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Optimal maintenance plan is proposed by evaluating structural conditions using asset management.
Maintenance management activity is conducted by partnership with a Hanshin Expressway affiliate company. The Hanshin Expressway develops and uses data base systems which store inventory, inspection and repair data. Science, Technology and Medicine open access publisher.Publish, read and share novel research.
An Efficient Failure-Based Maintenance Decision Support System for Smalland Medium IndustriesM.
Saleh and Ndubisi (2006) highlighted that SMI lack a comprehensive framework to be used in solving critical issues. Table 1.Decision-Making Grid (Labib, 1998b)In this phase the decision is developed by comparing two-dimensional matrices.
Table 2.DMG-TPM Strategy (Labib 1998b)The RCM approach should be applied for the upper triangle of the matrix as shown in Table 3. The question was how to develop a Maintenance Job Preparation and Planning Department in a Utility Business to support the Maintenance Teams from the Technical Services Department with their Maintenance Work Activities.
I have to provide them with a complete setup plan for the department on operational level, including all necessary work processes, and recommendations based on best practices and least cost option on organizational, technical and tactical level. Which maintenance system softwares (CMMS, Work Planning, Work Scheduling) will be relevant to use? If I take your online planning and scheduling course, will I be able to answer all these questions and more?
If you came to one of our three day Maintenance Planning and Scheduling Training Courses you would learn all that you need to know about maintenance planning and scheduling process design and the maintenance planning and scheduling process contents.
You can buy and download all the information that you need to know about best practice Maintenance Planning and Scheduling with the PowerPoint presentation from our 3-Day Maintenance Planning and Scheduling for Reliability training course PPT (PowerPoint) presentation available for purchase at the online store. But since you cannot attend the course start your education by reading these two books on maintenance planning and scheduling (MPS) processes and practices. At the start you need to conceptualise and explain to people what maintenance planning and scheduling will do for your company. Your MPS process outputs directly impact the way Maintenance Department Managers will run the Maintenance Crews, they affect your Materials Management process, and they define how you coordinate the Production Group and your subcontractors. Start with the basic maintenance management flowchart below and identify the main inputs and outputs required from each box in the flow loop. As you design more detailed flowcharts you will be able to clarify and specify the particular inputs required from throughout your organisation to feed into each MPS process activity. Then for each box draw a high level conceptual flowchart that shows how your operation will deliver those particular inputs and outputs. You will also need to explain how Purchasing and Materials Management will function during the planning, scheduling and execution of maintenance work. You should also read the article Maintenance Backlog Management for a summary of what you are trying to accomplish with a maintenance work planning process.
There is one more thing that you must work out how to do that is very important for the transfer of ownership of the processes you create to the people who will use those processes.
In some way be sure to involve the managers and the supervisors from Maintenance (and occasionally those from Production) in reviewing the proposed MPS process designs. Building ownership will require them to invest time and effort in the development of the processes they will manage.
You do not want to annoy them with too many interruptions, but somehow you must keep them involved in the process design and development so they know and understand the processes well and they will willing take them on as their own once they are implemented.
NOTE: Find out how you can do our certificated online 10 module Maintenance Planning and Scheduling training course by distance education. Immediately download all the information that you need to know about best practice Maintenance Planning and Scheduling with our PowerPoint presentation from our 3-Day Maintenance Planning and Scheduling for Reliability training course PPT (PowerPoint) presentation available for purchase at the online store.
Business Industrial Network makes no manner of an endorsement, representation or warranty regarding any contents located on this site. This system consists of Maintenance Information Management System (MIMS) and Hanshin Expressway Bridge Management System (HBMS). Later, Kittipong (2008) conducted more comprehensive studies on technology relationships in SMI. Corrective or Failure-based Maintenance (FBM) is unscheduled maintenance or repair to return the machine to a defined state. They have designed concrete policies and developed a framework to set up an industrial management centre.
RCM involved a study and measurement of the probability that a machine will operate as expected at the desired level, for a specific period of time, under the design operating conditions, and without any failures. Next, a strategic decision is identified by mapping at DMG in Table 1, given by Labib (1998b). The Technical Services department is responsible for the maintenance activities of these plants, and they need a (Maintenance) Job Preparation and Planning department to plan and schedule every maintenance activity. What are the steps that I need to take into account to develop a maintenance planning department? The planning aspect of MPS is definitely all about ‘Material and work planning for the diesel plants and the dual purpose plant.’ But you also need to include the coordination needed to get the planned work completed to schedule. Once the required activities are known in good detail you can then resource them with people who are competent in the necessary tasks. It is the sort of thing that you will end up with for each box of the Basic Maintenance Management Process. They are the people who will be responsible to make the processes work, and you want them in future to willingly provide the necessary support and guidance to people in their maintenance groups.
