03 Part 3 - PM Case Studies

Part 3:
PM CASE STUDIES
PREVENTIVE MAINTENANCE PLANNING

P2: The yearly PM programs information for six similar gas
turbines in a power station are as follows:
1- PM information:
Maintenance levels per gas turbine
Spare
No. of
PM Type Frequency Duration
parts Cost
Workers
$1000
Y Level 1
Yearly
15 days
20
10
S Level 2
6 Monthly 10 days
20
8
3M Level 3 3 Monthly
5 days
15
5
M Level 4
Monthly
2 days
10
2
2- Working conditions:
Gas turbine operating conditions: 24 hour/day
Workers operating conditions: 300 day/year & 8 hour/day
3- CM information:
Average effort of CM = 380 man-day per gas turbine

Average annual spare parts CM = $ 12000 per gas turbine
Average CM downtime = 15 days/year per gas turbine
Average downtime cost rate = $ 1000 per day
4- Cost rates:
Average labor cost rate = $ 10 per man-day
-----------------------------------------------------------------------------------------Part 3: PM Case Studies
-1 -
Overhead cost = 25 % direct cost (spare parts & labor)

-2 -
Required:
1)
2)
3)
4)
5)
6)
7)
8)
The size of maintenance labor force.

Average system availability.
Annual downtime cost losses.
Annual maintenance cost.
Annual PM plan.
Maintenance resource profiles.
Monthly PM plans.
Maintenance work order
The size of maintenance labor force

PM
Type
Y
S
3M
M
Annual Duration No. of

Man-day
Frequency
(day)
Worker
per PM type
1
15
20
300 * 1= 300
1
10
20
200 * 1 = 200
2
5
15
75 * 2 = 150
8
2
10
20 * 8 = 160
Annual PM man-day per gas turbine

Total PM annual man-day Required
810
810 * 6 = 4860
The size of PM labor force = 4860/300 =16.2 = 17 workers

The size of CM labor force = 380 * 6 / 300 = 8 workers
Total labor force = 17 + 8 = 25 workers
Crew check is ok (25 more than 20).

-3 -
The average down time per year

PM Type
Y
S
3M
M
Annual
Frequency
1
Duration
(day)
15
PM Downtime
(day)
15 * 1= 15
1
2
8
10
5
2
10 * 1 = 10
5 * 2 = 10
2 * 8 = 16
PM downtime per gas turbine
51
Average down time = 51 + 15 = 66 day/year per gas turbine

Annual downtime cost losses = 66 * 6 * 1000 = $ 396000
Average equipment availability =
Active operating time / Total time
= (364 66) / 364 = 82 %
System Reliability:
Series or chain structure: Rs = R1 * R2 * R3 * etc.
Parallel structure: Rs = 1 (1-R1)* (1-R2)* (1-R3) * .etc.
System time availability =
Parallel structure: As = 1 (1-A1)**6
= 1 (1-0.82)**6
= 1 (0.18)**6 = 99%

-4 -
Annual maintenance cost

PM Type
Y
S
3M
M
Annual
Frequency
1
1
2
8
Cost
$1000
10
8
5
2
Spare parts PM
Cost $1000
10 * 1= 10
8*1=8
5 * 2 = 10
2 * 8 = 16
Annual spare parts PM per gas turbine

44
=
Total annual spare parts PM cost =
44 * 6 = 264
The average annual spare parts CM cost =
$ 12000 * 6 = $ 72,000
Annual spare parts maintenance cost =
264000 + 72000 = $ 336,000
Annual labor cost =
25 workers * 300 day/year * $ 10 per man-day= $ 75,000
Annual direct maintenance cost = $ 336000 + $ 75000
= $ 411000
Overhead cost = 25 % direct cost
Annual maintenance cost = $ 411000 * 1.25 = $ 513750
Annual maintenance cost
= $ 513750
Annual downtime cost losses = $ 396000
-5 -
Basic Annual PM Plan

Eq.
code
G01
G02
G03
G04
G05
G06
Month #
6
7
3M
3M
M
M
S
M
M
M
3M
M
M
3M
Y
M
M
S
M
M
M
3M
M
M
M
Y
M
M
S
3M
M
M
3M
M
M
M
Y
M
M
M
3M
M
M
3M
S
M
M
Y
M
M
M
3M
M
M
M
S
M
M
Y
3M
M
M
3M
M
10
11
12
Resource analysis:
Manday
Day/
month
Workers
SP cost
DT
580 230 580 230 580 230 580 230 580 230 580 230
24
24
24
24
24
24
24
24
24
24
24
24
24
26
33
10
18
18
24
26
33
10
18
18
24
26
33
10
18
18
24
26
33
10
18
18
24
26
33
10
18
18
24
26
33
10
18
18
Y= 300 S= 200
Y= 10 S= 8
Y= 15 S= 10
3M= 75
3M= 5
3M= 5
M= 20
M= 2
M= 2
man-day
$1000
day

-6 -
Target Annual PM Plan # 1

Eq.
code
Month #
G01
G02
G03
G04
G05
G06
10 11 12
3M
3M
M M Y
M 3M M
M
S
M
3M M M
M M 3M
M
M
M
S
M
M 3M M M S
Y M M 3M M
3M M M
Y
M
M M 3M M M
M
S
M M 3M
M
M
M
Y
M
M 3M
S M
3M M
M M
M
Y
Resource analysis:
Manday
Workers
SP cost
DT
455 355 455 355 455 355 355 455 355 455 355 455
19
23
28
15
21
23
19
23
28
15
21
23
Y= 300 S= 200
Y= 10 S= 8
Y= 15 S= 10
19
23
28
15
21
23
3M= 75
3M= 5
3M= 5
15
21
23
19
23
28
M= 20
M= 2
M= 2
15
21
23
19
23
28
15
21
23
19
23
28
man-day
$1000
day

