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Article
Publication date: 1 April 2014

P.B. Ahamed Mohideen and M. Ramachandran

The purpose of this paper is to develop a systematic strategic approach to handle corrective maintenance onto the failures/breakdowns of construction equipment. For the…

Abstract

Purpose

The purpose of this paper is to develop a systematic strategic approach to handle corrective maintenance onto the failures/breakdowns of construction equipment. For the maintenance crew/team, a breakdown code management is proposed, which will provide focused and unambiguous approach to manage any kind of breakdowns in construction equipments.

Design/methodology/approach

The past breakdown records of a construction organization in the UAE are considered for analysis. From the failure data, through cause effect analysis (CEA) tools, the components and the breakdown codes namely breakdown main codes (BMC) and breakdown sub-codes (BSC) are formulated. With Pareto analysis, the critical codes are identified and validated through failure modes and effects analyses (FMEA) tools for the critical effect on the affected components. From this identified BSC's further closer failure identification codes namely breakdown symptom codes (BSyC) and breakdown reason codes (BRC) are identified through fault tree analysis (FTA) tools. The approach to modified breakdown maintenance management (MB2M) with breakdown maintenance protocol (BMP) is envisaged.

Findings

The study was conducted on four different types of heavy lifting/earth moving/material handling system of equipment and further focused with two earth moving equipment namely dumpers and wheel loaders. Failure analysis is performed and the failure ratio and the component contribution to the failures are identified. Based on the information, the preliminary codes namely BMC and BSC are identified through CEA tools and the BMC and BSC are identified to find the most contributing codes to the maximum number of failures through Pareto analysis. Further the critical sub-codes are further verified through FMEA tools on the severity levels of the sub components due to these codes. The FTA methods are used to identify the closer reasoning and relations of these codes and the further codes namely BSyC and BRC are identified which are the exact cause of the failures. The management of breakdowns is further proposed through MB2M which includes BMP which provides all resources for the breakdowns.

Research limitations/implications

The failure data collected are only pertaining to the Middle East region and applicable to similar regions for similar plant mix in construction companies. The sample equipment is only part representative of the construction equipment. A more robust model can be suggested in the future covering all aspects and for other regions as well.

Practical implications

The proposed methodology and model approach is highly adaptable to similar industries operating in the Middle East countries.

Originality/value

Many authors have studied the preventive maintenance models and procedures and proposals have been proposed. On the breakdown maintenance management of construction equipment, very few studies have been proposed mostly on the cost analysis. This model attempts to provide a code management solution to manage the unpredictable failures in construction equipment through failure data analysis on a construction organization.

Details

Benchmarking: An International Journal, vol. 21 no. 2
Type: Research Article
ISSN: 1463-5771

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Article
Publication date: 8 May 2017

Ernnie Illyani Basri, Izatul Hamimi Abdul Razak, Hasnida Ab-Samat and Shahrul Kamaruddin

The purpose of this paper is to provide comprehensive information on preventive maintenance (PM) planning and methods used in the industry in order to achieve an effective…

Abstract

Purpose

The purpose of this paper is to provide comprehensive information on preventive maintenance (PM) planning and methods used in the industry in order to achieve an effective maintenance system.

Design/methodology/approach

The literature review is organized in a way that provides the general overview of the researches done in the PM. This paper discusses the literatures that had been reviewed on four main topics, which are the holistic view of maintenance policies, PM planning, PM planning concept and PM planning-based in developing optimal planning in executing PM actions.

Findings

PM policy is one of the original proactive techniques that has been used since the start of researches on maintenance system. Review of the methods presented in this paper shows that most researches analyse effectiveness using artificial intelligence, simulation, mathematical formulation, matrix formation, critical analysis and multi-criteria method. While in practice, PM activities were either planned based on cost, time or failure. Research trends on planning and methods for PM show that the variation of approaches used over the year from early 1990s until today.

Practical implications

Research about PM is known to be extensively conducted and majority of companies applied the policy in their production line. However, most analysis and method suggested in published literatures were done based on mathematical computation rather than focussing on solution to real problems in the industry. This normally would lead to the problems in understanding by the practitioner. Therefore, this paper presented researches on PM planning and suggested on the methods that are practical, simple and effective for application in the real industry.

Originality/value

The originality of this paper comes from its detail analysis of PM planning in term of its research focus and also direction for application. Extensive reviews on the methods adopted in relation to PM planning based on the planning-based such as cost-based, time-based and failure-based were also provided.

