Showing papers in "Journal of Quality in Maintenance Engineering in 2013"

Maintenance performance metrics a state of the art review

Abstract: Purpose – The purpose of this paper is to provide an overview of research and development in the measurement of maintenance performance. It considers the problems of various measuring parameters and comments on the lack of structure in and references for the measurement of maintenance performance. The main focus is to determine how value can be created for organizations by measuring maintenance performance, examining such maintenance strategies as condition‐based maintenance, reliability‐centred maintenance, e‐maintenance, etc. In other words, the objectives are to find frameworks or models that can be used to evaluate different maintenance strategies and determine the value of these frameworks for an organization.Design/methodology/approach – A state‐of‐the‐art literature review has been carried out to answer the following two research questions. First, what approaches and techniques are used for maintenance performance measurement (MPM) and which MPM techniques are optimal for evaluating maintenance str...

A maintenance maturity assessment method for the manufacturing industry

Abstract: Purpose – The paper proposes a maturity assessment method to measure the state of maintenance practices in a company.Design/methodology/approach – The method assumes that a maintenance department is evaluated in terms of its managerial, organizational and technological capabilities. By its adoption it is possible to analyse the maturity level reached by a company, in order to classify the criticalities in its maintenance processes; a company can also make a benchmark with the best companies of a reference sample.Findings – The paper presents the method as a support to identify the levers to improve the maintenance management system. The method is demonstrated on a company whose maturity is assessed before making a benchmark against a sample of other manufacturing companies located in the Northern Italy.Originality/value – The paper presents a scoring method for maturity assessment and a procedure to use it in order to identify the criticalities in maintenance processes and to subsequently drive the improv...

A framework for the engineering asset management system

Abstract: – The role of engineering asset management (AM) system as a controlling element within organizations is not well defined or understood. The purpose of this paper is to include the role of AM in the organizational strategy making, an issue that has not received sufficient attention. The focus of the paper is on how such role is maintained by the AM system activities, relationships and mechanisms over the asset-related activities of an organization. , – As an approach, a reference framework is required that allows research of this area. By combining a number of possible views of an organizational management system a comprehensive view can be established. A review of literature was used to establish a framework identifying the AM system as an integrated part of the organization's management system. , – A framework is established that focuses on planning and controlling asset-related activities by involving a set of activities, relationships between these activities and feedback mechanisms. A system functional model is proposed integrating the established framework as part of the control of the enterprise system. , – The framework and system functional model are established on a theoretical basis and practical experience requiring applicability to be proven by further research. , – Asset managers in capital intensive organizations can utilize the framework and the system functional model in order to study their AM system, its relationships and to consider how it may be improved. , – Exploring a holistic and relatively new concept.

Profitable working capital management in industrial maintenance companies

Abstract: Purpose – The purpose of this paper is to analyze the impact of working capital management on profitability. This connection is further studied in industrial maintenance service companies. Design/methodology/approach – Analytical modeling has been used as the research method. The empirical analyses have been made on the basis of financial statements. Findings – The paper presents an analytical flexible asset management (FAM) model, which reveals a significant negative correlation between the cycle times of operational working capital and the return on investment. The importance of working capital management is emphasized in the industrial maintenance service sector, because of light fixed assets and good profitability. Research limitations/implications – There are some mathematical limitations in the applicability of the model introduced in this paper. These limitations should be addressed in further research. Practical implications – The FAM model can be utilized as a tool in decision making in firms, bo...

Production and maintenance performance analysis: manual versus semi‐automatic LHDs

Abstract: Purpose – The purpose of this paper is to evaluate and analyse the production and maintenance performance of a manual and a semi‐automatic load haul dump (LHD) machine to find similarities and differences.Design/methodology/approach – Real time process‐, operational‐ and maintenance data, from an underground mine in Sweden, have been refined and aggregated into KPIs in order to make the comparison between the LHDs.Findings – The main finding is the demonstration of how production and maintenance data can be improved through information fusion, showing some unexpected results for maintenance of automatic and semi‐automatic LHDs in the mining industry. It was found that up to one third of the manually entered workshop data are not consistent with the automatically recorded production times. It is found that there are similarities in utilization and filling rate but differences in produced tonnes/machine hour between the two machines.Originality/value – The originality in this paper is the information fusion...

