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Journal Cover Journal of Quality in Maintenance Engineering
  [SJR: 0.503]   [H-I: 37]   [4 followers]  Follow
   Hybrid Journal Hybrid journal (It can contain Open Access articles)
   ISSN (Print) 1355-2511
   Published by Emerald Homepage  [335 journals]
  • Problem-Solving Approaches in Maintenance Cost Management: A Literature
    • First page: 334
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose The purpose of this paper is to investigate the use of problem-solving approaches in maintenance cost management (MCM). In particular, the paper aims to examine characteristics of MCM models and to identify patterns for classification of problem-solving approaches. Design/methodology/approach This paper reflects an extensive and detailed literature survey of 68 (quantitative or qualitative) cost models within the scope of MCM published in the period from 1969 to 2013. The reviewed papers have been critically examined and classified based on implementing a morphological analysis which employs 8 criteria and associated expressions. In addition, the survey identified two main perspectives of problem-solving, first synoptic/incremental, second heuristics/meta-heuristics. Findings The literature survey revealed the patterns for classification of the MCM models, especially the characteristics of the models for problem-solving in association with the type of modelling, focus of purpose, extent and scope of application, and reaction and dynamics of parameters. Majority of the surveyed approaches is mathematical respectively synoptic. Incremental approaches are much less and only few are combined (i.e. synoptic and incremental). A set of features is identified for proper classification, selection and coexistence of the two approaches. Research limitations/implications This paper provides a basis for further study of heuristic and meta-heuristic approaches to problem-solving. Especially the coexistence of heuristic, synoptic and incremental approaches needs to be further investigated. Practical implications The detected dominance of synoptic approaches in literature - especially in the case of specific application areas - contrasts to some extent to the needs of maintenance managers in practice. Hence the findings of this paper particularly address the need for further investigation on combining problem-solving approaches for improving planning, monitoring and controlling phases of MCM. Continuous improvement of MCM, especially problem-solving and decision-making activities, is tailored to the use of maintenance knowledge assets. In particular, maintenance management systems and processes are knowledge-driven. Thus, combining problem-solving approaches with knowledge management (KM) methods is of interest, especially for continuous learning from past experiences in MCM. Originality/value This paper provides a unique study of 68 problem-solving approaches in MCM, based on a morphological analysis. Hence suitable criteria and their expressions are provided. The paper reveals the opportunities for further interdisciplinary research in the maintenance cost lifecycle.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:49Z
      DOI: 10.1108/JQME-04-2015-0012
  • Total Productive Maintenance, Total Quality Management and operational
           performance: An empirical study of Indian pharmaceutical industry
    • First page: 353
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose This study investigates the impact of Total Productive Maintenance (TPM) and Total Quality Management (TQM) practices on operational performance and their inter-relationship. Design/methodology/approach The present study includes three main constructs namely TPM, TQM and operational performance of pharmaceutical industry. Under TPM, four constructs namely Disciplined Maintenance, Information Tracking, Housekeeping and Operator Involvement has been considered with the help of literature. In TQM, four constructs namely Quality Data and Reporting, Product Innovation, Research and Development Management and Technology Management has been considered. Out of 410 Indian pharmaceutical plants contacted for survey, 254 responses have been used in the study for analysis. The factor analysis, path model and structural equation modelling has been used to analyze the proposed framework. The results for alternate models has been studied, interpreted and reported. Finally the direct and indirect effect of TPM and TQM on operational performance has been tested and checked for proving and disproving the hypotheses. Findings TPM practices have a significant impact on plant level operational performance. When TPM and TQM practices are coming together to achieve operational performance, then TPM is having strong influence on operational performance. TQM is having significant support from TPM to achieve operational performance. TPM impact TQM and TQM in turn helps to achieve operational performance. TPM practices impact significantly research and development, product innovation and technology management, whereas quality data and reporting is the least contributor towards TQM. This may help industry to understand implications of implementation of TPM and TQM to achieve plant level operational performance. TPM will help to reduce the cost of quality in terms of reduced scrap and less defective products. Practical implications The present study provides the useful insights to practicing managers. In literature it has been mentioned that TQM helps in TPM implementation. In practice TPM plays a great role to achieve quality in processes and therefore in products. In turn quality products, with