Maintenance

### Relationship

Finance (FIN),Purchasing (PMN),Production (PRD),Human Resources Management (HCM)

## **Maintenance**

The work of keeping something in proper condition, care or upkeep including taking steps to avoid something breaking down (preventative maintenance) and bringing something back to working order (corrective maintenance).

In MonsoonSIM, Maintenance is one of the core modules. In this case, the maintenance is about keeping the high valued asset, the production machines, in good working order.

MonsoonSIM supports multiple levels of complexity. Learners are encouraged to start with the basic module, called Baseline model, and slowly progress to more advanced functionalities.

### **Here are what you will learn in the MonsoonSIM Maintenance (Baseline) :**

* Concept of Preventive Maintenance
* Concept of Predictive Maintenance
* Concept of Work Order
* Concept of maintenance disruptions

### **In MonsoonSIM, the Maintenance module is related to the following department (modules)**

* Finance (FIN)
* Purchasing (PMN)
* Production (PRD)
* Human Resources Management (HCM)

Note: There is no pre-requisite to learning the MonsoonSIM Baseline concept

## **Operating model of MonsoonSIM Maintenance module**

### **Baseline:**

* A machine will degrade proportionally to usage
* Machine degradation will affect the production output
* A maintenance work is called a Work Order
* The state of the machine is characterized by a concept called OEE (Overall Equipment Efficiency). https://www.automationworld.com/article/topics/oee/how-calculate-overall-equipment-effectiveness-practical-guide
* OEE = Availability x Performance x Quality
* OEE of 100% indicates the machine is at its best state of health
* There are two types of maintenance
	+ Periodic or sometimes referred to preventive maintenance
	+ Predictive or sometimes referred to as conditional maintenance
* Characteristics of periodic maintenance
	+ maintenance work will be performed at a fixed period, regardless of the state of health of the asset
	+ each periodic work will cost a fixed amount of fee
	+ each periodic maintenance will improve the health of the asset, thereby, improve the production output
* Characteristics of predictive maintenance
	+ physical sensors must be installed onto the asset
	+ the sensors are designed to detect the state of
		- machine Availability
		- machine Performance and
		- machine Quality
	+ The three components (A,P,Q) makes up the overall OEE index.
	+ sensors will send out the state of the asset in terms of color codes
		- Green - to indicate that the machine is performing optimally
		- Yellow - to indicate that the machine is not performing optimally
		- Orange - to indicate that there is degradation, requiring attention
		- Red - to indicate that the problems are severe and require immediate maintenance work to be performed
		- each Work Order will cost a fixed amount of fee
* Staff Index affects the effectiveness of maintenance work. Hence, it is important to keep our staff index at 100% at all times.
* A machine may experience Breakdown if either of the A (Availability) P (Performance), or Q (Quality) index falls below a certain threshold.
* If a breakdown occurs:
	+ Regular maintenance will not be able to fix the machine
	+ The machine only be fixed by going through major repair (overhaul)
* Overhaul costs more than normal maintenance and it requires more time
* Players can analyze the machine performance and other useful intelligence by carefully examining the information from the Business Intelligence menu.