Modelling costs in maintenance networks

Abstract: Purpose – The purpose of this paper is to create a cost model at the general equipment level for industrial maintenance services.Design/methodology/approach – The study is divided into two main sections. In the first phase the idea is to create a framework for a cost model with a literature review. The second, empirical part of the study is based on costing information from interviews and information given by network companies: a pulp mill, a maintenance company and an equipment provider. The maintenance of three different equipment processes is examined in the network through a case study, to get more specific information from real world situations to develop the model.Findings – The findings concern the cost items that should be considered in the model, the structure of the model, and how the general cost model is constructed. During the research the model has been extended, and new cost categories included.Practical implications – The cost model can be used in various performance measurement and decisi...

Performance indicators and terminology for value driven maintenance

Abstract: Purpose – Value driven maintenance (VDM) is a fairly new maintenance management methodology based on four maintenance value drivers and the formula of net present value (NPV) to calculate the value of different maintenance strategies. However, the dependability of the engineering assets needs to be assessed in order to make an estimation of the NPV. Therefore, the purpose of this paper is to critically analyse standardised indicators to find the most essential indicators for the four value drivers and for estimation of the NPV. Terminology containing performance drivers and killers are common in the field of asset management, but not many publications can be found for their detailed descriptions. One section in this paper is therefore dedicated to review these terms. A comprehensive description and classification of performance killers and drivers, and of indicators for VDM are presented in this paper.Design/methodology/approach – Review of literature for technical terminology and review of standards for ...

Risk based integrity modeling of offshore process components suffering stochastic degradation

Abstract: Purpose – The purpose of this paper is to develop a risk‐based integrity model for the optimal replacement of offshore process components, based on the likelihood and consequence of failure arising from time‐dependent degradation mechanisms.Design/methodology/approach – Risk is a combination of the probability of failure and its likely consequences. Offshore process component degradation mechanisms are modeled using Bayesian prior‐posterior analysis. The failure consequences are developed in terms of the cost incurred as a result of failure, inspection and maintenance. By combining the cumulative posterior probability of failure and the equivalent cost of degradations, the operational life‐risk curve is produced. The optimal replacement strategy is obtained as the global minimum of the operational risk curve.Findings – The offshore process component degradation mechanisms are random processes. The proposed risk‐based integrity model can be used to model these processes effectively to obtain an optimal rep...

Life cycle cost analysis on the operation of power generation

Abstract: Purpose – The purpose of this paper is to study the life cycle cost (LCC) on the operation of power generation. LCC is the total cost of ownership including the cost of the project or asset acquisition, operation and maintenance, and disposal. LCC includes both deterministic costs (such as acquisition costs, improvement costs and disposal costs) and probabilistic (such as the costs of failure, repairs, spare parts, downtime, lost gross margin). Most of the probabilistic costs are associated directly with the reliability and maintenance characteristics of the system.Design/methodology/approach – To be able to analyze failure data using appropriate cost profile in order to represent the fact that each failure has different prices, in different time periods at an economical cycle the new methodology of LCCA Diagram is proposed. Developing criticality ranking of sub‐system, calculating values of Weibull Shape Factor β and Weibull Characteristic Life η for each sub‐system, calculating the time to failure of su...

