The competitiveness and performance of manufacturing companies depend on the availability, reliability and productivity of their production equipment. This recognition has led to a drastic change of ...perception on maintenance over the past decades, evolving from a “necessary evil” to a “value adding” activity. In order to ensure a good performance of the production plant, maintenance managers need a good overview of maintenance processes and achievements. This can be attained by a rigorously defined maintenance performance measurement (MPM) system and maintenance performance indicators (MPI). Many performance measurement frameworks and indicators are presented in literature; however some major issues remain unresolved. Many papers discuss the development of generic maintenance performance frameworks and corresponding indicators; however none of the publications considers the selection of relevant MPI for a specific business context and consequently in relation with the company's maintenance objectives. Moreover, the link with the manufacturing and corporate strategy should be established in order to establish an MPM system useable throughout the entire company. In this way, maintenance performance measurement should be defined on all management levels (i.e. strategic, tactical and operational). To overcome these problems, the objective of this paper is to develop an MPM framework that aligns the maintenance objectives on all management levels with the relevant MPI used. In order to assist the maintenance manager on selection of the relevant MPI, an analytic network process (ANP) model and methodology is presented which is based on the designed MPM framework. The methodology is applied to several case studies considering companies from different types of industry. The results illustrate the applicability and capability of the presented MPM framework and ANP model to assist maintenance managers in the definition and selection of MPI in line with the maintenance and corporate objectives and strategy. The ANP approach enables the decision maker to better understand the complex relationships in the decision problem, which improves the reliability of the corresponding decisions.
► A maintenance performance measurement framework is developed. ► ANP is applied to derive and prioritize business specific maintenance performance indicators. ► The developed methodology is illustrated and validated on five extensive case studies. ► The results confirm the importance of a methodological approach to select MPI. ► The developed methodology assists maintenance managers in the definition of MPI.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UL, UM, UPCLJ, UPUK
The performance and competitiveness of manufacturing companies is dependent on the reliability, availability and productivity of their production facilities. To ensure the plant achieves the desired ...performance, maintenance managers need a good track of performance on maintenance process and maintenance results. This can be attained through development and implementation of a rigorously defined performance measurement framework and indicators that are able to measure important elements of maintenance function performance. The purpose of this paper is to demonstrate that performance indicators are not defined in isolation, but should be the result of a careful analysis of the interaction of the maintenance function with other organisational functions, most evidently with the production function. In this paper, a conceptual framework that provide guidelines for choosing maintenance function performance indicators is proposed. It seeks to align maintenance objectives with manufacturing and corporate objectives, and provides a link between the maintenance objectives, maintenance process/efforts and maintenance results. Based on this conceptual framework, performance indicators of the maintenance process and maintenance results are identified for each category.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UL, UM, UPCLJ, UPUK
During the past decades, several joint maintenance and inventory optimization systems have been studied in literature. Compared to the sequential optimization of both models, Kabir and Al-Olayan ...(1996) reported a remarkable influence on total cost due to their joint optimization method. This review focuses on models that include cost and optimization parameters related to both maintenance and inventory. The purpose of this paper is to review the pertinent literature on joint maintenance and inventory optimization models for non-repairable parts and suggest possible gaps. A classification based on the following seven sets of criteria is made: inventory policies, maintenance characteristics, delays, multi-echelon networks, single-unit versus multi-unit systems, objective function and optimization techniques.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UL, UM, UPCLJ, UPUK
This paper proposes a spare part classification method based on item criticality. Starting from a multi-criteria analysis, the proposed model converts relevant criteria impacting item criticality ...into a single score presenting the criticality level. The obtained criticality level is used to rationalize the efficiency of the spare parts inventory policy. The model presents the multi-criteria classification problem in a logic decision diagram where AHP is used to solve the multi-criteria decision sub-problems at the different decision nodes of the diagram. The method was tested and implemented in a petrochemical plant and the results of this case study are presented.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UL, UM, UPCLJ, UPUK