He conducted the surveys and identified 20 factors of technology relationship and innovations.
After that, they focused on the enhancement and evolution of information systems in maintenance.Some important findings on enhancement of the development of information systems in maintenance are given, as they have discovered that new strategic development in maintenance is due to information system application and development. There is a group of people in the centre to control all maintenance work and escalate the work to the respective site.
Once the problematic machines are identified, the maintenance strategy should be adjusted to ensure the longest survival of the machine to complete a mission at a specific time (Elsayed, 1996).
You will also be able to select the appropriate supporting technologies now that you know what information needs to be available to each function in the process.
The effect of maintenance action is reevaluated and initial maintenance plan would be renewed. He conducted hypotheses and concluded that technology expertise is the first priority for SMI success in the area of manufacturing. Lewis (1999) addressed corrective maintenance as reactive maintenance, where any emergency breakdown will lead to a bigger impact on the operation.
Their model can be used to develop a customized maintenance concept that is suitable for multinational companies. The machines in this region are performing well and are easy to repairSkill levels upgrade (SLU): Machines that always fail (high frequency), but can be fixed quickly (low downtime).


Strategies such as CBM or DOM are executed based on measurements and estimates.Once the top ten worst performing machines are identified from DMG, the appropriate action to identify the next focused action is implemented. Table 4 shows the level of the frequency of failures decision analysis using formulas in (1), (2) and (3).
Ahmad2[1] Universiti Teknikal Malaysia Melaka, Malaysia[2] King Abdulaziz University Rabigh, Kingdom of Saudi Arabia1. SMI should start to look at the technology escalation procedure and manage their vendors or contractors efficiently. Since the failures are unplanned, they might result in a big loss to the organization in terms of cost and time. Since centralized maintenance control in a centre requires more people, Dhillon and Liu (2006) presented the impact of human errors on maintenance.
In other word, maintenance staffs need to move from the strategic systems level to the operational component level. This book covers the details of what occurs at the low levels of a planning and scheduling process.
Other product names used herein are for identification purposes only and may be trademarks of their respective owners.
He has suggested a further research direction for factorial and decisional analyses using longitudinal data in his thesis. Therefore, a better maintenance concept must be introduced to prevent this unplanned downtime and reduce the cost of the failure. They conducted a literature survey of human errors in maintenance and their impact on the manufacturing plant. SMI contributes in generating employment and engage in small and medium-scale manufacturing lines to generate profit and employment.
The breakdown maintenance concept is still applied to equipment that is not mission critical and where the downtime would not affect the main operation of the organization, such as light bulbs and consumable parts. However, this is a killer machine, as it takes a long time to bring it back to normal operation (high downtime). In fact, the largest portion of manufacturing firms fall into SMI categories and the SMI businesses are the backbone of the large-scale industry (Shamsuddin et al. Effects of the machinery failures in SMIThe primary functions of most machines in industries are concerned, in some way, with the need to earn revenue or to support revenue earning activities. Lam and Lin (2004) have introduced some numerical methods and designed optimal replacement policies in FBM.
Imad (2007) highlighted the role of maintenance as a profit-generating functionality, by introducing a maintenance quality concept in the manufacturing system.
At the end of the study, they concluded that buying sophisticated hardware or software is not the complete answer. According to Palmer (1999), if the plant spends a lot of time on breakdown maintenance, then it does not spend enough time on preventive maintenance.
He has intimated the relationship between a manufacturing system’s capacity and the total manufacturing costs per unit of quality item, in order to describe and illustrate how maintenance generates profit to the company.Finally, Imad (2007) proved that maintenance is not a cost centre, but a profit-generating centre in the manufacturing sectors. However, justification on middleware software, and an object-oriented system by integrating some maintenance techniques into the DSS, is another potential area to consider.
The breakdowns affect the production capability of physical assets by reducing output, increasing operational costs, and, thus, interfering with customer services. Thus, predictive maintenance is introduced to resolve deficiencies with scheduled downtime. There are various available techniques in maintenance that can be programmed into CMMS and can measure maintenance activities.