Assessing the value dimensions of outsourced maintenance services

Abstract: Purpose – The purpose of this paper is to investigate the diverse nature of tangible and intangible value dimensions that contribute to customers’ perception of value from outsourced maintenance services. Design/methodology/approach – A multiple case study approach has been adopted. Repertory grid, an in-depth structured interviewing technique, has been used in order to draw out the respondents’ hidden constructs in evaluating outsourced maintenance services. Data have been collected from four customer organizations of outsourced maintenance services, and a total of 33 interviews have been undertaken. Findings – The paper has identified a range of tangible and intangible value dimensions that are of importance in maintenance outsourcing decision making. The most important value dimensions for maintenance outsourcing were found to be specialist knowledge, accessibility (of the service provider), relational dynamic, range of products and services, delivery, pricing and locality. Although the paper has ident...

Skills for the management of turnaround maintenance projects

Abstract: Purpose – The aim of this study is to identify and establish management skills/knowledge required for the successful management of turnaround maintenance (TAM) projects.Design/methodology/approach – A mixed‐method research approach was adopted for this study involving questionnaire survey and case studies of major continuous process plants in the UK. Data were collected through questionnaires from 160 process plants and the case studies of six process plants in the UK. These data were triangulated to improve on the findings.Findings – The findings show that there are specific management skills very specific towards ensuring the successful management of TAM projects. The findings also show that TAM managers are mostly at present appointed without assessing them with any specific skills set.Practical implications – This study developed a set of management skills required for turnaround maintenance projects. These specific appropriate management skills established for TAM management should help to reduce mis...

Maintenance of subsea petroleum production systems: a case study

Abstract: Purpose – The purpose of this paper is to identify and discuss maintenance challenges and maintenance practices for subsea petroleum production systems.Design/methodology/approach – Maintenance challenges, current practices and factors that influence the maintenance and support practices were identified by a literature review and by using a case study conducted in the Norwegian oil and gas industry. The case study was based on semi‐structured face‐to‐face interviews with a number of experts working in the subsea systems’ design, installation and support services in the Norwegian oil and gas industry.Findings – The paper identifies and discusses subsea petroleum production system failures, maintenance, inspection, modification and support practices. Findings from literature are validated, and new challenges are identified and discussed.Research limitations/implications – The research is based on a case study in the Norwegian petroleum industry, but may be applicable in other countries as well. The subsea p...

Risk-based dependability approach to maintenance performance measurement

Abstract: Purpose – The purpose of this paper is to describe how a risk‐based dependability approach can be used to link maintenance performance measurement and management to overall objectives within an organization. Design/methodology/approach – The applied study approach is a case study at Trafikverket (the Swedish Transport Administration). Qualitative data were collected through interviews, workshops and document studies, while quantitative data was collected through data bases. As a framework for analysis, international standards within the risk and dependability areas were applied. Finally, the conclusions of the study were verified by key informants. Findings – Through the proposed risk‐based dependability approach, critical availability goals are communicated with and involve top management. The approach also contributes to enhanced data and information quality by pinpointing critical data and information for dependability management activities. The proposed availability indicator can be used to monitor th...

Detection of electrical faults in induction motors using vibration analysis

Abstract: Purpose – The objective is the application of vibration analysis for the detection and diagnosis of low isolation between the stator coil wind and the voltage phase unbalance in induction motors with different numbers of poles. The purpose of this paper is to provide an approach for maintenance engineers for diagnosis electrical fault through the vibration analyses. Design/methodology/approach – A detailed review of previous work carried out by some researchers and maintenance engineers in the area of machine fault detection is performed. By vibration analysis, the spectra were collected, which used to analyze the failure. Vibration spectra could detect particular characteristic for each fault in an initial condition, so the machine health can be preserved. Findings – Results show the efficiency of the technique of vibration analysis and their relevance to detect and diagnose faults in different induction motors. In this way, it may be included in future predictive maintenance programs. Practical implicat...