reduced work in process inventory, less defective products and reduced scrap helps to achieve the operational performance at plant level. TPM practices will help the organization to improve the pace of product innovation and improvement in productivity, which is critical to pharmaceutical industry. The continuous monitoring of TPM practices can help organizations to run day to day operations and maintenance requirement of each machine over a specified period of time. Originality/value The present study diagnose the inter-dimensional linkage between TPM, TQM and operational performance. The pharmaceutical industry is complex system of advance equipment’s and processes. After human resources, the health of machines/equipment’s describe the strength of an organization. The machines require the regular maintenance to produce the products with desired specifications. The specifications in medicines and very tight, which can be achieved only if machines/testing equipment’s are updated and maintained regularly. The TPM practices will helps the plants to achieve the operational performance by having quality in processes.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:55Z
      DOI: 10.1108/JQME-10-2015-0048
  • Improvement maintenance implementation based on downtime analysis approach
    • First page: 378
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose Improvement maintenance’s aim is identifying and implementing improvement action on equipment in service. This work proposes an approach based on downtime’s analysis to raise up equipment’s performance, such us reliability, maintainability, availability, and safety. Steps of this approach will be illustrated by industrial applications. Design/methodology/approach Furthermore, it proposes an approach based on a combination of several methods (FMECA, cause and effect diagrams, ABC analysis, 5W, RCA method, ..).This approach is based on the downtime analysis and lead to improve maintenance’s performance and equipment’s reliability, maintainability, availability and safety. Those objectives have a strong correlation with the downtime. Findings this approach led to apply easily improvement maintenance by using known methods. In the industrial application, this approach helps us to choose the good solution with the better life durance . Practical implications After following the steps simulated by the proposed approach, actions and concrete measures will be deducted and illustrated by the industrial’s application. Originality/value At present, there is not an explicit improvement maintenance, to lead to specific maintenance actions on equipment in service, in order to improve the maintenance function goals.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:51Z
      DOI: 10.1108/JQME-12-2013-0081
  • Effects of condition-based maintenance on costs caused by unscheduled
           maintenance of aircraft
    • First page: 394
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose This paper analyses the effects of condition-based maintenance based on unscheduled maintenance delays that were caused by ATA chapter 21 (air conditioning). The goal is to show the introduction of condition monitoring in aircraft systems Design/methodology/approach The research was done using the Airbus In-Service database to analyse the delay causes, delay length and to check if they are easy to detect via condition monitoring or not. These results were then combined with delay costs. Findings Analysis shows that about 80% of the maintenance actions that cause departure delays can be prevented when additional sensors are introduced. With already existing sensors it is possible to avoid about 20% of the delay causing maintenance actions. Research limitations/implications The research is limited on the data of the Airbus In-Service Database and on ATA chapter 21 (air conditioning). Practical implications The research shows that delays can be prevented by using existing sensors in the air-conditioning system for condition monitoring. More delays can be prevented by installing new sensors. Originality/value The research focuses on the effect of the air-conditioning system of an aircraft on the delay effects and the impact of condition monitoring on delays.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:53Z
      DOI: 10.1108/JQME-12-2015-0062
  • Availability forecast of mining equipment
    • First page: 418
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose This study presents a methodology for forecasting the availability off-highway trucks used in a fleet for large transport operations of ore and sterile rock from an open pit mine. Design/methodology/approach This methodology enables the estimation of the number of hours of preventive and corrective maintenance required, which are used to predict truck availability. We used historical data for our maintenance strategy based on the hours of operation. Findings These data are statistically analyzed to obtain the key quantities and statistical models required to project availability and to develop equipment replacement plans. Originality/value A methodology for forecasting availability to assets in open pit mining industry was implemented.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:52Z
      DOI: 10.1108/JQME-12-2015-0067
  • Reliability centered maintenance actions prioritization using fuzzy
           inference systems
    • First page: 433