According to her, SMI do not have a good system to evaluate the overall system of machines, contractors performance and their business's principles. Machinery failures in SMI production lines will increase the operation cost and reduce their profit margin.
Predictive maintenance involves monitoring certain conditions or variables associated with the equipment (Bentley, 1993). This region consists of the worst production machines and it is recommended that they be structurally modified.
Therefore, maintenance decision support system (DSS) is essential to ensure maintainability and reliability of equipments in industries. The simplest method of condition-based monitoring involves the four human senses of sight, sound, touch and smell to predict a failure.
Decision support system and optimization techniquesDSS gathers and presents data from a wide range of sources in a way that can be interpreted by humans.
Poor machinery maintenance management will result in capacity loss, poor product quality and customer dissatisfaction. For example, if a filling machine fails in a SMI production line, the end products will spill over. Repairing activities take place when the condition shows that a failure may be imminent.Unlike the Condition-based Maintenance (CBM) policy, in predictive maintenance the acquired controlled parameters data are analyzed to find a possible temporal trend. These downturns usually occur depending on the efficiency of the reliability programs executed by the organization. This makes it possible to predict when the controlled quantity value will reach or exceed the threshold values. In addition, high-rate communications allow them to quickly obtain several kinds of expertise and to accelerate the feedback reaction in the local loop, connecting the product, monitoring agent and maintenance support system together. They can simulate certain aspect of the organization's environment in order to decide how to react to a change in the conditions affecting it.
Related worksIt has been a long journey for the evolution of maintenance management models and techniques from 1940 until now. The maintenance staffs will then be able to plan when, depending on the operating conditions, the component substitution or revision is really unavoidable.
By changing the hypothetical inputs to the maximum and minimum levels, the managers can see how the model's outputs are affected. Decision Making Grid (DMG) to be embedded with computerized maintenance management system (CMMS) to aid maintenance strategies for the machines as an adoption of technology management in SMI. Maintenance is a wide area, and involves planning, coordinating, controlling, supervising and managing activities in order to achieve the organization’s purposes and goals. TPM is applied globally and one of the TPM concepts is to empower the operators to maintain continuous production on totally efficient lines (Nakajima,1988). Next this chapter demonstrates on how DMG model can be used as a decision support module in Failure-based Maintenance (FBM).2.
Palmer (1999) defines maintenance management as control that must be taken to keep the equipment in its working state, by preserving it from any failures. Preventive maintenance is carried out using a planned, periodic and specific schedule to keep a machine in a stated working condition, throughout the process of checking and reconditioning.
Consequently, the amount of time it takes to communicate a production problem to the potential expert solution provider can be reduced, the quality of the information shared can be improved, and thereby the resolution time reduced. TPM is the continuous knowledge transfer to operators and the maintaining of the production equipment together with the maintenance crew.


The goals of the maintenance study are to reduce downtime and cost, while improving the adequacy and quality of service to maximize the availability of equipment in an operative state. Preventive maintenance is defined as the pre-breakdown model performed on equipment to either eliminate or reduce the emergency failures within pre-determined economic limits (Lewis, 1999). Decision-making gridThe maintenance Decision-Making Grid (DMG), introduced by Labib (1998) acts as a map where the performances of the worst machines are placed based on multiple criterions, i.e.
Hence, we can slowly reduce the waiting time for technicians to be in the production plant.
There are many literatures available from various researchers and practitioners in the field of maintenance management.
The model has been introduced to enhance reliability and confidence of the machine in advance. Downtimes could be conceivably reduced through direct troubleshooting with source designers and engineers.
On the other hand it gives operator the opportunity to eliminate the root causes of the machines' errors on a small level, before they become big ones. The results provide guidelines for the action, which will lead to the movement of machines towards an improvement of the maintenance strategies with respect to multiple criterions. The service is repeated at a pre-determined frequency to avoid any unplanned breakdown of the machine. With the availability of tools for interacting, handling, and analysing information about product state, the development of maintenance engineering for product lifecycle support, including maintenance and retirement stages such as disassembly, recycling, reuse and disposal, is becoming feasible.The excellent-maintenance concept requires a good information technology system. Bentley (1993) divides the preventive maintenance (PM) model into CBM with two main categories, as follows:Monitored PM, which involves monitoring when the machine is in operation. There are very promising developments in information technology, which can help to improve maintenance practice.
