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Article
Publication date: 4 November 2020

Leandro Reis Muniz, Samuel Vieira Conceição, Lásara Fabrícia Rodrigues, João Flávio de Freitas Almeida and Tãssia Bolotari Affonso

The purpose of this paper is to present a new hybrid approach based on criticality analysis and optimisation to deal with spare parts inventory management in the initial…

Abstract

Purpose

The purpose of this paper is to present a new hybrid approach based on criticality analysis and optimisation to deal with spare parts inventory management in the initial provisioning phase in the mining industry. Spare parts represent a significant part of mining companies' expenditures, so it is important to develop new approaches to reduce the total inventory value of these items.

Design/methodology/approach

This hybrid approach combines qualitative and quantitative methods based on VED (vital, essential and desirable) analysis, analytical hierarchical process (AHP), and e-constraint optimisation method to obtain the spare parts to be stocked. The study was applied to a large mining company. The mineral sector was chosen due to the great importance to the emerging Brazilian economy and the lack of researches in this sector. In addition, the spare parts have a relevant weight on the total inventory cost.

Findings

Present a novel approach combining multi-objective optimisation and multi-criteria evaluation approaches to tackle the inventory decision in spare parts management. This work also defines and classifies relevant criteria for spare parts management in the mineral sector validated by specialists. The proposed approach achieves an average increase of 20.2% in the criticality and 16.6% in the number of items to be stocked compared to the historical data of the surveyed company.

Research limitations/implications

This paper applies the proposed approach to a mining company in Brazil. Future research in other companies or regions should analyse the adequacy of the criticality criteria, hierarchy and weights adopted in this paper.

Practical implications

The proposed approach is useful for mining industries that deal with a large variety of resource constraints as it helps in formulating appropriate spare part strategies to rationalise financial resources at both tactical and strategic levels.

Originality/value

The paper presents a new hybrid method combining the AHP a multi-criteria decision making (MCDM) approach coupled with e-constraint optimisation to deal with spare parts inventory management allowing for a better spare parts inventory analysis in the initial provisioning phase and providing managers with a systematic tool to analyse the trade-off between spare parts criticality and total inventory value.

Details

The International Journal of Logistics Management, vol. 32 no. 1
Type: Research Article
ISSN: 0957-4093

Keywords

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Article
Publication date: 9 April 2018

Maheshwaran Gopalakrishnan and Anders Skoogh

The purpose of this paper is to identify the productivity improvement potentials from maintenance planning practices in manufacturing companies. In particular, the paper…

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3402

Abstract

Purpose

The purpose of this paper is to identify the productivity improvement potentials from maintenance planning practices in manufacturing companies. In particular, the paper aims at understanding the connection between machine criticality assessment and maintenance prioritization in industrial practice, as well as providing the improvement potentials.

Design/methodology/approach

An explanatory mixed method research design was used in this study. Data from literature analysis, a web-based questionnaire survey, and semi-structured interviews were gathered and triangulated. Additionally, simulation experimentation was used to evaluate the productivity potential.

Findings

The connection between machine criticality and maintenance prioritization is assessed in an industrial set-up. The empirical findings show that maintenance prioritization is not based on machine criticality, as criticality assessment is non-factual, static, and lacks system view. It is with respect to these finding that the ways to increase system productivity and future directions are charted.

Originality/value

In addition to the empirical results showing productivity improvement potentials, the paper emphasizes on the need for a systems view for solving maintenance problems, i.e. solving maintenance problems for the whole factory. This contribution is equally important for both industry and academics, as the maintenance organization needs to solve this problem with the help of the right decision support.

Details

International Journal of Productivity and Performance Management, vol. 67 no. 4
Type: Research Article
ISSN: 1741-0401

Keywords

Content available
Article
Publication date: 16 January 2019

Maheshwaran Gopalakrishnan, Anders Skoogh, Antti Salonen and Martin Asp

The purpose of this paper is to increase productivity through smart maintenance planning by including productivity as one of the objectives of the maintenance…

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3277

Abstract

Purpose

The purpose of this paper is to increase productivity through smart maintenance planning by including productivity as one of the objectives of the maintenance organization. Therefore, the goals of the paper are to investigate existing machine criticality assessment and identify components of the criticality assessment tool to increase productivity.

Design/methodology/approach

An embedded multiple case study research design was adopted in this paper. Six different cases were chosen from six different production sites operated by three multi-national manufacturing companies. Data collection was carried out in the form of interviews, focus groups and archival records. More than one source of data was collected in each of the cases. The cases included different production layouts such as machining, assembly and foundry, which ensured data variety.

Findings

The main finding of the paper is a deeper understanding of how manufacturing companies assess machine criticality and plan maintenance activities. The empirical findings showed that there is a lack of trust regarding existing criticality assessment tools. As a result, necessary changes within the maintenance organizations in order to increase productivity were identified. These are technological advancements, i.e. a dynamic and data-driven approach and organizational changes, i.e. approaching with a systems perspective when performing maintenance prioritization.