Intelligent performance measures for condition‐based maintenance

Abstract: Purpose – The purpose of this paper is to develop a comprehensive approach to efficiently integrate maintenance and operation by combining process and condition monitoring data with performance measures.Design/methodology/approach – Intelligent stress, condition and health indicators have been developed for control and condition monitoring by combining generalised moments and norms with efficient nonlinear scaling. The data analysis resulting nonlinear scaling functions can also be used to handle performance measures used for management. The generalised norms provide limits for an advanced statistical process control.Findings – The data‐driven analysis methodology demonstrates that management‐oriented indicators can be presented in the same scale as intelligent condition and stress indices. Control, condition monitoring, maintenance and performance monitoring are represented as interactive feedback loops.Practical implications – Performance analysis can be based on real‐time information by using various s...

A computerised model to enhance the cost-effectiveness of production and maintenance dynamic decisions : A case study at Fiat

Abstract: Purpose:– To develop and test a model and software-based support system for better understandingof the interactions between man-machine-maintenance-economy (MMME), and enable cost-effective decisio

Maintenance reengineering framework: a case study

Abstract: Purpose – The purpose of this paper is to radically redesign the methodology of plant maintenance and develop a three phase framework. A framework for effective and continuous maintenance improvement is presented.Design/methodology/approach – The first phase determines the key performance area, the second phase makes decision about the appropriate policy selection and third phase aims to generate capability in an organization to compete at world level. A case is presented here, of the implementation of a “maintenance reengineering framework”, developed with the aid of certain maintenance components.Findings – The maintenance reengineering framework, when implemented, proved successful with a more than 90 per cent rise in production rate.Research limitations/implications – The paper contributes some guidelines which can be helpful in making decision about the selection of maintenance policy and for the achievement of world‐class effectiveness.Practical implications – Maintenance reengineering (MR) framewor...

Optimal maintenance policies for cumulative damage models with random working times

Abstract: Purpose – The purpose of this paper is to consider maintenance policies for an operating system which works at random times for jobs. Each job causes some damage to the system and these damages are additive, and the system fails when the total damage has exceeded a failure level K.Design/methodology/approach – Using techniques of cumulative damage models, the maintenance is made at the N‐th completion of working time for the first model and at a damage level Z with a limit number of working times N for the second model.Findings – The system is maintained at the first completion of the working time over time T for the third model. The system fails with probability p(x) when the total damage is x and undergoes minimal repair at failure for the fourth model. The expected cost rates are obtained and optimal maintenance policies are discussed analytically and computed numerically.Originality/value – The paper discusses four maintenance policies for an operating system which works at successive random times for...

Measuring the status and alignment of maintenance and manufacturing strategies – the development of a new model and diagnostic tool

Abstract: Purpose – The purpose of this paper is to outline the development of a new conceptual model and the associated diagnostic tool which can measure the status of maintenance and manufacturing strategies and how well they are linked together Design/methodology/approach – The new model was developed in two stages First, a conceptual framework was produced and then a holistic diagram From this theoretical model a diagnostic tool was generated This tool was then verified and tested during an empirical research phase which produced four extensive and detailed case studies A brief overview of one of the case studies is provided in this paper Findings – It was found that the conceptual model provided an accurate representation of the strategic processes and links which should exist in a manufacturing plant Moreover the diagnostic tool proved a valid and reliable instrument to measure and display this information Research limitations/implications – The diagnostic tool provides a snapshot of the status of man

A geometric process maintenance model and optimal policy

Abstract: Purpose – The purpose of this paper is to study a geometric process (GP) maintenance model and policy for a repairable system.Design/methodology/approach – Lam first introduced the GP and its application to maintenance model. Assume that a replacement policy N is applied by which the system will be replaced by a new, identical one following the Nth failure.Findings – For a deteriorating system, an optimal replacement policy is determined analytically, and the monotonicity properties of the optimal replacement policy are then studied.Originality/value – For an improving system, the paper shows that the optimal replacement policy is the ∞ policy, i.e., the policy without replacement.