•The significance of maintenance to the remanufacturing process is demonstrated.•Remanufacturing proposed solution to life extension and spare obsolescence•End-user role and influence on ...remanufacturing decision investigated•Remanufacturability indicator defined using empirically relatable and identifiable factors•The significance of end-user actions and influence to remanufacturing process is demonstrated.•Core condition classified as a function of obsolescence, maintenance actions
The decision for remanufacturing as a life extension solution for ageing equipment approaching their end of life (EOL), has marginalized the active role of the end-users and maintenance functions, by predominantly considering the remanufacturers (OEM/R) context. However, the decisions influencing the immediate core (used item/part of its component) condition like corrective maintenance actions used, and when to return a core for remanufacturing or exchange with a remanufactured part, are often the end-users responsibility. Factors like remanufacturing cost, alternative maintenance and spare strategies, introduce conflicting preferences, hence an asymmetric relationship between the end-user and the remanufacturer. This paper develops an integrated methodology to optimize maintenance, remanufacturing, and multiple spare strategies (new and remanufactured exchange) jointly, for life extension of an ageing multi-component system with dependencies. The model inculcates the asymmetric relationship to assist the end-user to derive decision support on optimal maintenance and remanufacturing strategies while minimizing the costs. A case study of an ageing turbine rotor assembly of a turbocharger with spare obsolescence demonstrates the utility of the proposed model. The study shows that the approach offers robust decision support, and further demonstrates the significance of the maintenance function and end-user influence in the remanufacturing decision making.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
Dialysis processes within the home care context is associated with risk factors which are not very prominent in the hospital context. This includes risk factors such as unanticipated device ...malfunction, or erroneous operation of the equipment, which exposes the patient to injury while undergoing dialysis. Importantly, the mentioned risk factors are further attributed to technical aspects such as sub-optimal equipment maintenance or following improper clinical procedures when administering care to the patient. Hence, it is important to follow a methodological approach to identify and assess hazards embedded within the dialysis treatment process, and on this basis, formulate effective strategies to mitigate their negative consequences on patient safety. This paper presents a comparative risk assessment for in-hospital versus in-home dialysis care. For the two cases, the risk assessment considers expertise of care givers involved in administering dialysis. The findings show that performing risk assessment for hospital environment, is more structured owing to expertise of clinicians and care givers responsible for administering dialysis. However, assessing risks for the home-care environment is more challenging owing to absence of domain knowledge, hence a survey approach to structure the risk assessment process is necessary. Moreover, risks in the home care context is influenced by logistical aspects, and lack of domain knowledge for maintaining dialysis equipment. Overall, insights from the comparative studies yields important learning points expected to improve dialysis care as more healthcare providers transfer care to the home environment.
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EMUNI, FIS, FZAB, GEOZS, GIS, IJS, IMTLJ, KILJ, KISLJ, MFDPS, NLZOH, NUK, OBVAL, OILJ, PNG, SAZU, SBCE, SBJE, SBMB, SBNM, UKNU, UL, UM, UPUK, VKSCE, ZAGLJ
PurposeThe purpose of this paper is to develop a maintenance decision support system (DSS) framework using in-service lubricant data for fault diagnosis. The DSS reveals embedded patterns in the data ...(knowledge discovery) and automatically quantifies the influence of lubricant parameters on the unhealthy state of the machine using alternative classifiers. The classifiers are compared for robustness from which decision-makers select an appropriate classifier given a specific lubricant data set.Design/methodology/approachThe DSS embeds a framework integrating cluster and principal component analysis, for feature extraction, and eight classifiers among them extreme gradient boosting (XGB), random forest (RF), decision trees (DT) and logistic regression (LR). A qualitative and quantitative criterion is developed in conjunction with practitioners for comparing the classifier models.FindingsThe results show the importance of embedded knowledge, explored via a knowledge discovery approach. Moreover, the efficacy of the embedded knowledge on maintenance DSS is emphasized. Importantly, the proposed framework is demonstrated as plausible for decision support due to its high accuracy and consideration of practitioners needs.Practical implicationsThe proposed framework will potentially assist maintenance managers in accurately exploiting lubricant data for maintenance DSS, while offering insights with reduced time and errors.Originality/valueAdvances in lubricant-based intelligent approach for fault diagnosis is seldom utilized in practice, however, may be incorporated in the information management systems offering high predictive accuracy. The classification models' comparison approach, will inevitably assist the industry in selecting amongst divergent models' for DSS.
