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Structured maintenance engineering policy development based on a production machine process perspective

Rosmaini Ahmad (School of Manufacturing Engineering, Universiti Malaysia Perlis, Arau, Malaysia)
Shahrul Kamaruddin (Department of Mechanical Engineering, University Technology Petronas, Bandar Seri Iskandar, Malaysia)

Journal of Quality in Maintenance Engineering

ISSN: 1355-2511

Article publication date: 8 May 2017

Abstract

Purpose

The purpose of this paper is to present the development of a maintenance engineering policy in the context of a decision support model based on a production machine process perspective.

Design/methodology/approach

The structure of the policy is called the maintenance decision support (MDS) model, which consists of three steps: initial setup, deterioration monitoring, and decision making. A detailed presentation of each step of the proposed model together with a real case example from the pulp manufacturing industry proves the applicability of the model.

Findings

Validation of the proposed MDS model is as follows. In Task 1 of Step 1, the cutting, sealing, and perforating line processes are classified as critical machining processes. The analysis of Task 2 of Step 1 found that cutting knife, bearing, and motor are classified as the components that most possibly contribute to the cutting appearance quality. In Task 3 of Step 1, it was found that the cutting knife is classified as a maintenance-significant component with non-repairable and single-component type characteristics. The result of Step 2 suggested that at the 29th hour of operating time, the decision of do-something was suggested. In the following step (Step 3), for the case of the cutting knife, which has been classified as a non-repairable type component, the decision to perform preventive replacement of cutting knife is recommended to be carried out at the 29th hour of operating time.

Research limitations/implications

The uniqueness of this model is that it systematically considers different machinery component(s) characteristics, including single- and multiple-component cases, repairable and non-repairable types, and functional or/and physical failure types, to make maintenance decisions.

Practical implications

The proposed MDS model provides a systematic guideline for identifying, evaluating, and monitoring, which makes maintenance-related decisions. Three significant maintenance decisions can be determined based on the proposed MDS model, which includes an appropriate time-to-perform maintenance, correct maintenance actions to be performed, and the right component required for maintenance (for multi-component cases).

Originality/value

One of the vital elements in considering the production machine process perspective toward the development of the MDS model is the need to use product output/quality characteristics for machine deterioration-monitoring and decision-making processes.

Keywords

Acknowledgements

The authors wish to acknowledge support from Universiti Malaysia Perlis (via Research Acculturation Grant Scheme, No: 9018-00076) and Universiti Sains Malaysia (via USM Fellowship). The authors also thank the referees for their useful suggestions.

Citation

Ahmad, R. and Kamaruddin, S. (2017), "Structured maintenance engineering policy development based on a production machine process perspective", Journal of Quality in Maintenance Engineering, Vol. 23 No. 2, pp. 180-194. https://doi.org/10.1108/JQME-03-2016-0009

Publisher

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Emerald Publishing Limited

Copyright © 2017, Emerald Publishing Limited