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Journal Cover Journal of Quality in Maintenance Engineering
  [SJR: 0.851]   [H-I: 29]   [4 followers]  Follow
   Hybrid Journal Hybrid journal (It can contain Open Access articles)
   ISSN (Print) 1355-2511
   Published by Emerald Homepage  [312 journals]
  • Electrical fault diagnosis in induction motors using local extremes
    • 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
  • Availability analysis of a LNG processing plant using the Markov process
    • 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
  • Asset integrity management: offshore installations challenges
    • 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
  • The role of performance measurement in developing industrial services.
    • 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
  • Human factors in maintenance: a review
    • 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
  • Observing the effect of a policy; a maintenance case
    • 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
  • Investigation of maintenance performance for a gasification process unit
           using Weibull analysis
    • 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
  • Airline maintenance strategies – in-house vs. outsourced – an
           optimization approach
    • First page: 114
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose This study offers a new mathematical modeling approach to help airlines identify which types of heavy aircraft maintenance checks be performed in-house or outsourced. Design/methodology/approach This study offers a mathematical model to minimize the total cost of heavy maintenance programs over a planning period subject to performing all maintenance programs on time and other side constraints. Findings The results are very encouraging and somewhat counter-intuitive. The solutions recommend that more expensive and labor intensive checks be outsourced. A detailed analyses of the total maintenance cost breakdown is presented with implications and recommendation Originality/value To the best of our knowledge, the literature on quantitative models for airline in-house and outsourced maintenance checks is very limited. We believe the model and airline cases presented in this paper can help airlines with their strategic maintenance strategies and will initiate further studies in this important area.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:44Z
      DOI: 10.1108/JQME-08-2015-0038
  • A SWOT analysis of reliability centered maintenance framework
    • First page: 130
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose The paper aims at using well established methodology Strengths, Weaknesses, Opportunities and Threats (SWOT) analysis – in order to identify the important factors for Reliability Centered Maintenance (RCM) implementation. Design/methodology/approach The paper demonstrates a SWOT analysis for different 19 frameworks of RCM to make a strategic decision for implementing RCM in different organizations. The various 19 frameworks are grouped together into three clusters, namely Group A, Group B and Group C based on their qualitative or theoretical, quantitative and practical approach respectively. Findings The strengths and weaknesses are identified by internal factors while the opportunities and threats are identified by external factors of an organization for each group of frameworks. Also, it was observed that each group of frameworks has a unique set of strengths and weaknesses. Research limitations/implications In this paper, the SWOT analysis for RCM implementation is limited to the comparison of various 19 RCM frameworks which are available in literatures and based on internal or external factors of an organization. Practical implications The SWOT analysis also suggests that the implementation of RCM is not an easy task for any practitioner and one should weigh in all the opportunities and threats before arriving at any strategic decision. Originality/value A unique approach applied to analysis the frameworks of RCM.The SWOT analysis of Various RCM frameworks will help the practitioner to take any strategic decision for RCM implementation in an organization
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:46Z
      DOI: 10.1108/JQME-01-2015-0002
  • Cleaning historical maintenance work order data for reliability analysis
    • First page: 146
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose Identify quality issues with using historical work order data from computerised maintenance management systems (CMMS) for reliability analysis. Develop an efficient and transparent process to correct these data quality issues to ensure data is fit for purpose in a timely manner. Design/methodology/approach This paper develops a rule-based approach to data cleansing and demonstrates the process on data for heavy mobile equipment from a number of organisations. Findings Although historical work order records frequently contain missing or incorrect functional location, failure mode, maintenance action and work order status fields we demonstrate it is possible to make these records fit for purpose by using a) data in the freeform text fields, b) an understanding of the maintenance tactics and practices at the operation, and c) knowledge of where the asset is in its life cycle. We demonstrate that it is possible to have a repeatable and transparent process to deal with the data cleaning activities. Originality/value How engineers deal with raw maintenance data and the decisions they make in order to produce a data set for reliability analysis is seldom discussed in detail. Assumptions and actions are often left undocumented. This paper describes typical data cleaning decisions we all have to make as a routine part of our analysis and presents a process to support the data cleaning decisions in a repeatable and transparent fashion.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:45Z
      DOI: 10.1108/JQME-04-2015-0013
  • Representation of replacement rules in the form of a matrix
    • First page: 164
