Proaktivt underhåll - Från brandkårsutryckning till planerade underhållsinsatser
Author
Summary, in English
This master thesis was commissioned for the company IAC Group AB in
Gothenburg. The factory assembles and delivers instrument panels in sequence to
Volvo Car Corporation.
The task was to create and implement a maintenance system where all maintenance
processes such as preventive maintenance and corrective maintenance can be
registered. The purpose was to give the company a deeper knowledge of the work
that was to be performed by the maintenance organization. But also to give the
maintenance staff better conditions to measure and analyze their own work with
the main purpose to improve themselves.
Knowledge was obtained through literature studies of how a maintenance system is
generally built and how different processes within maintenance are managed. The
studies also helped with the understanding of how efficiency and costs within the
production is affected by the maintenance work. Manufacturing economical
simulation, developed at Lund Institute of Technology, is a method that (in this
project) was used to determine which economical consequences improved
maintenance would result in.
After an economical analysis and mapping of the production it became obvious
that the labor costs would stand for the majority of the production expenses. This is
not something unusual since assembling productions often have a larger demand of
personnel. The high labor cost therefore makes it crucial to keep the production
running at all costs. The economical calculations showed that a reduced stoppage
time in the production could result in savings up to half a million swedish crowns a
month due to reduced production costs.
Today’s maintenance organization is working after emergency discharges and the
work can be resembled of being more reactive than proactive. In other words this
means that the maintenance technicians more or less await a problem to occur in
the production site before actually doing something about it.
The first step to be made to implement the maintenance system was to map and
categorize the production site. Information about specific equipments was gathered
from supplier manuals. This information was then used to create a theoretical
model of the production site in the computer system. The model contained all
necessary objects which needed maintenance such as robots and motors. Measures
for preventive maintenance were then created based on the experience of the
maintenance technicians but also from supplier recommendations.
To only look at the availability of the production equipment when measuring
maintenance improvements was considered static. An attempt was therefore made
to develop an alternative formula that combined availability with economical consequences in the production for analyzing maintenance improvements. The main purpose of the formula was to provide better knowledge of which production
sections or equipment that has largest economical advantages when having a high
availability. This can be a powerful tool when deciding were in the production
investment should be pointed. It can also be used to evaluate different production
sites were the difference in stop costs makes it impossible to compare them by
using availability as a measurement.
The thesis resulted in a maintenance system which was developed, implemented
and deployed for preventive and corrective maintenance. The repair technicians
were educated in the developed maintenance program as well as in theories
regarding maintenance. Models were also developed for measuring and evaluating
the results of maintenance modifications.
Since the system was deployed at the end of the project it was never included to
review the result of the maintenance system. After continuous work with the
maintenance system there will be a lot of data available which will help with
analyzing and evaluating the result. It is therefore suggested that the design and
structure of the maintenance system is further analyzed and evaluated in a fallowup
study. There is also more work to be done by further developing and testing the
economical availability formula that could be considered to be in a test phase.
Gothenburg. The factory assembles and delivers instrument panels in sequence to
Volvo Car Corporation.
The task was to create and implement a maintenance system where all maintenance
processes such as preventive maintenance and corrective maintenance can be
registered. The purpose was to give the company a deeper knowledge of the work
that was to be performed by the maintenance organization. But also to give the
maintenance staff better conditions to measure and analyze their own work with
the main purpose to improve themselves.
Knowledge was obtained through literature studies of how a maintenance system is
generally built and how different processes within maintenance are managed. The
studies also helped with the understanding of how efficiency and costs within the
production is affected by the maintenance work. Manufacturing economical
simulation, developed at Lund Institute of Technology, is a method that (in this
project) was used to determine which economical consequences improved
maintenance would result in.
After an economical analysis and mapping of the production it became obvious
that the labor costs would stand for the majority of the production expenses. This is
not something unusual since assembling productions often have a larger demand of
personnel. The high labor cost therefore makes it crucial to keep the production
running at all costs. The economical calculations showed that a reduced stoppage
time in the production could result in savings up to half a million swedish crowns a
month due to reduced production costs.
Today’s maintenance organization is working after emergency discharges and the
work can be resembled of being more reactive than proactive. In other words this
means that the maintenance technicians more or less await a problem to occur in
the production site before actually doing something about it.
The first step to be made to implement the maintenance system was to map and
categorize the production site. Information about specific equipments was gathered
from supplier manuals. This information was then used to create a theoretical
model of the production site in the computer system. The model contained all
necessary objects which needed maintenance such as robots and motors. Measures
for preventive maintenance were then created based on the experience of the
maintenance technicians but also from supplier recommendations.
To only look at the availability of the production equipment when measuring
maintenance improvements was considered static. An attempt was therefore made
to develop an alternative formula that combined availability with economical consequences in the production for analyzing maintenance improvements. The main purpose of the formula was to provide better knowledge of which production
sections or equipment that has largest economical advantages when having a high
availability. This can be a powerful tool when deciding were in the production
investment should be pointed. It can also be used to evaluate different production
sites were the difference in stop costs makes it impossible to compare them by
using availability as a measurement.
The thesis resulted in a maintenance system which was developed, implemented
and deployed for preventive and corrective maintenance. The repair technicians
were educated in the developed maintenance program as well as in theories
regarding maintenance. Models were also developed for measuring and evaluating
the results of maintenance modifications.
Since the system was deployed at the end of the project it was never included to
review the result of the maintenance system. After continuous work with the
maintenance system there will be a lot of data available which will help with
analyzing and evaluating the result. It is therefore suggested that the design and
structure of the maintenance system is further analyzed and evaluated in a fallowup
study. There is also more work to be done by further developing and testing the
economical availability formula that could be considered to be in a test phase.
Department/s
Publishing year
2008
Language
Swedish
Full text
- Available as PDF - 468 kB
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Document type
Student publication for college degree higher education diploma
Topic
- Technology and Engineering
Supervisor
- Ola Alexanderson
ISBN/ISSN/Other
- 08/5302