Main Factors Governing System Downtime - Assignment Example

1. The two main factors governing system downtime are equipment design and maintenance philosophy (maintenance concept). Discuss this statement with examples to illustrate your ideas. It is imperatively correct that two key factors determining the down time of any system are system design and the maintenance philosophy (Blanchard, 2006). However, to understand this, it should be kept in view that design determines the active repair elements, whereas passive elements are affected by the maintenance philosophy. When it comes to keeping the down time minimal, simplified diagnosis and easy repair methodology, play very vital role. The simplified diagnosis is something which is a logical outcome of a good system design, whereas the ease of system repair is affected by the maintenance methodology adopted. It is also crucial to understand that both these factors governing downtime are interdependent. It is imperative for designer to have idea of maintenance strategy and they should be aware of possible modes of system failure. Designers should also understand that complexity of system assembly can complicate the field maintenance too (Blanchard and Fabrycky, 2006) . Let us understand this through some illustrative examples. Accessibility is one of the key design elements that are taken into consideration while designing a system. If a designer, while designing the system, does not take care of the accessibility aspect of a low reliability part, it is apparent that frequent breakdown of this low reliable part with difficult access would result in enhanced system down time. Similarly, a technician should also be discouraged from resorting to repair by replacement of the easily accessible part. Rather a technician should conduct through diagnosis before carrying out the repair work. As such, as part of system designs, incorporating captive fasteners in spite of standard fasteners would discourage such practices (Blanchard, 2004). Now let us come to maintenance philosophy, which not only includes maintenance procedure but also involves personnel, their training or motivation, spare provisioning, maintenance tools and logistics. As the cost implication of each of these elements is high in any system breakdown, it calls for striking a right balance while considering their deployment to achieve minimal downtime. An unorganised or ad-hoc repair approach based on a subjective opinion of an immature or desperate maintenance technician, although occasionally resulting into a favourable short cut, can even proof to be permanently damaging approach. A good maintenance concept covering, well trained technicians, formal procedures, correct system manuals, mandatory diagnostic checks, well calibrated test equipments etc. would ensure optimised down times and would also avoid unwarrantedly recurring system breakdowns after maintenance is imparted. Thus in long run, the downtime would be minimal is correct maintenance philosophy is adopted. Similarly, the logistics aspect of the site of maintenance is also a key factor to be considered. If the availability of skills, tools and other maintenance support is unlikely to be at the site then option of undertaking the repair at central depot can be considered to check the overall downtime. The decision on time and cost associated with onsite repair or central depot repair need to be undertaken and form critical part of the maintenance concept for any system breakdown. Thus it is apparently clear that both the key factors i.e. system design as well as maintenance philosophy, are critical in governing the overall downtime of any system. 2. Integrated Logistic Support (ILS) has a role throughout a systems lifecycle. Using an appropriate model of the system life-cycle, identify some of the risks pertaining to effective ILS effort in each life-cycle phase. Suggest how, as a manager, you might address these risks. The term 'Logistics' can be understood from various perspectives. However, the most widely used is from the perspective that is associated with supply chain management. Logistics generally is being associated with acquisition and delivery of consumable items for any system. But it is vital and deep correlation with every stage of any system's life cycle in most instances goes unexplored. When dealing with system's life cycle, the stages would be design & development, production or construction, operations & support and phase-out or disposal/recycling. When talking about integrated logistics support, each of these stages of system life cycle need to be thoroughly analysed to arrive at an effective business oriented model. For any system to achieve its desired purpose the logistic support paraphernalia has to be in place and it has to be aligned as per the desired purpose to be achieved. Further, the comprehensive or integrated logistics support requirements must be made available from the start of the system life cycle when system requirements are initially defined and initial phase of planning and conceptualisation is in progress’s a matter of fact, it is worth noting that a considerable proportion of life cycle cost of the overall system can be attributed to the outcome of decision made during the initial stage of conceptualisation. Decisions like choice of technologies, material, tools, manufacturing processes, maintenance and support infrastructure etc. have significant affect on the downstream costs and hence have impact on the overall life cycle cost. Having said that, it is also apparent, that there are various inherent risks pertaining to effective integration of logistics support in each of the life cycle stages. This is more crucial if, going by conventional norms, logistics support is only considered for downstream stages of the system life cycle. One of the key risks is lack of 'Total Cost Visibility'. This risk become more crucial when analysed with the fact that there are more hidden costs associated with production, distribution maintenance and support stages of any system. Further, another risk