Fault tree analysis considering sequence dependence and repairable input events

Abstract: Purpose – This paper aims to present two methods for calculating the steady state probability of a repairable fault tree with priority AND gates and repeated basic events when the minimal cut sets are given.Design/methodology/approach – The authors consider a situation that the occurrence of an operational demand and its disappearance occur alternately. We assume that both the occurrence and the restoration of the basic event are statistically independent and exponentially distributed. Here, restoration means the disappearance of the occurring event as a result of a restoration action. First, we obtain the steady state probability of an output event of a single‐priority AND gate by Markov analysis. Then, we propose two methods of obtaining the top event probability based on an Inclusion‐Exclusion method and by considering the sum of disjoint probabilities.Findings – The closed form expression of steady state probability of a priority AND gate is derived. The proposed methods for obtaining the top event pr...

Minimal cut sequences and top event probability of dynamic fault tree

Abstract: Purpose – This paper aims to present a method for calculating the top event probability of a fault tree with priority AND gates.Design/methodology/approach – The paper makes use of Merle's temporal operators for obtaining the minimal cut sequence set of a dynamic fault tree. Although Merle's expression is based on the occurrence time of an event sequence, the paper treats the expression as an event containing the order of events. This enables the authors to treat the minimal cut sequence set by using the static fault tree techniques. The proposed method is based on the sum of disjoint products. The method for a static FT is extended to a more applicable one that can deal with the order operators proposed by Merle et al.Findings – First, an algorithm to obtain the minimal cut sequence set of dynamic fault trees is proposed. This algorithm enables the authors to analyze reasonably large scale dynamic fault trees. Second, the proposed method of obtaining the top event probability of a dynamic fault tree is e...

Certification of maintenance providers: a competitive advantage

Abstract: Purpose – The purpose of this paper is to synthesize some relevant norms, namely European norms (EN), to the maintenance field.Design/methodology/approach – The methodology is based on the conjunction of the most relevant norms to the maintenance field that represent a coherent set of tools to aid maintenance activity and maintenance companies to achieve a new level of competitiveness.Findings – Until now, the companies have not given relevance to specific certifications, such as PAS 55 or NP4492. But, with the increase of competitiveness and the market more and more exigent, it is necessary to introduce this new paradigm to raise the maintenance activity at an upper level.Practical implications – The approach presented in the paper constitutes a base for an upper level of competitiveness among companies, based on common standards that make the maintenance activity more exigent and transparent.Originality/value – The paper presents a conjunction among standards, including the newest ones, that constitutes...

Vibration‐ and acoustic‐emissions based novelty detection of fretted bearings

Abstract: Purpose – The purpose of this paper is to examine the use of a new feature reduction technique with novelty detection on vibration and acoustic‐emission sensors monitoring bearings mounted in the test benches of automotive manufacturers.Design/methodology/approach – Signals from standard accelerometers and acoustic‐emission sensors were gathered from bearings operating under steady conditions on an accessory‐drive test bench. The bearings under test were subject to a variety of faults including fretting. These signals were processed and reduced to standard feature vectors, the dimensionality of which was reduced using a new principal‐component‐like technique optimized for novelty detection. The reduced data were analyzed with a novelty detection technique called the Support Vector Data Descriptor.Findings – The classification results from these sensors, after being reduced with the proposed feature reduction technique, are substantially improved over those achievable with only standard novelty detection; ...

Life restoration degree following minimal repair and its application for maintenance decision optimization

Abstract: Purpose – The purpose of this paper is to address the issues whether or not minimal repair is effective for a repairable item with a known life distribution and when the minimal repair process should be stopped. Design/methodology/approach – The life restoration degree (LRD) following minimal repair is defined and related to the shape parameter of the distribution so that a choice between minimal and perfect repairs can be made based on the shape parameter. Three replacement policies with minimal repair are considered and the corresponding decision rules are derived to determine when the minimal repair process should be stopped. Findings – Main findings are: first, the LRD of minimal repair is inversely or approximately inversely proportional to the shape parameter, second, the effectiveness of minimal repair increases as the cost ratio of perfect and minimal repairs increases and the shape parameter decreases, and third, the unconditional mean residual life equal the mean time between the first and secon...