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose Deploying an effective maintenance strategy across an organization stands out as an essential risk mitigation measure that plays a critical role towards improving the reliability and availability of production facilities. This article proposes a simple, yet well-structured approach towards prioritizing maintenance actions as part of a reliability centered maintenance implementation plan, and selecting the most important subset of those actions subject to time and budget constraints. Design/methodology/approach A comprehensive RCM actions prioritization methodology is proposed using four criteria: severity, benefit to cost ratio, customer satisfaction, and easiness of action implementation. The method utilizes fuzzy inference system (FIS) to incorporate subject matter experts’ feedback into the decision making process. The output of the FIS, which takes the form of a numerical weight that assesses the relative importance of each criterion, is then fed into a binary integer program (BIP) that selects the optimal maintenance actions out of a set of possible actions. Findings The implementation of the developed methodology is demonstrated using a real life example of a hydraulic brake system circuit that is used in construction equipment. The computational results illustrate the validity of the proposed approach and indicate that the selection of which maintenance actions to carry out is impacted by the relative importance (i.e. weight) of the considered criteria. Originality/value The work presented in this paper provides the decision makers with a systematic procedure that helps in selecting the most relevant maintenance actions instead of making the selection in a complete ad-hoc manner or based merely on subjective opinions.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:51Z
      DOI: 10.1108/JQME-07-2015-0029
  • Optimal periodic inspection policy for systems generating environmental
           damage over a finite time horizon
    • First page: 453
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016.
      Purpose We consider systems that generate damage to environment as they get older and degrade. The purpose of this study is to develop an optimal condition-based maintenance strategy for such systems in situations where they have a finite operational time requirement. We determine simultaneously the optimal number of inspections and the threshold level of environmental damage which minimize the total expected cost over the considered finite time horizon. Design/methodology/approach The environmental degradation level is monitored through periodic inspections. We model the environmental degradation process due to the equipment’s degradation by the Wiener process. A mathematical model and a numerical procedure are developed. Numerical calculations are performed and the influence of the variation of key parameters on the optimal solution is investigated. Findings Numerical tests indicate that as the cost of the penalty related to the generation of an excess damage to environment increases, inspections should become more frequent and the threshold level should be lowered in order to favor preventive actions reducing the probability to pay the penalty. Research limitations/implications Given the complexity of the cost function to be minimized, it is difficult to derive analytically the optimal solution. A numerical procedure is designed to obtain the optimal condition-based maintenance policy. Also, the developed model is based on the assumption that the degradation follows a process with stationary independent increments. This may not be appropriate for all types of degradation processes. Practical implications The proposed optimal maintenance policy may be relevant and very useful in the perspective of green operations. In fact, this paper offers to decision-makers a comprehensive approach to implement a green maintenance policy and to rapidly understand the net effect of the maintenance policy with respect to environmental regulation requirements. Originality/value The main contribution consists in the modeling and optimization of the condition-based maintenance policy over a finite time horizon. Indeed, existing condition-based maintenance models over an infinite time horizon are not applicable for systems with a finite operational time requirement.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-08-23T11:27:54Z
      DOI: 10.1108/JQME-09-2015-0045
  • Human factors in maintenance: a review
    • First page: 218
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose This article reviews current literature analyzing human factors in maintenance, and areas in need of further research are suggested. Design/methodology/approach Design/methodology/approach – The review applies a novel framework for systematically categorizing human factors in maintenance into three major categories; human error/ reliability calculation, workplace design/macro-ergonomics and human resource management. The framework further incorporates two well-known human factor frameworks, i.e. the Swiss Cheese Model and the ergonomic domains framework. Findings Findings – Human factors in maintenance is a pressing problem. The framework yields important insights regarding the influence of human factors in maintenance decision making. By incorporating various approaches, a robust framework for analyzing human factors in maintenance is derived. Originality/value Originality/value – The framework assists decision makers and maintenance practitioners to evaluate the influence of human factors from different perspectives, e.g. human error, macro-ergonomics, work planning and human performance. Moreover, the review addresses an important subject in maintenance decision making more so in view of few human error reviews in maintenance literature.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:14Z