-7 -
Target Annual PM Plan # 2

Eq.
code
Month #
G01
G02
G03
G04
G05
G06
10 11 12
3M
3M
M
M
M
M
M
M
3M
S
M
3M
Y
M
M
M
M
M
M
3M
S
M
M
Y
M
M
M
3M
M
M
3M
S
M
M
Y
M
M
M
3M
M
M
3M
M
M
M
Y
M
S
M
3M
M
M
M
M
M
M
Y
3M
S
M
3M
M
Resource analysis:
Manday
Workers
SP cost
DT
400 410 400 410 400 410 400 410 400 410 400 410
17
20
25
17
24
26
17
20
25
17
24
26
Y= 300 S= 200
Y= 10 S= 8
Y= 15 S= 10
17
20
25
17
24
26
3M= 75
3M= 5
3M= 5
17
20
25
17
24
26
M= 20
M= 2
M= 2
17
20
25
17
24
26
17
20
25
17
24
26
man-day
$1000
day

-8 -
Monthly Maintenance Plan: Month # 1

Day
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
G01
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
SB
G02
G03
G04
G05
G06
M
M
SB
M
M
SB
M
M
SB
M
M
SB
M
M
SB
PM worker
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
10
10
10
10
10
10
10
10
10
10
-

-9 -
MAINTENANCE WORK ORDER

010120
Requester Section:
Power Station PS03 - Gas Turbine G01 - Priority: A
Maintenance type/level: Annual PM
1- Check .
2- Clean ..
3- Replace ..
4- Adjust
5- Repair ..
Eng. Attia Gomaa
Planning Section:
Labor: 4 Mech. 2 Helper
5 days
5 Elec. 4 Helper
10 days
Spare parts: 2 valve xx1, 4 air filter yy3, .. etc.
Special tools: xxx, yyyy, etc,
Expected down time (from 01/01 to 15/01/2004)
Cost estimation ($ 10,000)
Safety instructions:
- Check
Eng. Aly Ahmed
Craft Feedback:
1- Check .
2- Clean ..
3- Replace ..
4- Adjust
5- Repair ..
Labor: 3 Mech. 2 Helper
5 days
6 Elec.
3 Helper
11 days
1 Vib.
1 Helper
2 days
Spare parts: 2 valve xx1, 4 air filter yy3, .. etc.
Special tools: Vibrometer, etc,
Down time (01/01 to 17/01/2004) Actual Cost ($ 12,000)
Eng. Omer Aly
Coding:
- 10 -
P3: The yearly PM programs information for four similar

gas turbines (GT01 through GT04) in a power station are as
follows:
PM Level
Maintenance levels per gas turbine

Frequency
PM
Maint.
No. of
Type
duration workers
Spare
parts
cost $1000
10
8
5
2
---
Y Level 1 Yearly
Shutdown 14 day
20
S Level 2
6 Monthly Shutdown 7 day
15
3M Level 3 3 Monthly Shutdown 4 day
10
M Level 4 Monthly
Shutdown 2 day
8
W Level 5 Weekly
Running 5 hours
2
D Level 6 Daily
Running 1 hours
2
Gas turbine operating conditions: 24 hour/day
Average effort of CM = 380 man-day per gas turbine
Average annual CM cost = $ 12000 per gas turbine
Average CM downtime = 15 days/year per gas turbine
Labor cost rate = $ 10 per man-day
Required:
1. The size of maintenance labor force.
2. Average system availability.
3. Annual PM plan.
4. Annual downtime cost losses.
5. Annual maintenance cost.

- 11 -
P4:
The yearly PM programs information for six similar fire tube
boilers (FB01 through FB06) in a textile company are as
follows:

- 12 -
Preventive Maintenance Program:

Daily
(Running)
Weekly
Monthly
(Shutdown)
(Shutdown)
Check for tight
closing of fuel
Inspect burner
valves
Check fuel and Analyze
air linkage
combustion
Check indicating
Check cams
lights and alarms
S. Annually
(Shutdown)
Clean low
Check water
water cutlevel
off(s)
Blowdown
Check oil
boiler
preheater
Blowdown
Inspect
water column
refractory
Check
Clean oil
Check operating Inspect for flue
combustion
pump strainer
and limit controls gas leaks
visually
and filter
Treat water
Clean air
Check safety
according to the
Inspect for hot cleaner and
and interlock
established
spots
air/oil
controls
program
separator
Record boiler
Check low water Review boiler Check pump
operating
cutoff(s)
blowdown
coupling
pressure/
operation
procedures
alignment
temperature
Check for leaks,
Record feed
Check
noise, vibration,
Reset
water pressure/
combustion air
unusual
combustion
temperature
supply
conditions
Inspect
Record flue gas Check operation Check all filter
mercury
temperature
of all motors
elements
switches
Record oil
Check general Check fuel
pressure and
burner operation systems
temperature
Annually
(Shutdown)
Clean fireside
surfaces
Clean breeching
Clean waterside
surfaces
Check oil storage
tanks
Check fluid levels
on hydraulic
valves
Check gauge
glass
Remove and
recondition safety
valves
Check oil pumps
Check boiler feed
pumps
Record gas
pressure
Check lubricating Check belt

oil levels
drives
Check
condensate
receivers
Record
atomizing
pressure
Check general
boiler/burner
operation
Check flame
scanner
assembly
Check chemical
feed systems
Check packing
glands
Check
lubrication
requirements
Tighten all
electrical
terminals

- 13 -
PM Level
Y Level 1
S Level 2
M Level 4
W Level 5
Maintenance levels per boiler

Frequency Maintenance
No. of
duration (hour) workers
Yearly
160
6
6 Monthly
60
3
Monthly
20
2
Weekly
10
2
Spare parts
cost $1000
4
2
1
0.5
Boiler operating conditions: 24 hour/day

Average effort of CM = 250 man-hour per boiler
Average annual CM cost = $ 2000 per boiler
Average CM downtime = 120 hours/year per boiler
Labor cost rate = $ 10 per man-day
Required:
3. Annual PM plan.
4. Annual downtime cost losses.