Originality/value

Machine criticality assessment studies are rare, especially empirical research. The originality of this paper lies in the empirical research conducted on smart maintenance planning for productivity improvement. In addition, identifying the components for machine criticality assessment is equally important for research and industries to efficient planning of maintenance activities.

Details

International Journal of Productivity and Performance Management, vol. 68 no. 5
Type: Research Article
ISSN: 1741-0401

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Article
Publication date: 11 October 2021

Ammar Chakhrit and Mohammed Chennoufi

This paper aims to enable the analysts of reliability and safety system to assess the criticality and prioritize failure modes perfectly to prefer actions for controlling…

Abstract

Purpose

This paper aims to enable the analysts of reliability and safety system to assess the criticality and prioritize failure modes perfectly to prefer actions for controlling the risks of undesirable scenarios.

Design/methodology/approach

To resolve the challenge of uncertainty and ambiguous related to the parameters, frequency, non-detection and severity considered in the traditional approach failure mode effect and criticality analysis (FMECA) for risk evaluation, the authors used fuzzy logic where these parameters are shown as members of a fuzzy set, which fuzzified by using appropriate membership functions. The adaptive neuro-fuzzy inference system process is suggested as a dynamic, intelligently chosen model to ameliorate and validate the results obtained by the fuzzy inference system and effectively predict the criticality evaluation of failure modes. A new hybrid model is proposed that combines the grey relational approach and fuzzy analytic hierarchy process to improve the exploitation of the FMECA conventional method.

Findings

This research project aims to reflect the real case study of the gas turbine system. Using this analysis allows evaluating the criticality effectively and provides an alternate prioritizing to that obtained by the conventional method. The obtained results show that the integration of two multi-criteria decision methods and incorporating their results enable to instill confidence in decision-makers regarding the criticality prioritizations of failure modes and the shortcoming concerning the lack of established rules of inference system which necessitate a lot of experience and shows the weightage or importance to the three parameters severity, detection and frequency, which are considered to have equal importance in the traditional method.

Originality/value

This paper is providing encouraging results regarding the risk evaluation and prioritizing failures mode and decision-makers guidance to refine the relevance of decision-making to reduce the probability of occurrence and the severity of the undesirable scenarios with handling different forms of ambiguity, uncertainty and divergent judgments of experts.

Details

Journal of Engineering, Design and Technology , vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1726-0531

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Article
Publication date: 1 June 2003

Marcello Braglia, Marco Frosolini and Roberto Montanari

This paper presents a tool for reliability and failure mode analysis based on an advanced version of the popular failure mode, effects and criticality analysis (FMECA…

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2127

Abstract

This paper presents a tool for reliability and failure mode analysis based on an advanced version of the popular failure mode, effects and criticality analysis (FMECA) procedure. To help the analyst formulating efficiently effective criticality assessments of the possible causes of failure, the fuzzy logic technique is adopted. Particular attention has been devoted to support the maintenance staff with a fuzzy criticality assessment model easy to implement and design. To test the proposed methodology, an actual application concerning a process plant in milling field for human consumption flour is showed in the paper.

Details

International Journal of Quality & Reliability Management, vol. 20 no. 4
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 25 February 2020

Mouloud Bourareche, Rachid Nait Said, Fatiha Zidani and Nouara Ouazraoui

The purpose of this paper is to show the impact of operational and environmental conditions (risk influencing factors) on the component criticality of safety barriers…

Abstract

Purpose

The purpose of this paper is to show the impact of operational and environmental conditions (risk influencing factors) on the component criticality of safety barriers, safety barrier performance and accidents frequency and therefore on risk levels.

Design/methodology/approach

The methodology focuses on the integration of criticality importance analysis in barrier and operational risk analysis method, abbreviated as BORA-CIA. First, the impact of risk influencing factors (RIFs) associated with basic events on safety barrier performance and accident frequency is studied, and then, a risk evaluation is performed. Finally, how unacceptable risks can be mitigated regarding risk criteria is analyzed.

Findings

In the proposed approach (BORA-CIA), the authors show how specific installation conditions influence risk levels and analyze the prioritization of components to improve safety barrier performance in oil and gas process.

Practical implications

The proposed methodology seems to be a powerful tool in risk decision. Ordering components of safety barriers taking into account RIFs allow maintenance strategies to be undertaken according to the real environment far from average data. Also, maintenance costs would be estimated adequately.

Originality/value

In this paper, an improved BORA method is developed by incorporating CIA. More precisely, the variability of criticality importance factors of components is used to analyze the prioritization of maintenance actions in an operational environment.

Details

World Journal of Engineering, vol. 17 no. 2
Type: Research Article
ISSN: 1708-5284

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Article
Publication date: 29 April 2014

Debasis Das Adhikary, Goutam Kumar Bose, Dipankar Bose and Souren Mitra

The purpose of this paper is to present a multi criterion failure mode effect and criticality analysis for coal-fired thermal power plants using uncertain data as well as…

Abstract

Purpose

The purpose of this paper is to present a multi criterion failure mode effect and criticality analysis for coal-fired thermal power plants using uncertain data as well as substituting the traditional risk priority number estimation method.

