Are you a Mechanical Maintenance and Manufacturing technician looking for a decent job where your skills can be put to appropriate use? If yes, then you can browse through the wisdomjobs page where you will find various job vacancies in different industries such as automotive, construction and aerospace. In a Maintenance and Manufacturing job, you can ensure that the equipments and machineries operate efficiently at all times on a regular basis. In recent times many leading enterprises are looking for maintenance solutions where they can cut down their costs and improve their production levels. You can search the wisdomjobs page and select the best job option for yourself. You can also read the Maintenance and Manufacturing job interview questions and answers which will help you pass the interview process easily.
Maintenance is one of the major activities in manufacturing as it highly influences production quality and quantity and directly affects production cost and customer satisfaction. As new manufacturing technologies emerge and global communication advances, new maintenance practices are developed to cope with these changes.
The role of maintenance in maintaining asset value over time is getting more visible at the business level with the increase in its acquisition and maintenance costs.
various manufacturing systems are introduced along with their distinctive features that influence maintenance strategies and practices.
The oldest type of manufacturing system is the custom manufacturing where a person or a machine makes a certain product tailored to a specific need. A shoemaker is an example of this system. Modern manufacturing have intermittent, continuous or flexible production systems.
The most flexible and responsive to changes manufacturing system is the flexible manufacturing system (FMS). It absorbs sudden large scale changes in production volume, capacity and capability. FMS produces a product just like intermittent manufacturing and is continuous like continuous manufacturing.
The main advantage of FMS is its high flexibility in managing manufacturing resources. The resulting gains are numerous including:
However, FMS implementation requires a large initial capital and substantial preplanning. It also requires high skilled labor.
Maintenance in the manufacturing environment is one of the most complicated types of maintenance in comparison to construction, transportation and service business. Manufacturing is becoming highly competitive with extremely high pressure in reducing cost and increasing value of assets and improving the quality of outcomes (products). Manufacturing systems has grown over the years to be parts of global networks and supply chains. All of these changes in the manufacturing business have put maintenance in a great pressure on developing more effective and efficient operations.
Other special feature of manufacturing environment that makes it distinct from other environment is its complicated interrelation with large number of stakeholders, internal and external. The management structure in manufacturing environment is usually highly structured with many several decision layers and many parallel functional areas.
The main decisive factor for maximizing manufacturing asset value in terms productivity, reliability, cost, etc. is maintenance management, the body of the organization that is in charge of planning, implementing, controlling, and improving maintenance activities. Maintenance management is often considered as a centralized functional unit within the overall organizational structure in parallel with other functional units such as, production, Decentralized maintenance units is another common structure adopted by large organizations with multiple production units. The decision of adopting centralized or decentralized management structure is usually mad at the high management level taking into consideration, the size of the organization, the complexity of its operations, and the organization culture.
Maintenance philosophy is the step of designing on the general maintenance concept selected from known best practices as the maintenance philosophy for the organization. Total productive maintenance and reliability based maintenance concepts are two widely spread concepts. The selected concept is supported with right combinations of maintenance strategies such as preventive maintenance, condition based maintenance, and shutdown maintenance.
Maintenance forecasting is a major part of planning concerned with estimating the current and future amount of maintenance work and type needed. Maintenance load forecasting is a complex task that involves a lot of uncertainties and influenced by many factors such as the age of the equipment, the rate of use, usage climate, and skills of workers.
Capacity planning is the translation of the maintenance load into resource needed to meet the forecasted load. Resources include, number and skills of craftsmen, maintenance tools, labor, material, spare parts, etc.
Maintenance scheduling is the process of assigning resources for tasks to be accomplished at a certain time in a certain frequency. Scheduling of tasks should take into account production schedules, optimization of resources and reducing costs.
The organizing responsibility of maintenance management includes:
Job design involves defining for each major maintenance job, the work content, the method of maintenance the required skills and the needed tools.
Time standards are determined for major components of major maintenance jobs following the scientific approach. This helps in controlling maintenance tasks and efficient utilization of resources. It is also useful for planning and scheduling maintenance activities and forecasting workload.
Project management is used for optimizing and controlling major complex time consuming maintenance operations, such as shutdown maintenance projects for large plants. Critical Path Method (CPM) and Program Evaluation and Review (PERT) are common project management tools.
Controlling activities of maintenance management include the following:
Work control is done using work order system in an integrated data base system for controlling reporting and analyzing. Intelligent maintenance systems are developed and integrated with ERP systems are commonly used and proven to be efficient and effective.
Inventory control is an important element of maintenance management that ensures the availability of spare parts and tools in the right quantity at the right time. Ordering and re-ordering quantities taking into consideration costs and lead times are built into automated information systems to assist management in this task by raising red flags at reorder points.
Cost control involves tracing all cost components of maintenance activities that include direct maintenance costs, lost production, equipment degradation, backups, and over maintenance costs.
Quality control of maintenance work involves assuring that the maintenance work is following standards and producing the expected results. Control is done by the supervision and testing final outcomes following a predetermined control procedure.
Several maintenance concepts were developed in different parts of the world that are usually based on cultural and philosophical backgrounds. These trends encompass other strategies and technologies of maintenance. Some of these concepts are briefly introduced below:
Total Productive Maintenance (TPM) is developed from the preventive maintenance methodology introduced from the USA and further developed and implemented in many Japanese companies since 1971. It is then spread throughout the world.
TPM is defined as a system of maintaining and improving the integrity of production and quality systems through the machines, equipment, processes and employees that add business value to the organization. Total Productive Maintenance (TPM) is a proactive and cost-effective approach to maximize equipment effectiveness using the principles of teamwork, empowerment, ‘zero breakdowns’ and ‘zero defects’.
Some of the key objectives of TPM are:
There are seven major elements of TPM as follows :
Reliability Centered Maintenance (RCM) was initiated by the commercial aviation industry and then adopted by the U.S. military in the 1970s and then by the U.S. commercial nuclear power industry (in the 1980s) followed by other commercial industries and fields in the early 1990s.
RCM is defined by the technical standard SAE JA1011, as ‘‘an engineering framework that enables the definition of a complete maintenance regime. It regards maintenance as the means to maintain the functions a user may require of machinery in a defined operating context’’.
The primary principles upon which RCM is based are the following:
Maintenance and Manufacturing Related Tutorials
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Maintenance and Manufacturing Related Interview Questions
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Maintenance and Manufacturing Related Practice Tests
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Introduction To Production And Operation
Plant Location And Layout
Production Planning And Control
Work Study (time And Motion Study)
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