- 14 -
P5: The yearly PM programs information for some

machines in a company are as follows:
M/c
Type
Number
of M/C
Turning
Grinding
M/c
Type
Turning
Grinding
6
3
Maintenance level for each machine

Weekly
Monthly
Yearly
Man
Hour Man
Hour Man
Hour
3
3
5
24
2
3
4
12
-
Maintenance Spare Parts Cost for each machine

Weekly level
Monthly level
Yearly level
400
3000
500
1600
-
(Maint. working conditions: 52 week/year, 6 day/week, 8 hr/day)
Required:
1. The size of PM labor force.
2. Annual PM cost.
3. Annual PM plan.
4. Average down time per month.

- 15 -
P6: The yearly Reliability and PM programs information for

some machines in a company are as follows:
T
0.95
0.9
0.95
0.9
0.8
0.8
G
0.9
M/c
Type
Number
Maintenance level
of
10 days
6 Monthly
Yearly
M/cs
W D O
W
D
O
W
D
Lath
4
3 1 10
4
2
20
5
4
Drilling
2
2 1 10
4
2
20
Grinding 1
3
2
20
3
3
W: Number of workers D: Maint. duration (day) O: Oil (liter)
- Working conditions:
Operating: 52 week/year, 6 day/week, two shifts
Manpower: 45 week/year, 6 day/week, one shift

- 16 -
O
20
20
Annual CM analysis per

machine
Average Manpower (workers)
Average oil quantity (liter)
Average Spar parts costs ($/year)
Average Down time (day/year)
Lath
2
100
2000
20
Drilling Grinding
2
60
1000
12
2
80
1000
10
- Oil cost is $ 5 /liter

- Average labor rate is $ 10 / man-hour
- Average Indirect costs (or Overhead) are 40 % direct
maintenance cost
- Average down time cost rate of the PM is $ 100 / machinehour, whereas that of CM is $ 300 / machine-hour.
Required:
2. Annual oil quantity.
3. Annual maintenance budget.
4. Annual maintenance plan with the best manpower
profile.
5. Annual down time for each machine.
6. Average availability for each machine.
7. Annual down time cost for each type.
8. System availability.
9. System reliability.

- 17 -
P7: The yearly PM programs information for a production

line in a shop are as follows:
T
T
T
Standby
Standby
M/c
Type
Number
of
machines
Turning
3
Milling
2
Drilling
1
Grinding
1
M/c Type
Turning
Milling
Drilling
Grinding
PM Maintenance levels per machine

10 days
6 Monthly
Yearly
Man Day Man day Man day
3
1
4
2
5
4
2
1
4
3
2
1
4
2
3
2
3
3
PM Spar parts and materials cost (L.E.)

10 days
6 Monthly
Yearly
400
1500
3000
600
4000
500
1600
1000
2000
- Working conditions:
Production & maintenance 52 week/year, 6 day/week, two
shifts.
Manpower 45 week/year, 6 day/week, one shift.
- 18 -
- Average labor rate is 10 L.E./ man-hour

- Average other costs are 40 % direct maintenance cost
- Average CM Spare parts costs are 15 % PM spar parts
costs.
- Average CM manpower are 30 % PM manpower.
- Average down time cost rate is 100 L.E./machine-hour.
- Average CM down times per machine (day /year) are as
follows:
Machine
Turning Milling
Down time
15
10
Drilling
12
Grinding
8
Required:
3. Annual maintenance plan with the best manpower
profile.
4. Average down time for each machine type.
5. Average availability for each machine type.
6. Average system availability
7. Average down time cost for each machine type.

- 19 -
MAINTENANCE FORECASTING
Y=a+bX
Sum Y = n . a + b Sum X ,
Sum XY = a Sum X + b Sum X2
Measuring the accuracy of forecasting:

1- Coefficient of correlation
r =( n Sum XY - Sum X Sum Y) /
( n Sum X2 (Sum X) 2 ) 0.5 ( n Sum Y2 (Sum Y) 2 ) 0.5
2- Mean Absolute Deviation
MAD = sum | A F | / (n -1)
3- Mean Squared Error
MSE = sum (A F)2 / (n -1)
Controlling the forecast:
CLs = 0 Z S
0
S = Standard deviation of the distribution of errors

= MSE
Z=3
Z=2
Z=1
99.7% of the values can be expected.