Design/methodology/approach

Grey-complex proportional assessment (COPRAS-G) method, a multi criteria decision making tool is applied to evaluate the criticalities of the failure modes (alternatives). In this model the criteria (criticality factor) against each alternative are expressed in grey number instead of crisp values.

Findings

Rupture failure of the straight tube of economizer (ECO) due to erosion is the highest critical failure mode whereas rupture failure of the stub of ECO due to welding defect is the lowest critical failure mode.

Originality/value

This paper incorporates human and environmental factors as additional factors which also influence the failure modes significantly. The COPRAS-G method is modified according this problem. Uncertainty in the scoring of criticality factors against each failure mode by various maintenance personnel is expressed in grey numbers.

Details

International Journal of Quality & Reliability Management, vol. 31 no. 5
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 2 August 2013

Vijaya Dixit, Rajiv Kumar Srivastava and Atanu Chaudhuri

This work aims at integrating materials management with project management in the context of manufacturing of complex products which require a variety of items. To achieve…

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1609

Abstract

Purpose

This work aims at integrating materials management with project management in the context of manufacturing of complex products which require a variety of items. To achieve this, we propose two prioritization measures of items: material criticality (MC) at activity level and overall criticality (OC) at project level by incorporating project network characteristic through activity criticality (AC) values.

Design/methodology/approach

The costs or penalties which determine criticality of items are hidden in nature and are difficult to measure and model mathematically. Hence, Fuzzy Inference System (FIS), which captures experts’ tacit knowledge in the form of linguistic If‐Then rules has been used.

Findings

OC obtained can be used as a measure to prioritize items for procurement aligned with on‐site build strategy and as a surrogate measure of shortage cost coefficient for inventory models. The analyses of output to observe the effect of AC on OC values of items, clearly demonstrate the novelty and importance of incorporating project network characteristics in materials management decision making.

Originality/value

In this work, we are able to leverage managerial tacit knowledge derived through years of experience and convert it into a readily usable quantitative parameter OC for prioritization of items to be procured. For identifying the input parameters for OC, we brought in the new perspective of including project network characteristics to align materials and project management.

Details

Journal of Advances in Management Research, vol. 10 no. 2
Type: Research Article
ISSN: 0972-7981

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Article
Publication date: 13 February 2019

Kong Fah Tee and Ejiroghene Ekpiwhre

The purpose of this paper is to present a study of reliability-centred maintenance (RCM), which is conducted on the key sub-assets of a newly constructed road junction…

Abstract

Purpose

The purpose of this paper is to present a study of reliability-centred maintenance (RCM), which is conducted on the key sub-assets of a newly constructed road junction infrastructure in Nigeria.

Design/methodology/approach

The classical RCM methodology, a type of RCM, which has a top down, zero-based approach for maintenance analysis, is implemented in this study.

Findings

The implementation of the classical RCM is successful in its application of various PM policies assigned to the assets and it shows that its application in the highway industry could reduce excessive maintenance backlog and frequent reactive maintenance by effective optimisation of its preventive maintenance (PM) intervals.

Practical implications

Road junctions are originators of more than 70 per cent of road traffic congestion and account for high accident rate. The traditional methods of reliability assurance used in the highway industry such as reactive maintenance and routine maintenance are often inadequate to meet the round the clock usage demands of these assets, thus the consideration for the application of a systematic RCM process for maintaining the system function by selecting and applying effective PM tasks.

Originality/value

It uses an approach that critically develops and analyses thoroughly preventive and continuous maintenance strategy in a new circumstance with environment of uncertainty and limited operating data. The case-based reasoning cycle has been applied in the RCM approach with real-time data obtained from a UK-based network maintenance management system for highway infrastructures.

Details

International Journal of Quality & Reliability Management, vol. 36 no. 5
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 6 June 2016

Ilaria De Sanctis, Claudia Paciarotti and Oreste Di Giovine

The purpose of this paper is to propose a practical method of performing maintenance in the offshore industry where engineers have to manage problems such as the high cost…

Abstract

Purpose

The purpose of this paper is to propose a practical method of performing maintenance in the offshore industry where engineers have to manage problems such as the high cost of operations, assuring an high availability of the plant, safety on board and environmental protection. Indeed an efficient maintenance method it is necessary in order to offer methods and criteria to select the rights maintenance strategies keeping in to account the environmental, safety and production constrains.

Design/methodology/approach

The paper provides an overview of reliability centered maintenance (RCM) and reliability, availability, maintainability methodologies and an integration of the two methodologies in a particular case study in the oil and gas sector.

Findings

This paper suggests an improvement of the well-established RCM methodology applicable to industries with high priority level. It is proposed an integration between a reliability analysis and an availability analysis and an application on the offshore oil and gas industry.

Practical implications

The methodology provides an excellent tool that can be utilized in industries, where safety, regulations and the availability of the plant play a fundamental role.

Originality/value

The proposed methodology provides a practical method for selecting the best maintenance strategy considering the equipment redundancy and sparing, the asset’s performance over long time scales, and the system uptime, downtime and slowdowns.

Details

International Journal of Quality & Reliability Management, vol. 33 no. 6
Type: Research Article
ISSN: 0265-671X

Keywords

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