance backlog to effective scheduling and labor utilization.
6. Understand how backlog is controlled. What is the common range in weeks?
7. Describe and explain at least four forms or reports used for planning and scheduling maintenance.
8. Explain two types of maintenance scheduling techniques.
9. Know the best use of bar charts and network techniques in maintenance planning and scheduling. V. Maintenance Work Measurement and Standards

1. Explain the history of work measurement.
2. Understand the goal of the work measurement program.
3. Describe three systems of maintenance work measurement.
4. Explain the purpose of a maintenance standards program.
5. Know the four parts of a maintenance standard: sequence of tasks, craft and tool hours, materials, and safety requirements.
6. Compute raw time to standard time using the applicable mathematical formula.
7. Explain the advantages of using maintenance standards for maintenance control.
8. Know and understand the concept of Universal Maintenance Standards (UMS).
9. Explain how Universal Maintenance Standards are computed.
10. Explain the use of allowances in the preparations of UMS.

VI. Preventive Maintenance 1. Describe preventive maintenance.
2. Know at least five benefits of a preventive maintenance program.
3. Explain the steps involved in initiating a preventive maintenance program.
4. Explain indexes. What are their purposes?
5. Describe the factors that determine PM coverage.
6. Explain the factors that influence PM frequency.
7. Describe the factors that influence the time period in which PM will scheduled.
8. Compute the equipment priority for PM using the applicable formula. ,
9. Describe the "first breakdown" approach to PM.
10. Explain the PM paperwork system.
11. Describe nondestructive inspection, on-stream, and off-stream techniques.
12. Explain the three characteristics of vibration measurement.
13. Describe infrared thermography.
14. Describe three instruments used in PM. VII. Measuring Maintenance Performance 1. Explain the function of performance indexes. Describe three of them.
2. Describe four reports used to control labor productivity.
3. Describe and explain maintenance work sampling. Describe bias and randomness.
4. Identify two status-of-load indicators.
5. Name two planning indicators.
6. Define productivity. How is it computed?
7. Explain and be able to compute the composite maintenance index. VIII. Maintenance Material Control

          1. Describe spare parts, normal stock, and equipment as they relate to inventory categories.
          2. Describe three factors that relate to inventory fluctuations.
          3. Explain the components that comprise both carrying costs and acquisition costs.
          4. Describe the cyclical and the order-point inventory systems.
          5. Explain EOQ. At what point in the inventory total cost curve does it occur? Describe the relationship of AC to CC
          at the point of EOQ.
          6. Describe the ABC inventory categorization method.
          7. Describe three methods of reordering material.
          8. Describe the purpose of blanket-order releases.

IX. Maintenance Budgeting and Forecasting

1. Describe cost centers
2. Describe program budgeting.
3. Explain the rate of return concept in capital investment planning.
4. Know the concept of present worth. Explain the present worth factor.
5. Explain how to project maintenance costs by factored budgeting.
6. Describe the variables that determine maintenance manpower, emergency maintenance, and turnaround maintenance needs. X. Computerized Maintenance Systems 1. Know and explain at least five advantages of automation in maintenance management.
2. Explain the relative advantages of buying, renting, or sharing a computer.
3. Understand the computer acquisition model explained in our text (Mann, 1983).
4. Explain the paperwork changes required for initiation of a computer system.
5. Explain the four-phase computer installation procedure. XI. Maintenance Training 1. Explain the source a within the plant for identifying training needs.
2. Describe five types of maintenance training programs.
3. Explain Performance Based Training (PBT).
4. Identify three sources of maintenance trainers.
5. Explain the six-step procedure for designing a training program.
6. Explain the six-step model for designing a maintenance supervisor-training program.
7. Describe how training costs are often hidden. XII. Contract Maintenance. 1. Explain the elements that must be present in an enforceable contract.
2. Describe the General President's Maintenance Agreement.
3. Describe the advantages of the General President's Maintenance Agreement for maintenance management.
4. Explain the advantages of contract maintenance. Disadvantages?
5. Enumerate three factors that should be considered in the selection of a contractor.
6. Explain fixed cost and cost plus contracts.
7. Explain bid and negotiation. Explain the advantages/disadvantages of each.
8. Describe at least three points of concern in the contract: statement of work, staff assignments, records, training, etc.
9. Describe the three types of maintenance contracts in general use: labor and parts, labor only, and preventive maintenance agreements.
10. Explain three ways to motivate contract maintenance workers. XIII. Managing Maintenance Craftsmen 1. Diagram and explain the Johari Window.
2. Describe intrinsic and extrinsic motivation. Relate these concepts to both the Herzberg and Maslow models.
3. Explain the concept of job enrichment. Describe the basic concepts of a job-enriched program. XIV. Statistical Techniques in Maintenance 1. Using the appropriate queuing theory formula for several service channels and given the appropriate data, compute the probability that a compressor that fails will not have to wait to be required.
2. Compute EOQ using the provided data.
3. Describe estimation theory as it applies to choosing between two brands of equipment. SCHEDULE: WEEK TOPIC

1                  Introduction
2                  Organizing for Maintenance Operations
3                  Paperwork Control
4                  Planning and Scheduling
5                  Measurement and Standards
6                  Preventive Maintenance
7                  Appraising Maintenance Performance
8                  Maintenance - Material Control
9                  Budgeting and Forecasting
10                Information Systems in Maintenance
11                Training
12                Contracts in Maintenance
13                Managing Maintenance Personnel
14                Statistical Operations in Maintenance
15                Other Topics in Maintenance