- 20 -
P8: Maintenance spare parts cost ($):

Year
1999
Year
2000
Year
2001
Year
2002
Exp.
2003
1450
1300
1200
1000
3
1200
3600
4
1000
4000
X
Y
XY
1
1450
1450
2
1300
2600
n=4
Sum X = 10
Sum Y = 4950
Forecasting
limits
2003
?
5
?
Sum X2 = 30
Sum XY = 11650
Sum Y = n . a + b Sum X ,
Sum XY = a Sum X + b Sum X2
4950 = 4 a + 10 b
11650 = 10 a + 30 b
14850 = 12 a + 30 b
a = 1600
b = - 145
Y = 1600 145 X
X
A
F
(A-F)
(A-F)2
Y5 = 1600 145 (5) = 875

1
1450
1445
5
25
2
1300
1310
10
100
3
1200
1165
35
1225
4
1000
1020
20
400
5
875
MSE = 1750 / (4 -1) = 583

S = 24
Z=2
CLs = 0 Z S = 0 48
- 21 -
P9:
An casting company has the following yearly production and
overhead cost data:
Year
Production
quantity
(1000 ton)
Maintenance
cost (M L.E.)
96
5.2
97
5.5
98 99
6.0 6.4
00
6.5
01
7.0
02
7.5
03
7.9
1.3
1.5
1.8 2.0
2.1
2.2
2.5
3.0
Required:
1)
Plot the maintenance cost vs. production quantities?
2)
Estimate and plot a trend for the maintenance cost and

production quantities?
3)
Compute the maintenance cost forecast for year 2004, if the

production plan is 8,500 tons?
4)
Find the unit maintenance fixed cost and unit maintenance

variable cost, for the year 2003?
5)
Measure and discuss the accuracy of the maintenance cost

forecasts using both the correlation coefficient and mean
absolute deviation?
6)
Develop and discuss a forecasting control chart with 99.7%

and 95.5% confidence levels (probability of expected
values)?

- 22 -
P10:
Uncertain spare parts cost
Spare parts cost
Probability
$ 100,000
9
10
11
12
13
%
20
50
20
7
3
Estimate the spare parts budget based on the following:

1- Average method ($ 1,100,000)
2- Probability method ($ 1,023,000)
3- PERT method ($ 1,033,000)

- 23 -
MONTHLY M. PLANNING USING CPM
P11: The monthly PM programs information for a

machining shop are as follows:
Machine
Code
Machine
Description
Predecessors
Duration
(day)
Worker/day
Spare Parts
cost $ 1000
T01
D01
M01
T02
M02
Turning Drilling Milling Turning Milling

8
T01
8
M01
20
5
5
8
4
7
3
5
6
5
12
Required:
1. If the maximum worker limit is 12 worker/day,
construct the corresponding monthly maintenance
plan.
2. Calculate the monthly spare parts cost.
3. Construct the monthly spare parts cost profile.

- 24 -
P12: The monthly PM programs information for a

machining shop are as follows:
Machine
T01
D01
M01
T02
D02
M02 M03
Code
Turning Drilling Milling Turning Drilling Milling Milling
Machine
Description
Predecessor
T01
D01
M01
M02
Duration
8
4
6
8
5
8
12
(day)
Worker/day
5
6
7
5
6
5
5
Spare Parts
2
1.5
3
4
2
4
5
cost $ 1000
Required:
1. If the maximum worker limit is 12 worker/day,
construct the corresponding monthly
maintenance plan.
2. Calculate the monthly spare parts cost.
3. Construct the monthly spare parts cost profile.

- 25 -
CAPITAL MAINTENANCE (OVERHAUL) PLANNING

USING CPM
P13: A Bus company has about 1500 bus. The capital maintenance
and engine overhaul is carrying out after about 250,000 to 300,000
km (about two years) and its duration is about 10 day. The overhaul
information for each bus engine are as follows:
Activity ID
Predecessors
Duration (day)
Worker/day
A
2
4
B
1
2
C
1
3
D
1
2
E
B&D
2
4
F
C
1
3
G
F
2
1
Average spare parts cost = 10,000 L.E./Bus.

Average labor cost rate = 20 L.E./man-day
Indirect cost rate = 50 L.E./day
Down time cost rate = 300 L.E./Bus-day
Required:
1. Construct the bus overhaul plan, If the maximum
worker limit for each overhaul is 6 worker/day.
2. Construct the Annual maintenance plan for all
buses.
3. Calculate the size of maintenance labor force.
4. Comparison between the current and developed
maintenance planning systems.

- 26 -
H
E&G
2
1
P14: Monthly Maintenance Plan for Wire Production Line

9
W01
W02
Project Name : MMPW

Planning unit : Day
W03
Project start: 1 Jan. 2004

6 DAYS /WEEK
1- Activity List
ID
Activity
1
2
3
Preparation
PRP
Mech. maintenance # 01 MM1
Elec. maintenance # 01 EM1
4
5
6
7
8
Mech. maintenance # 02
Elec. maintenance # 02
Mech. maintenance # 03
Setup
MM2
EM2
MM3
EM3
STP
Duration
Predece
(day)
ssors
2
7
PRP
9
M
M
1
6
PRP
8
MM2
5
PRP
7
MM3
1
EM1
EM2
EM3
Relations
(SS, FS,
FF, and SF)
SS 3
SS 2
SS 2
-
2- Resource List
Resource
Code
L01
L02
SPS
Resources description
Unit
Mechanical worker
Electrical worker
Spare parts & supplies
md
md
cost
Limits/day
Norm. Max.
3
6
4
8
-
Price
LE/unit
40
60
1000

- 27 -
3- Resource Allocation
ID
Activity
1
2
3
4
5
6
7
8
Preparation
PRP
EM1
EM2
EM3
Setup
STP
L01/
day
2
4
3
2
2
Resource
L02/
SPS
day
(Total)
1
1
3
5
4
2
4
3
2
3
3
2
1
4- Base Calendar (Working periods)

Saturday Sunday
Monday
Tuesday
Wednesday
Thursday
X
1/01/04
Friday
Holidays: 20 to 21 Jan. 2004
Required:
1. Draw the project network (logic diagram)?
2. Draw the corresponding Gantt chart?
3. Construct the corresponding smoothed worker
loading?
4. Construct the corresponding worker leveling?
5. Construct the target action plan?.
6. Construct the cost profile & S-curve?
7. Construct the target master plan?