      DOI: 10.1108/JQME-12-2015-0064
  • Asset integrity management: offshore installations challenges
    • First page: 238
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose The purpose of this paper is to identify the challenges facing asset integrity management (AIM) practices in the oil and gas industry, in order to continually develop AIM practices in organisations. The focus is to investigate various challenges in fluctuating oil and gas market conditions, and how organisations can continuously ensure the safety and integrity of their offshore facilities. Design/methodology/approach AIM challenges were identified by analysing data from literature study, guided interviews and web-based questionnaire with industrial experts in regions in North America, Southeast Asia and Norway. The results are validated through triangulation method with both quantitative and qualitative technique, as well as comparison with other studies. Findings The paper identifies, analyses and validates the challenges and factors that may impact the management of asset integrity on offshore installations. The challenges were discussed to develop understanding of the root cause and thus aim to resolve underlying issues. Research limitations/implications The paper focuses on offshore production installations with experts from organisations that have experience in Gulf of Mexico, Brazil, South Asia, Southeast Asia and Norway fields. The sample of respondents may not represent the entire population; however, the same approach and result can be used in similar topics and conditions. Originality/value The identified challenges can be used by organisations to resolve underlying AIM challenges, improve their AIM strategy and obtain insights into current AIM practices in the petroleum industry.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:53Z
      DOI: 10.1108/JQME-06-2015-0023
  • Investigation of maintenance performance for a gasification process unit
           using Weibull analysis
    • First page: 252
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose The purpose of this paper is to investigate maintenance performance of a gasification process unit by identifying reliability, failure and hazard rate. The prediction on the number of preventive maintenance activities and size of labour are being analyzed. Design/methodology/approach The study collects maintenance data for 4000 hours operation to perform Weibull analysis in order to determine two key factors which are beta shape factor, β and characteristic life, η. Findings The results for estimation of failure, reliability and hazard rate show that the pump was most likely contributed to the biggest failure. On the other hand, reaction chamber was able to maintain the longest operation among other components. It is estimated that the total PM activities should be within 20 to 50 activities per month for whole processing plant. Meanwhile, the estimation of size of labour should be within the range of 60 to 130 numbers of workers per month for all components. Originality/value The method of Weibull analysis for investigating current maintenance performance has been analyzed using real case study data. The data collection is obtained from a typical gasification process unit.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:03Z
      DOI: 10.1108/JQME-08-2015-0039
  • The role of performance measurement in developing industrial services.
    • First page: 264
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose This study examines inter-organisational cooperation in delivering maintenance services, focusing on the level of maturity of this cooperation and the current role of performance measurement in evaluating its effectiveness. It also determines how performance measurement should be developed to support the needs of networked maintenance. Design/methodology/approach The empirical evidence is based on two cases of networks operating in the field of industrial maintenance. The first network operates in the energy industry, while the second operates in the mining industry. Both networks consist of machine supplier companies, performance partner companies and system supplier companies. A total of seven companies participated in workshops and interviews in 2013-2014. Findings As a result of the study, suggestions for improving the performance measurement of service value in maintenance are presented and a framework is offered that meets the needs of the customer, service provider and equipment provider. The significant innovation of the research is its combination of network, service and value perspectives in performance measurement by presenting a framework for measuring created value of cooperation. Originality/value The literature calls for new measurement models and frameworks that support the new management challenges. This research creates a framework for practical applications. The framework helps to identify possible development needs and increases our understanding of what is required when cooperation in a maintenance network deepens, moving from machine partner towards value partner.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:29Z
      DOI: 10.1108/JQME-01-2015-0004
  • Observing the effect of a policy; a maintenance case
    • First page: 277