There are many researchers who have studied the DMG and apply it in the equipment management area. Among those, there are three selected reviews that are worth discussing under this sub-section.
Repair activities are to be conducted before any unplanned breakdown; andScheduled maintenance, where the service is being conducted on the same machine at specific counter or time intervals.
Maintenance information systemThe information system is becoming an important tool for achieving efficiency and effectiveness within maintenance, provided that the correct and relevant information technology is applied.
In the first Labib (1998a) has introduced the DMG model to help maintenance management identify breakdown maintenance strategies. The maintenance crew always follows the standard checklist to conduct PM activities, which involves scheduled replacement of parts, service, alignment, greasing, lubrication, confidence testing, etc. In fact, there are many papers on the maintenance information system and technologies, where they are always integrated with other disciplines such as inventory control, supply chain management and communication technology on the manufacturing shop floor. The columns of the matrix show the three criterions of the downtime, whilst the rows of the matrix show another three criterions of the frequency of the failures. The first review is given by Labib (2004), who discusses the CMMS development to facilitate the management of maintenance resources, to monitor maintenance efficiency and to provide appropriately analysed management information for further consideration. Labib (2004) has suggested some benefits that CMMS can offer, as follows:It allows operators to report faults faster by filling-up the electronic-form.
The matrix offers an opportunity to decide what maintenance strategies are needed for decision-making such as to practice Operate to Failure (OTF), Fixed Time Maintenance (FTM), Service Level Upgrade (SLU), Condition-based Maintenance (CBM), Designed-out Maintenance (DOM), Total Productive Maintenance (TPM) and Reliability-centered Maintenance (RCM).The second important review was undertaken by Fernandez et al.
They examined the basis of various maintenance management strategies used to date in international manufacturing.
They extended the theory of the maintenance maturity grid and implemented it into a disk brake pad manufacturing company in England. They have demonstrated how CMMS is used to capture maintenance activities, and analysed maintenance time and cost in an Irish textile manufacturing company. The results can provide maintenance policies in the respective functional group in production lines, to achieve their common goal to reduce downtime.Later, Zulkifli et al. Lately, rapid growth in computer technology has opened up new possibilities in CMMS development. This brings us to the third review, in which Mirka (2008) reported that CMMS provides tremendous benefit to maintenance. In their study, the DMG is employed in small and medium food processing companies to identify their maintenance strategies.
She identified salient characteristics of CMMS by showing that information technology investment has a positive correlation to company profitability and competitiveness.
DMG is used in these study as the model is flexible, and considers OTF, FTM, SLU, CBM, DOM, TPM and RCM strategies in the same grid. She also developed information technology tools based on a company’s factors of goal and purpose. The model is able to analyze multiple criteria and is the best choice when the number of machines is less than fifty (Pascual et al, 2009). Despite providing significant characteristics of CMMS, which may fit in with the needs of the industries, Labib (2004) also discovered that the majority of available CMMS in the market lack decision support for management. It can be used to detect the top ten problematic machines on the production floor with several system conditions. This is with regards to failures such as fatigue, imbalance, misalignment loosened assemblies, and turbulence, which can occur in rotational or reciprocating parts such as bearings, gearboxes, shafts, pumps, motors and engines. The rule states that eighty percent of the problems arise from the same twenty percent of the root causes.
DSS constitutes a class of computer-based information systems, including knowledge-based systems that support decision-making activities.
A computer program is written using available maintenance techniques to automate the analysis and results. Development of the decision-making grid modelThere are many publications on CMMS and DMG applications in the area of maintenance.
Among them, there are three journal papers that are most related to this study of the DMG model, written by Labib (1998b and 2009) and Fernandez et al.
The columns of the matrix show the three criterions of the downtime, whilst the rows of the matrix show another the criterions of the frequency of the failure.
A better maintenance model for quality management can be formed by handling both the rows and columns of the matrix respectively.
The matrix offers an opportunity to decide what maintenance strategies are needed for decision-making such as to practice OTF, FTM, SLU, CBM or DOM.
The matrix also suggests maintenance concepts that are useful for each defined cell of the matrix such as TPM or RCM approaches. The results can provide maintenance policies in the respective functional group in production lines to achieve their common goal, to reduce downtime.
The machines, as regards each criterion are sorted and placed into a top ten list of high, medium, and low boundaries, which are divided into three categories using the tri-quadrant approach as follows (Burhanuddin (2009)).



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maintenance management training 2013



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