- 28 -
P15: Annual Maintenance Plan for AUC-IT Labs.

Project Name : AMIT
Planning unit : Day
Project start: 1 Jan. 2004

6 DAYS /WEEK
1- Activity List
1
2
3
4
5
6
7
8
9
Activity
Preparation
Server maintenance
Hardware maintenance
Lab #01
Software maintenance
Lab #01
Lab #02
Lab #02
Lab #03
Lab #03
Setup
PRP
SRM
HM1
Duration
(day)
1
3
4
Predece Relations
ssors
PRP
SRM
-
SM1
HM1
SS 2
HM2
SRM
SM2
HM2
SS 1
HM3
SRM
SM3
HM3
SS 1
STP
SM1
SM2
SM3
ID
2- Resource List
Resource
Code
L01
L02
SPS
Resources description
Unit
Hardware Engineer
Software Engineer
Spare parts & supplies
md
md
cost
Limits/day
Norm. Max.
3
6
4
8
-
Price
LE/unit
120
100
1000

- 29 -
3- Resource Allocation
ID
Activity
1
2
3
Preparation
Server maintenance
Lab #01
Lab #01
Lab #02
Lab #02
Lab #03
Lab #03
Setup
4
5
6
7
8
9
Resource
L02/
SPS
day
(Total)
1
1
1
1
2
PRP
SRM
HM1
L01/
day
2
1
4
SM1
HM2
SM2
HM3
SM3
STP
4- Base Calendar (Working periods)

Saturday
Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
X
X
X
X 1/01/04
Holidays: 20 to 21 Jan. 2004
Required:
1. Draw the project network (logic diagram)?
2. Draw the corresponding Gantt chart?
3. Construct the corresponding smoothed worker loading?
4. Construct the corresponding worker leveling?
5. Construct the target action plan?.
6. Construct the cost profile & S-curve?
7. Construct the target master plan?
- 30 -
MATERIALS REQUIREMENTS PLANNING (MRP)

FOR MAINTENANCE
P16:A monthly maintenance plan for 50 similar equipment

to replace the gear box for these equipment. The gear box
structure is shown below.
A
B(2)
D(2)
C(2)
E(2)
E(2)
F(2)
G(1)
Component
Lead time (week)
On-Hand
A
1
10
B
2
15
D(2)
C
1
20
D
1
10
E
2
10
F
3
5
Required:
1. Time-phased for the gear box structure
2. Gross requirements plan for 50 gear box
3. Net material requirements plan for 50 gear box.

- 31 -
G
2
0
CM CAPACITY PLANNING USING WAITING LINES

MODELS
P17: A maintenance service facility has Poisson arrival

rates, negative exponential service times, and operates on a
first-come first-served queue discipline. Breakdowns occur
on an average of = three per day with a range of zero to
eight. The maintenance crew can service an average of =
six machines per day with a range of from zero to seven.
Find the following:
1) Utilization factor of the service facility.
2) Percent idle time % I
3) Mean time in the system Ts
4) Mean number in the system Ns
5) Mean Waiting time Tw
6) Mean number in the queue Nq
7) Probability of finding n=2 machines in the system

- 32 -
Solution
Mean arrival
rate
= 3, {0,8}
Maintenance
service
facility
Mean service
rate
= 6, {0,7}
1) Utilization factor of the service facility =

= Mean arrival rate / Mean service rate
= / = 3 / 6 = 50 %
2) Percent idle time % I =
% I = (Total) - (Utilization factor)
= 100 50 = 50 %
3) Mean time in the system Ts =
Ts = 1 / (Mean service rate Mean arrival rate)
= 1 / ( - ) = 1 / (6 3) = 1/3 day
4) Mean number in the system Ns =
Ns = (Mean time in system) (Mean arrival rate)
= / ( - )= 3 / (6 3) = 1 machine
- 33 -
5) Mean Waiting time Tw

Tw = Total time in system Service time
= {1/( - )} { 1/ }
= {1/(6 - 3)} { 1/6 } = 1/6 day
6) Mean number in the queue Nq =
= (Mean number in system)-(Mean number being served)
= { / ( - )} {/}
= {3 / (6 3)} - {3/6} = 1/2 machine
Pn = (1 - /) (/)n = (1 - 3/6) (3/6)2 = 0.125
Pn = (1 - /) (/)n = (1 - 3/6) (3/6)4 = 0.03125
Pn = (1 - /) (/)n = (1 - 3/6) (3/6)6 = 0.0078

- 34 -
P18: A maintenance service facility has Poisson arrival

rates, negative exponential service times, and operates on a
first-come first-served queue discipline. Breakdowns occur
on an average of = five per day with a range of zero to
nine. The maintenance crew can service an average of =
six machines per day with a range of from zero to eight.
Find the following:
1. Utilization factor of the service facility.
2. Percent idle time % I
3. Mean time in the system Ts
4. Mean number in the system Ns
5. Mean Waiting time Tw
6. Mean number in the queue Nq
7. Probability of finding n=2 machines in the system
8. Probability of finding n=4 machines in the system
9. Probability of finding n=6 machines in the
system

- 35 -
P19:
The CM information for a production department are as
follows:
1. Labor maintenance cost rate = $10/hr
2. Downtime cost rate = $50/hr per machine.
3. The mean number of failures is four/hr, and distributed
according to a Poisson distribution.
4. The mean number of repairs is six repairs per workerhour, and distributed exponentially
What is the best maintenance crew size?

