In this report, the Process Failure Modes and Effects Analysis (PFMEA) and the Reliability-Centered Maintenance (RCM) analysis are used in tandem to initialize a cost-effective maintenance plan for the Amada HFA-330 band saw. The intent of this report is to describe and demonstrate how the two analyses are used to develop the maintenance plan.

As part of the maintenance plan development, consideration is given to the effects of processor down time on the throughput and profitability of the manufacturing system. Any processor failure that decreases throughput of the manufacturing system will create a loss in opportunity to fulfill demand.

After determining a maintenance plan, data should be collected from the system to reaffirm or revise the maintenance decision. Data collected from the manufacturing system may provide move accurate estimates allowing the analyst to reiterate the procedures and improve the plan.

This methodology would be useful in the design phase to assess the lifecycle cost of a system design. This methodology can be used to estimate the cost of maintenance. The life-cycle cost of the system can then be estimated from estimates of research and development, construction, start-up, operation and maintenance, and system disposal estimates. Given multiple alternatives, a decision on the preferred system can be made based on life-cycle costs.