Product Support Financial Value Drivers. 5/10 – Preventive Maintenance Processes Employed

Oct 25

This post is the fifth of ten entries that will discuss product support financial value drivers for solutions supplied by a commercial or military focused capital good Product Support Enterprise [PSE]. The 10 topics that will be discussed are the following:

  1. # of products employed by end-users
  2. End-user product utilization rate
  3. Product failure
  4. Environment in which end users engage the product
  5. Preventive maintenance processes employed
  6. Volatility of product technology
  7. Regulatory requirements
  8. Chronological age of the product installed base
  9. Life cycle stage of the product
  10. Manufacturer’s warranty coverage

Product Support Business Case Analysis – Product Support Financial Value Drivers

Preventive Maintenance [PM] is a Product Support process that attempts to avoid an unplanned failure event; it is typically described and recommended to be employed by an end-item maintainer in the maintenance manual generated by an OEM.

There are three key flavors of PM:

  1. Use-based (i.e. after every 1,000 cycle remove reparable item to be overhauled and re-installed)
  2. Period-based (i.e. every 6 months remove/dispose non-reparable part and replace with a new condition part)
  3. Condition-based (i.e. when consumable brake pad wears down to 1 inch thickness, remove/dispose and replace)

All the above actions lend themselves to dependent demand financial planning; all you need to know is the forecast of each of the PM drivers and you develop a lock on the financial impact of a PM schedule.

For example;

  1. A reparable item has a PM schedule of a removal every 1,000 hours of end-item use; the item is to be overhauled and re-installed
  2. The end-item’s utilization is forecasted to be 4,000 hours per year or a planned removal event every 3 months/4 times per year
  3. The estimated cost of an overhaul is $2,000; the annual cost of the PM schedule is $8,000 (4 removals*$2,000).

The great tragedy of PM is that once established, there is often little adjustment to its frequency; comparing real-world failure experience and that of the PM schedule. The exception is when there is a major reliability issue which requires an immediate PM schedule adjustment. This lack of proactive adjustment, either up or down, can have a major impact upon Product Support financial value drivers.

Note that there are some PM schedules that are safety related and are required by Governmental regulations to be performed, but in almost all cases the PM schedule can be changed upon Governmental approval.

The following is an example of a project I designed and managed which was able to ultimately reduce the frequency of PM events by 50% over a 5-year period. There were about 100 non-reparable items that were selected that had PM scheduled removals every year. A slow frequency adjustment was employed in order to mitigate any unfavorable Materiel Availability performance risks; if actual unplanned failures increased, then we could quickly recover by going back to the original PM schedule frequency.

Product Support Business Case Analysis – Product Support Financial Value Drivers

In the project’s first year, the PM schedule of all 100 items was changed from 12 months to 13 months; an 8% reduction in removal frequency. The project team then waited 1 year to review failure analysis and end-user issues regarding these parts; there was no impact on the end-user community. In year two, the team stretched the PM schedule to 15 months; a 15% frequency reduction. Year three the PM schedule was moved to 18 months, with year four to 21 months and finally year five to 24 months; with a total decrease in PM schedule frequency of 50% ((24-12)/24). These 100 items drove 10% of the Total Ownership Cost [TOC]; the reduction in PM frequency resulted in a weighted 5% (50% reduction * 10% of cost) reduction in TOC.

The use of scenario based Product Support financial planning tools enables “what if” calculations on the changing of the frequency of PM schedules. There are big reductions in TOC to be harvested, but it has to be slow and methodical in its execution.

Hypatia©, a Giuntini & Company financial software tool, provides a highly automated means of calculating the above and other product support financial value drivers, as well as an effortless way of being able to change any utilization assumption and immediately understand its impact upon total ownership costs. Hypatia is also a proven, trusted and highly effective tool for assisting in the development of product support business case analysis.

One comment on “Product Support Financial Value Drivers. 5/10 – Preventive Maintenance Processes Employed

  1. Ron,
    Nice article. An effective PM program is essential to good product support. When logistician plan PM requirements much of it is driven by reliability predictions which are made during the intial product development phase. Predictions are really informed best guesses. As you know after a product is fielded, no one ever goes back and changes to predictions to actual reliability data which results in PM checks and services never being updated to reflect reality or to reflect changes in operational tempo, equipment age, or condition. PM checks and services need to be continuously updated to reflect the variables associated with an aging fleet. Frequencies may be adjusted upward over time or changed to cover different checks and services to reflect the condition of the fleet over time.
    John K.

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