- 36 -
Solution
Mean arrival rate
= 4, Poisson
Mean service rate

Maintenance
service
facility
Labor cost =
$10/hr
= 6 /worker,
Exp.
Crew Size?
Downtime cost =
$50/hr/machine
Crew
Size
1
2
3
4
5
6
12
18
24
30
Ns =
Labor
Downtime
Total
/ ( - )
cost
cost
cost
2.00
0.50
0.29
0.20
0.15
$/hr
10
20
30
40
50
$/hr
100.00
25.00
14.29
10.00
7.69
$/hr
110
45
44.29
50.00
57.69
The best maintenance crew size is 3 workers

- 37 -
P20:
The CM information for a production department are as
follows:
5. Labor maintenance cost rate = $20/hr
6. Downtime cost rate = $150/hr per machine.
7. The mean number of failures is five/hr, and distributed
8. The mean number of repairs is five repairs per workerhour, and distributed exponentially
What is the best maintenance crew size?

- 38 -
P21:
The CM information for a production department is as
follows:
Labor maintenance cost rate = $20/hr
Downtime cost rate = $150/hr per machine.
The mean number of failures is five/hr, and distributed
The mean number of repairs is five repairs per worker-hour,
and distributed exponentially
Required:
1. Determine the best maintenance crew size?
2. Calculate the utilization factor of the maintenance
crew?
3. Determine the mean time in the system?
4. Calculate the probability of finding two machines in the
system?

- 39 -
P22:
A factory has 200 machines and the maintenance
engineer supervises the repair crews who repair
malfunctioning machines. The maintenance policy is to
repair the broken down machine and bring back in
production within 2 hours on the average. If average
breakdown rate is 3.5 machines/hour and each repair
crew can repair 0.25 machine per hour on the average.
How many repair crews are required ?
The formula for average repair rate () is
1
ts = ---------or
-
Where = repair rate
= + 1/ ts
= arrival rate of malfunctioning machines

ts = average time arrivals in the system
Required average repair rate
= 3.5 + 1 / 2 = 4 machines / hour
No. of Crews =
machines/hour a crew can repair
=
4 0.25 = 16 repair crews required
- 40 -
MAINTENANCE WORK CONTROL USING

CONTROL CHARTS
P23: The weekly backlog data for the mechanical section of

the maintenance department are given as follows in terms of
labor-hours for the last four months:
Number
1
Month
March
Week 1
360
Week 2
320
Week 3
300
Week 4
380
April
340
350
320
380
May
420
412
452
380
June
390
370
350
410
Determine and plot the control chart for the weekly backlog.
(For n = 4, d2 = 2.059.)

- 41 -
SPARE PARTS COST CONTROL
P24: The monthly plan and the actual maintenance spare

parts in ABC Company are as follows:
Spare
part #
A11
A12
A13
A14
A15
Plan (Jan. 2001)

Planned
Standard
quantity
cost
(unit)
(L.E./unit)
40
1000
30
1200
50
900
20
850
20
950
Actual (Jan. 2001)

Actual
Actual cost
quantity
(L.E./unit)
(unit)
40
1100
20
1200
40
1000
10
800
20
900
Based on these data, determine the different performance

indicators.

- 42 -
TOTAL MAINTENANCE CONTROL

P25:
Monthly production information on Foundry Shop FS510 was as
follows:
Item
January February
2004
2004
Working days
31
28
8
8
Standard production rate (ton/hr)
24
24
Average daily time (hr/day)
Average down time (hr/day)
6
4
Average standby (hr/day)
3
3
Average target quantity (ton/day)
120
136
Average actual quantity (ton/day)
80
105
Average sound quantity (ton/day)
70
98
Average defect quantity (ton/day)
10
7
Average energy consumption (1000 kwh/day)
49
67
130
Material cost (1000 L.E/day)
100
Required:
1. Equipment avaliability.
2. Equipment performance efficiency.
3. Equipment utilization factor.
4. Equipment quality rate
5. Equipment uptime ratio.
6. Energy productivity.
7. Material productivity
8. Overall equipment effectiveness (OEE).
9. Total effective equipment productivity (TEEP).
10. Net equipment effectiveness (NEE).

- 43 -
Basic data
Item
January
February
2004
2004
Production rate (ton/hr)
8
8
Total time (hr/day)
24
Average down time

6
(hr/day)
Average available time
18
(hr)
Average standby
3
(hr/day)
Average used time
15
(hr/day)
Average target quantity
120
(ton/day)
Average actual quantity
80
(ton/day)
Average sound quantity
70
(ton/day)
Average defect quantity
10
(ton/day)
(14%)
Energy productivity
700
(kwh/ton)
Material productivity
1429
(1000 L.E/ton)
Feb. / Jan.
100 %
24
100 %
67 %
20
111 %
100 %
17
113 %
136
113 %
105
125 %
98
129 %
7
(7%)
684
64 %
1326
98 %
92 %

- 44 -
Performance Evaluation
Indicator
January
2004
Availability
18/24= 75 %
February
2004
20/24= 83 %
Feb. / Jan.
111 %
Performance
efficiency
Quality rate
80/120= 67 %
105/136= 77 %
115 %
70/80= 88 %
98/105= 93 %
106 %
Utilization ratio
15/18= 83 %
17/20= 85 %
102 %
Uptime (hr/day)
70/8= 8.75
98/8= 12.25
140 %
Uptime ratio
8.75/15= 49%
12.25/17=72 %
147 %
OEE
44 %
60 %
136 %
TEEP
37 %
51 %
138 %
NEE
29 %
52 %
179 %
700
684
98 %
1326
92 %
Energy
productivity
(kwh/ton)
Material
productivity (1000
L.E/ton)
1429

