Establishment of a maintenance plan based on quantitative analysis in the context of RCM in a JIT production scenario

This paper presents a quantitative method for supporting the preparation or review of an equipment maintenance plan in a Just-in-time production scenario. The proposed method includes the following steps: (i) identifying the parts that influence reliability; (ii) surveying the failure rates and times to repair the parts; (iii) classification of parts according to the effect of their failures; (iv) surveying the line occupation parameters; (v) identifying the probability distributions for time to failure, time to repair, and line occupation; (vi) simulating the production and maintenance using the Monte Carlo approach; (vii) conducting a sensitivity analysis concerning variations in demand, MTTF, and MTTR; and (viii) establishing optimized intervals for preventive maintenance. The method is illustrated through an application in a labeling and filling gallons line at a paints and dyes production company. This method allowed the identification of critical parts as it relates to the productive scenario in question. The results can support companies in their decision making regarding the need and/or type of maintenance investment that would best fit an expected demand scenario.