that can be visualised is related to the variation in demand of the logistics support during the production and distribution stage of any system life cycle. The variation in demand can come due to various reasons like that of increased market demand and increased competition. Also, the risk pertaining to the disposal or recycling stage is important to analyse. Here the system is often subjected to reverse logistics approach. Here the flow of logistics of backwards and it is also important the while the reverse logistics is being undertaken, the system performance is not being affected. In order to address these risks, it goes without mentioning that total cost visibility is crucial. To bring in the same it is important to understand the relationship between system characteristics and elements of logistics support and establish the required interrelationship between them. This can be done more effectively through application of various new technologies e.g. Information Technology, e-Commerce, Global positioning system, bar-coding and database applications. 3. Summarise your understanding of “Maintenance (Support) Concept”. Indicate the factors that might influence the choice of one support concept over another. Maintenance concept has very wide coverage and involves holistically on the maintenance support front. There are various aspects which can distinguish between two support concepts (Blanchard, 2004). Broadly, they can be among the followings: Organisation of Maintenance Resources: This point to the division of maintenance resources based on the type of maintenance being carried out. Broadly, the categorisation is among corrective maintenance, preventive maintenance and repair depot maintenance. The skill sets of the resources vary across these categories. Maintenance Procedures: it goes without mentioning that an optimum and effective maintenance can only be achieved through rational and formal maintenance procedure. In turn, a formal maintenance procedure can only be ensured by right manual and through right training. The correct maintenance procedure, in logical order, calls for making and interpreting test results, pin pointing the reason of fault, imparting repair or replacement and finally adjusting the system of optimum performance. Maintenance Tools & Test Equipments: The maintenance tools and test equipments should adhere on the lines of simplicity of use, calibration, reliability and standardisation. Maintenance Personnel (Training and Motivation): An unorganised or ad-hoc repair approach based on a subjective opinion of an immature or desperate maintenance technician, although occasionally resulting into a favourable short cut, can even proof to be permanently damaging prospect. Thus it calls for properly trained and rightly motivated maintenance personnel to carry out the maintenance support. Maintenance Spare Provisioning: Availability of necessary maintenance spare is very important for timely completion of the maintenance support job. This is especially critical in case of support requiring replacement of parts. Logistics: Logistics of man and material from or to the location of maintenance affects the time and cost involved in a maintenance support job. 4. Integrated Logistic Support (ILS) is important for systems of some complexity and significant lifespans. But are the concepts relevant, say, if you were a manufacturer and vendor of mobile phones? Justify your answer. Considering the comprehensive approach of Integrated Logistics Support (ILS) and its association with various stages of system life cycle, it seems that cost benefits analysis of application of Integrated Logistics Support would only be rational for complex systems which have significant life span across various life cycle stages. However, Integrated Logistics Support has its applicability across various systems irrespective of its complexity and lifespan. For an example, let us take case of a mobile phone. When dealing with said system's life cycle, like any other system, the stages here too would be design & development, production, operations/maintenance support and phase-out or disposal/recycling. During the design and development stage, the logistics support would be applicable for various testing and evaluation components, materials and tools. If needed, even it can be applicable to consumer surveys and ideation. On the production front, the application of logistics support can be attributed to raw material and parts, production processes and operations, inspection and testing, repair and rework as well as finished products. Associated with the same would be inventory and warehousing for material flow and product distribution wherein the logistics support would play a very vital role. On the production and maintenance front the logistics support would either be needed for bringing the flawed phones to the repair canters or if severely damaged, then replacement of the mobile sets would call for reverse logistics. The last stage of disposal or recycling would in fact completely rely on the reverse logistics. Since, the disposal or recycling of mobile phones entails specialised treatments, the logistics support from the customer or repair centres to such specialised disposal or recycling stations would be crucial. Thus from this example it is apparent that the concept of integrated logistics support can be applied to any system irrespective of its complexity and lifespan. However, it is important to understand that the application of this concept should have its cost benefit analysis properly done. It is just important to understand the relationship between system characteristics and elements of logistics support and establish the required interrelationship between them. References: Blanchard, B.S., Logistics Engineering and Management, 6th Ed., Prentice Hall, Upper Saddle River, NJ, 2004 Blanchard, B.S. and W.J. Fabrycky, Systems Engineering and Analysis, 4th Ed., Prentice Hall, Upper Saddle River, NJ, 2006 Blanchard, B.S., System Engineering Management, 3rd Ed., John Wiley & Sons, Hoboken, NJ, 2004 Read More