- 45 -
P26:
The six-monthly maintenance costs ($1000) for a
productive system are as follows:
Target Costs:
Jan
Feb
Month #
Mar Apr May
100
50
100
50
100
50
100
50
100
50
100
50
100
50
200
150
300
200
150
300
200
150
300
200
150
300
200
150
300
200
150
300
200
150
300
Feb
Month #
Mar Apr May
Jun
Jly
23
32
38
65
49
96
56
94
68
94
65
90
54
72
231
503
407
213
370
397
181
293
320
185
164
290
199
201
330
196
193
320
157
142
362
Cost item
PM Cost:
Spar parts
Labor
CM Cost:
Spar parts
Labor
DT Cost
Jun
Jly
Actual Costs:
Cost item
PM Cost:
Spar parts
Labor
CM Cost:
Spar parts
Labor
DT Cost
Jan

evaluation indicators for the maintenance system.

- 46 -
Target:
Cost item
PM Cost
CM Cost
TM Cost
DT Cost
TM+DT
PM/TM
CM/PM
Jan
150
350
800
300
1100
0.14
2.33
Feb
150
350
800
300
1100
0.14
2.33
Mar
150
350
800
300
1100
0.14
2.33
Month #
Apr May
150 150
350 350
800 800
300 300
1100 1100
0.14 0.14
2.33 2.33
Jun
150
350
800
300
1100
0.14
2.33
Jly Total
150 1050
350 2450
800 5600
300 2100
1100 7700
0.14 0.955
2.33 16.33
Actual:
Cost item
PM Cost
CM Cost
TM Cost
DT Cost
TM+DT
PM/TM
CM/PM
Jan Feb Mar

55
103 145
734
583 474
1196 1083 939
407
397 320
1603 1480 1259
0.05 0.10 0.15
13.35 5.66 3.27
Month #
Apr May
150 162
349 400
789 892
290 330
1079 1222
0.19 0.18
2.33 2.47
Jun
155
369
864
320
1184
0.18
2.38
Jly Total
126
896
299 3208
787 6550
362 2426
1149 8976
0.16 1.007
2.37 31.82
Change %:
Cost item
Jan
Month #
Feb Mar Apr May Jun
Jly
Total
PM Cost
CM Cost
TM Cost
DT Cost
TM+DT
PM/TM
CM/PM

- 47 -
P27:
The yearly PM programs information for six similar gas
turbines in a power station are as follows:
Target work performed:

Item
Total labor force (worker)
Annual spare parts cost ($1000)
Annual labor cost ($1000)
Overhead cost ($1000)
Average down time
(day/year per gas turbine)
PM
18
264
--51
CM
7
72
--15
Total
25
336
75
514
66
Actual work performed:

Item
Annual spare parts cost ($1000)
Average down time
(day/year per gas turbine)
PM
20
300
--45
CM
10
100
--5
Total
30
400
80
520
50


- 48 -
Performance Evaluation Sheet:

Item
Target
Actual

Annual s. parts cost
25
336
30
400
Change
%
+ 20
+ 19
($1000)
Total m. cost ($1000)
Average down time
Down time cost ($1000)
75
514
925
66
66
80
520
1000
50
50
+ 6.6
+ 1.2
+ 8.1
- 24.3
- 24.3
991
81.9
7/18 =
38.9
72/264 =
27.3
514/411=
1.25
1050
86.3
10/20 =
50
100/300 =
33.3
520/480=
1.08
+ 6.0
+ 5.3
+ 28.5
25/6=
4.17
30/6=
5.00
- 16.6
TMC + DTC
Availability %
CM/PM % (labor force)
CM/PM % (Spare parts)
Overhead %
Labor productivity %
(worker/gas turbine)
+ 22.0
- 13.6
P28:
The six-monthly maintenance costs ($1000) for a productive
system are as follows:
Target Costs:
Cost item
Month #

- 49 -
PM Cost:
Spar parts
Labor
CM Cost:
Spar parts
Labor
DT Cost
100
50
100
50
100
50
100
50
100
50
100
50
100
50
200
150
300
200
150
300
200
150
300
200
150
300
200
150
300
200
150
300
200
150
300
Actual Costs:
Cost item
PM Cost:
Spar parts
Labor
CM Cost:
Spar parts
Labor
DT Cost
Jan
Feb
Month #
Mar
Apr May
Jun
Jly
23
32
38
65
49
96
56
94
68
94
65
90
54
72
231
503
407
213
370
397
181
293
320
185
164
290
199
201
330
196
193
320
157
142
362


- 50 -
Target:
Cost item
Jan
PM Cost
CM Cost
DT Cost
TM Cost
150
350
300
800
Feb
150
350
300
800
Month #
Mar Apr May
150
350
300
800
150
350
300
800
150
350
300
800
Jun
Jly
150
350
300
800
150
350
300
800
Jun
Jly
155
369
320
864
126
299
362
787
Actual:
Cost item
Jan
PM Cost
55
CM Cost
734
DT Cost
407
TM Cost 1196
Feb
103
583
397
1083
Month #
Mar Apr May
145
474
320
939
150
349
290
789
162
400
330
892

- 51 -
P29: The monthly budget and the actual maintenance cost

for XXX Company are as follows:
Cost item
Spare parts
Direct labor
Indirect materials
Indirect labor
Fixed overhead
Standard
Quantity
Rate
20,00
6000
ton
40,000
L.E.
15
hour
L.E.
150,000 L.E.
100,000 L.E.
300,000 L.E.
Actual
Quantity
Rate
15,00
6400
ton
45,000
L.E.
18
hour
L.E.
180,000 L.E.
80,000 L.E.
350,000 L.E.

indicators.