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose To show that maintenance performance is potentially better predictable from recording routines. Design/methodology/approach An attempt is made to observe an effect of a policy. Maintenance cases seem exceptional because of the efficiently obtainable evidence about policy violations which potentially provides access to the counterfactual reality to be avoided by the decision maker. The approach followed in this work is to use maintenance policy compliance to observe the effect of a maintenance policy. Findings – Conventional maintenance scorecards are not geared to accommodate maintenance performance predictions. – The proposed alternative representation of maintenance performance indicators much better accommodates maintenance performance predictions. Research limitations/implications This work focuses on the operationalisation and the sampling procedure of maintenance performance indicators; the selection of a predictive model is not considered. Practical implications – This work demonstrates that maintenance decision makers have the possibility to observe the effects of their policy, which potentially enables them to better control their objectives. – This work provides guidelines to construct performance indicators that much better accommodate maintenance performance predictions than conventional maintenance performance indicators. Originality/value – The approach to make the effects of maintenance policy compliance observable is an original contribution to normative decision theory. – To construct a maintenance scorecard that accommodates maintenance performance predictions is an original contribution to the field of maintenance performance measurement.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:13Z
      DOI: 10.1108/JQME-10-2014-0055
  • Availability analysis of a LNG processing plant using the Markov process
    • First page: 302
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose The purpose of this paper is to propose a state dependent stochastic Markov model for availability analysis of process plant instead of traditional time dependent model. Design/methodology/approach The traditional concepts of system performance measurement and reliability (viz. binary; two-state concepts) are observed to be inadequate to characterize performance of complex system components. Availability analysis considering an intermediate state, such as a degraded state, provides a better alternative mechanism for system performance mapping. The availability model provides a better assessment of failure and repair characteristics for equipment in the sub-system and its overall performance. In addition to availability analysis, this article also discusses the preventive maintenance program to achieve target availability. In this model, the degraded state is considered as a preventive maintenance state. Using Markov analysis the optimum maintenance interval is determined. Findings Markov process provides an easier way to measure the performance of the process facility. This study also revealed that the maintenance interval has a major influence in the availability of a process facility as well as in maintaining target availability. The developed model is also applicable to the varying target availability as well as having the capability to handle even the reconfigured process systems. Research limitations/implications Considering the degraded state as an operative state, a higher availability of the plant is predicted. The consideration of the degraded state of the system makes the availability estimation more realistic and acceptable. Availability quantification, target availability allocation and a preventive maintenance model are exemplified in a sub-system of an LNG facility. Originality/value The unique features of the present study are; i) Markov modeling approach integrating availability and preventive maintenance, ii) optimum PM interval determination of stochastically degrading components based on target availability, iii) consideration of three-state systems and, iv) consideration of increasing failure rates.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:55Z
      DOI: 10.1108/JQME-05-2012-0018
  • Electrical fault diagnosis in induction motors using local extremes
    • First page: 321
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 3, August 2016.
      Purpose This work introduces an algorithm based only on local extreme analysis of a time sequence to further the detection and diagnosis of inter-turn short circuits and unbalanced voltage supply using vibration signals. Design/methodology/approach The upper and lower extreme envelopes from a modulated and oscillatory time sequence present a particular characteristic being of, theoretically, symmetrical versions with regard to amplitude reflection around the time axis. Thus, one may say that they carry the same characteristics in terms of waveforms and, consequently, frequency content. These envelopes can easily be built by an interpolation process of the local extremes, maximums and minimums, from the original time sequence. Similar to modulator signals, they contain more detailed and useful information about the required electrical fault frequencies. Findings Results show the efficiency of the proposed algorithm and its relevance to detecting and diagnosing faults in induction motors with the advantage of being a technique that is easy to implement in any computational code. Practical implications A laboratory investigation carried out through an experimental set-up for the study of faults, mainly related to the stator winding inter-turn short circuit and voltage phase unbalance, is presented. Originality/value The main contribution of the work is the presentation of an alternative tool to demodulate signals which may be used in real applications like the detection of faults in three-phase induction machines.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-06-17T11:34:57Z
      DOI: 10.1108/JQME-07-2015-0026
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