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose The propose of the article is to represent replacement policies (rules) in the form of a matrix. Visualization of replacement rules is useful for maintenance records. Matrix representation is more effective than the verbal description usually provided, as it allows better understanding of the specifics of the different replacement rules without careful research of their mathematical models. Design/methodology/approach This approach employs mathematical models to investigate the simple conditions (requirements) for replacement of system component with illustrative examples. When comparing the different replacement rules a cost structure is applied to takes into account the nature and technology of disassembly-assembly actions for the repair unit. Findings Representation of replacement rules in the matrix form is useful when describing planned replacement models, opportunity replacement models, group replacement models and others, as well as computer modeling of the renewal process. Forming simple conditions for the replacement of system components ensures the total average repair cost is minimized. These conditions can be applied in the early stages of creating a maintenance program for the machine. Practical implications Replacement matrices can be specified in a technical manual for maintenance of machines to achieve reliable operation and to reduce repair costs. Replacement matrices can be put into practical use for maintenance records and may be included in the maintenance procedures library of CMMSs. Developed in the article, the replacement matrix, the conditions for replacement of system components and the cost structure will help engineers to make decisions at the time of repair for assembly units. Originality/value Proposed in the paper is a new approach to the visualization of the replacement rules and cost structure which simplifies the analysis of options for repair actions. The proposed technique contributes to the record of maintenance actions and the decision making process for replacement.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:43Z
      DOI: 10.1108/JQME-06-2015-0022
  • Optimal maintenance level of equipment with the multiple components
    • First page: 180
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose The purpose of the paper is to provide a method for selection of an optimum level of repair by replacement of an equipment based on its cost. In a ship where the engineer has a vast variety of equipment and systems to operate and maintain within limited time frames and availability of human resources, it is often difficult to disassemble a whole equipment to replace a faulty component. It is instead a lot easier to just replace the faulty equipment with whole new equipment. However, such a decision comes at an enormous capital cost. Therefore, the key question is, can we have a model to help us arrive at a decision on the correct level of carrying out repairs ? Design/methodology/approach The paper uses a model based on cost and convolution of failure distributions of critical sub-components of an equipment. Necessary assumptions based on real life experience have been incorporated in the model. Findings The paper used an example of a particular type of motor driven sea water centrifugal pump which was commonly used in main engine sea water system, firefighting system, Air conditioning system etc. The pump had one of the highest failure rates in the ship (approximately one failure per 150 days) and the engineers found it cost and time effective to replace the entire pump on failure rather than carrying out replacement of the failed components. The model analyzed that the engineer’s hunch wasn’t off the mark. Research limitations/implications The implication of the work presented in the paper will be savings in maintenance cost and downtime due to optimal level of repairs on a multi-component equipment. The limitations of the work are assumption of independence of failures of components. This may not be true in all the cases. Further, opportunity based maintenance has also not been considered. Originality/value The originality of the paper lies in the presentation of a method for selection of an optimum level of maintenance for a multi-component equipment
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:42Z
      DOI: 10.1108/JQME-07-2014-0043
  • Optimizing production while reducing machinery lockout/tagout
           circumvention possibilities
    • First page: 188
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose The optimization of production imposes a review of facility maintenance policies. Accidents during maintenance activities are frequent, sometimes fatal, and often associated with deficient or absent machinery lockout/tagout. Lockout/tagout is often circumvented in order to avoid what may be viewed as unnecessary delays and increased production costs. To reduce the dangers inherent in such practice, this study proposes a production strategy that provides for machinery lockout/tagout while maximizing manufacturing system availability and minimizing costs. Design/methodology/approach The joint optimization problem of production planning, maintenance and safety planning is formulated and studied using a stochastic optimal control methodology. Hamilton-Jacobi-Bellman equations are developed and studied numerically using the Kushner approach based on finite difference approximation and an iterative policy improvement technique. Findings The analysis leads to a solution that suggests increasing the “comfortable” inventory level in order to provide the time required for lockout/tagout activities. It is also demonstrated that the optimization of lockout/tagout procedures is particularly important when the equipment is relatively new and the inventory level is minimal. Research limitations/implications This paper demonstrates that it is possible to integrate production, maintenance and lockout/tagout procedures into production planning while keeping manufacturing system cost objectives attainable as well as ensuring worker safety. Originality/value This integrated production and maintenance policy complements is unique and complements existing procedures by explicitly accounting for safety measures.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:44Z
      DOI: 10.1108/JQME-04-2014-0015
  • Assessing remaining useful life of lubricant using Fourier Transform
           Infrared Spectroscopy
    • First page: 202
      Abstract: Journal of Quality in Maintenance Engineering, Volume 22, Issue 2, May 2016.
      Purpose To check the actual life of lubricating oil Design/methodology/approach Present work aims to find the remaining useful life of the lubricant based on study of periodic deterioration of oil. Chronological samples of oil were selected from the dumper of a local open cast mine. The deterioration in oil was studied using Fourier Transform Infrared Spectroscopy. Findings The data obtained from Fourier Transform Infrared Spectroscopy was used in Vector Projection approach and Analytical hierarchy process to evaluate the Remaining Useful Life of the lubricating oil. Originality/value Fourier Transform Infra Red (FTIR) spectra were used to study the periodic deterioration of oil. IR radiation with all frequencies in the range was passed through the sample. Radiations at certain frequency, depending upon the molecular structure of compounds in the sample were absorbed and rest was transmitted by the sample. A spectrum representing molecular absorption or transmission was obtained. Transmission spectra have been used in the study. Comparing the percent value of transmission peak of different chronological sample with that of fresh oil was used to represent the periodic degradation in oil.
      Citation: Journal of Quality in Maintenance Engineering
      PubDate: 2016-03-22T12:20:41Z
      DOI: 10.1108/JQME-01-2016-0001
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