- 52 -
P30:
The annual budget and the actual maintenance cost for XXX
production department are as follows:
Cost item (L.E.)

Direct labor
Indirect labor
Spare parts
Indirect materials
Other overheads
Budget
Current Year to
Actual
Current
Year to
month
6000
5936
2000
1000
1000
month
5000
4111
700
500
1200
date
60000
53834
12000
10000
10000
date
65000
58834
10000
5000
12000

indicators.

- 53 -
P31:
Maintenance Planning for Spare Parts Work Shop
1- Equipment List
Plant
Systems
Productive
systems
Supportive
systems
Location
Machining
shop
Equipment Type
Turning
Milling
Drilling
Grinding
Press
Induction furnaces
Molding machines
Arc Welding
Foundry
shop
Welding
shop
Material
Fork lift
handling
Air room
Compressor
Water room Pump 50 HP
Pump 100 HP
Power
Diesel generator
room
Number of
Machines
4
2
2
2
1
2
5
1
4
2
2
2
2

- 54 -
2- Layout of machining shop

T
3- Equipment reliability
T
0.9
0.9
0.8
0.8
0.9
0.9
0.9
0.8
0.8
0.9
4- Equipment PM Program for machining shop

4-1- PM Manpower & Downtime:
Eq. Type
Weekly
Man Hr
Turning
2
5
Milling
2
5
Drilling
1
3
Grinding
2
3
Press
1
2
Monthly
Man Hr
3
16
3
12
-
6 Monthly
Yearly
Man Hr
Man Hr
5
24
5
16
2
10
3
12
3
12
3
16
2
6
3
12

- 55 -
4-2- PM Spare Parts & Supplies:

Eq. Type
Weekly
B
O
Turning
3
Milling
2
Drilling
1
Grinding
1
Press
1
B : Bearing
4-3- PM Cost:
Monthly
6 Monthly
B
O
B
O
5
4
4
6
4
8
4
6
O: Oil (liter)
Yearly
B
O
4
12
4
10
4
8
4
8
4
8
Average labor rate $ 10 / hour

Spare Parts & Supplies cost:
Bearing $ 50 /unit
&
Oil $ 5 /liter
Other costs (Indirect or Overhead) 40 % PM

5- Failure Analysis for the last year (CM)
Average per
Turning Milling Drilling Grinding Press
equipment
Man-hour
100
60
40
50
30
Down time hr
50
40
30
40
30
Spare parts cost 1000
800
500
600
500
$
Oil (liter)
20
15
12
16
10
6- Working conditions:
Machine Working conditions:
- 56 -
2 shifts/day, 8 hr./shift, 6 day/week, 45

week/year.
Manpower working conditions:
8 hr./day, 6 day/week, 45 week/year.
II- Maintenance Planning Elements
Required:
1. Equipment coding.
2. Equipment priorities.
3. Maintenance labor force.
4. Spare parts & supplies requirement planning.
6. Equipment average down time per month.
7. Equipment average time availability.
8. System average down time per month.
9. System average time availability
10. System reliability
11. Annual PM plans.
12. Annual man-hours & manpower profile
13. Monthly PM plans.
14. Maintenance Work orders
----------------------------------------------------------

- 57 -

03 Part 3 - PM Case Studies

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Part 3:

PREVENTIVE MAINTENANCE PLANNING

Average effort of CM = 380 man-day per gas turbine

Overhead cost = 25 % direct cost (spare parts & labor)

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

The size of maintenance labor force.

The size of maintenance labor force

Annual Duration No. of

Annual PM man-day per gas turbine

The size of PM labor force = 4860/300 =16.2 = 17 workers

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

The average down time per year

PM downtime per gas turbine

Average down time = 51 + 15 = 66 day/year per gas turbine

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Annual maintenance cost

Annual spare parts PM per gas turbine

Basic Annual PM Plan

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Target Annual PM Plan # 1

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Target Annual PM Plan # 2

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Monthly Maintenance Plan: Month # 1

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

MAINTENANCE WORK ORDER

P3: The yearly PM programs information for four similar

Maintenance levels per gas turbine

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Preventive Maintenance Program:

Check lubricating Check belt

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Maintenance levels per boiler

Boiler operating conditions: 24 hour/day

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

P5: The yearly PM programs information for some

Maintenance level for each machine

Maintenance Spare Parts Cost for each machine

(Maint. working conditions: 52 week/year, 6 day/week, 8 hr/day)

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

P6: The yearly Reliability and PM programs information for

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Annual CM analysis per

- Oil cost is $ 5 /liter

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

P7: The yearly PM programs information for a production

PM Maintenance levels per machine

PM Spar parts and materials cost (L.E.)

- Average labor rate is 10 L.E./ man-hour

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

Sum XY = a Sum X + b Sum X2

Measuring the accuracy of forecasting:

S = Standard deviation of the distribution of errors

99.7% of the values can be expected.

-----------------------------------------------------------------------------------------Part 3: PM Case Studies

P8: Maintenance spare parts cost ($):

Sum XY = a Sum X + b Sum X2

Y5 = 1600 145 (5) = 875

MSE = 1750 / (4 -1) = 583

Plot the maintenance cost vs. production quantities?

Estimate and plot a trend for the maintenance cost and

Compute the maintenance cost forecast for year 2004, if the