In the changing and increasingly competitive industrial arena, companies are striving towards world-class competitiveness. This also puts maintenance under increasing pressure to improve, e.g., ...availability and reliability of production facilities, and to reduce cost and waste. With the introduction of Reliability-Centred Maintenance, Total Productive Maintenance, Business-Centred Maintenance and other concepts, maintenance already evolved a lot during the last decades. However, the resource intensiveness of these concepts and their validity for only a special class of equipment make a more general framework for maintenance concept development necessary. Such a general framework should provide decision guidelines about the focus of the maintenance concept, how to select the right maintenance policies and finally how to implement them.
The CIBOCOF framework described in this paper is the result of several years of research (doctoral research in co-operation with industry) and can be used to develop a customized maintenance concept in a specific company. Specific and new to this framework is that the optimization problem of maintenance is also taken into account. As such, Models described in literature finally find a way to practice, and the gap between theory and practice is closed a little bit in this paper; the framework is presented and illustrated by means of a case study.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UL, UM, UPCLJ, UPUK
Safety plays a key role when implementing collaborative robots (cobots) in human-shared workspace scenarios. Nevertheless, the significance and understanding of safety-related aspects may ...significantly vary with different stakeholders’ perspectives. In particular, there is often a misconception that cobots are inherently safe with the result of significantly underestimating the need of adopting adequate safety measures and features for the deployment of collaborative robots in industrial and non-industrial frames. Accordingly, this article develops an in-depth analysis of the stakeholders and their stakes in human–robot collaboration in the manufacturing industry with particular attention to the safety aspects. The proposed approach consists of a field study, with an online questionnaire and structured interviews, directed at the main stakeholders. The field study results are presented and compared with insights from two recent explorative studies. Finally, careful analysis and discussion is provided. This research focuses on three topics: (i) the specific phases in the collaborative robot application cycle, (ii) the stakeholders that are involved in each phase, and (iii) the stakes that affect the stakeholders in general, and specifically the role of safety within these stakes. The findings show that awareness of safety issues is still jeopardized between stakeholders. In addition, key stakeholders still significantly underestimate safety-related issues when implementing cobots in new production lines. This implies the need for objective assessment tools that can systematically address and assess all safety-related aspects. This study provides industry practitioners with a broader view of how different stakeholders regard safety-related aspects in the cobot life cycle. This will enable more informed decision-making when implementing cobot solutions and potentially avoid unconsidered safety risks later on. This article also adds to the scant research on the role of each stakeholder in human–robot collaboration.
Performance measurement is a fundamental instrument of management. For maintenance management, one of the key issues is to ensure the maintenance activities planned and executed have given the ...expected results. This can be facilitated by effective use of rigorously defined key performance indicators (KPI) that are able to measure important aspects of maintenance function. In this paper, an industrial survey was carried out to explore the use of performance measurement in maintenance management. Based on survey responses, analyses were performed on popularly used KPI, how these KPI are sourced or chosen; the influence of manufacturing environment and maintenance objectives on KPI choice and effective use of these KPI in decision support and performance improvement. It was found that maintenance performance measurement is dominated by lagging indicators (equipment, maintenance cost and safety performance). There is lesser use of leading (maintenance work process) indicators. The results showed no direct correlations between the maintenance objectives pursued and the KPI used. Further analysis showed that only a minority of the companies have a high percentage of decisions and changes triggered by KPI use and only a few are satisfied with their performance measurement systems. Correlation analysis showed a strong positive linear relationship between degree of satisfaction and process changes/decisions triggered by KPI use, with the least satisfied people having the least decisions and changes triggered by KPI use. The results indicate some ineffectiveness of performance measurement systems in driving performance improvement in industries.
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BFBNIB, GIS, IJS, IZUM, KILJ, KISLJ, NUK, PILJ, PNG, SAZU, UL, UM, UPUK
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