Details

Journal of Quality in Maintenance Engineering, vol. 23 no. 2
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 24 April 2007

M. Braglia, G. Fantoni and M. Frosolini

The purpose of this paper is to provide a structured methodology for performing build‐in reliability (BIR) investigation during a new product development cycle.

Abstract

Purpose

The purpose of this paper is to provide a structured methodology for performing build‐in reliability (BIR) investigation during a new product development cycle.

Design/methodology/approach

The methodology in this paper represents an extension of the Quality Functional Deployment/House of Quality (QFD/HoQ) concepts to reliability studies. It is able to translate the reliability requisites of customers into functional requirements for the product in a structured manner based on a Failure Mode And Effect Analysis (FMEA). Besides, it then allows it to build a completely new operative tool, named House of Reliability (HoR), that enhances standard analyses, introducing the most significant correlations among failure modes. Using the results from HoR, a cost‐worth analysis can be easily performed, making it possible to analyse and to evaluate the economical consequences of a failure.

Findings

The paper finds that the application of the proposed approach allows users to identify and control the design requisites affecting reliability. The methodology enhances the reliability analysis introducing and managing the correlations among failure modes, splitting the severity into a detailed series of basic severity aspects, performing also cost/worth assessments.

Practical implications

It is shown that the methodology enables users to finely analyse failure modes by splitting severity according to the product typology and the importance of each Severity criterion according to laws or international standards. Moreover the methodology is able to consider the “domino effects” and so to estimate the impact of the correlation between the causes of failure. Finally a cost/worth analysis evaluates the economical consequences of a failure with respect to the incurred costs to improve the final reliability level of the product.

Originality/value

The paper proposes a completely new approach, robust, structured and useful in practice, for reliability analysis. The methodology, within an integrated approach, overcomes some of the largely known limits of standard FMECA: it takes into account multiple criteria, differently weighted, it analyses the product considering not only the direct consequence of a failure, but also the reaction chain originated by a starting failure.

Details

International Journal of Quality & Reliability Management, vol. 24 no. 4
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 5 March 2018

Panagiotis Tsarouhas

The purpose of this paper is to provide results for a complete reliability, availability, and maintainability (RAM) analysis utilizing data sets from a production system…

Abstract

Purpose

The purpose of this paper is to provide results for a complete reliability, availability, and maintainability (RAM) analysis utilizing data sets from a production system in a wine packaging line. Through the illustrated case study, the author demonstrates how RAM analysis is very useful for deciding maintenance intervals, and for planning and organizing the adequate maintenance strategy.

Design/methodology/approach

RAM analysis has been done for each machine by using failures data. The parameters of some common probability distributions, such as Weibull, exponential, lognormal, and normal distributions, have been estimated by using the Minitab software package. An investigation to determine which of these distributions provide the best fit for characterizing the failure pattern at machine and line level has been made. Reliability and maintainability of both wine packaging and its machines has been estimated at different mission times with their best fit distribution. High maintainability issues and potential factors with their potential failure modes were presented, through failure mode and effect analysis process.

Findings

Analysis of the total downtime, breakdown frequency, reliability, and maintainability characteristics of different machines shows that: first, the availability for the wine packaging line was 91.80 percent, and for the remaining 8.2 percent the line is under repair. Second, about two failures per shift are displayed on the line, whereas for the mean time-to-repair (TTR) a failure is 24 minutes. Third, there is no correlation between the time-between-failures and the TTRs for the wine packaging line. Fourth, the main three factors affecting the maintainability process in the production line are: resources availability, manpower management, and maintenance planning procedures.

Originality/value

This study is anticipated to serve as an illuminating effort in conducting a complete RAM analysis in the much advertised field of wine packaging production line which on the other hand so little has been published on operational availability and equipment effectiveness. It can also be useful to serve as a valid data source for winery product manufacturers, who wish to improve the design and operation of their production lines.

Details

International Journal of Quality & Reliability Management, vol. 35 no. 3
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 2 October 2017

Rajkumar Bhimgonda Patil, Basavraj S. Kothavale, Laxman Yadu Waghmode and Shridhar G. Joshi

The paper presents reliability, maintainability and life cycle cost (LCC) analysis of a computerized numerical control (CNC) turning center which is manufactured and used…

Abstract

Purpose

The paper presents reliability, maintainability and life cycle cost (LCC) analysis of a computerized numerical control (CNC) turning center which is manufactured and used in India. The purpose of this paper is to identify the critical components/subsystems from reliability and LCC perspective. The paper further aims at improving reliability and LCC by implementing reliability-improvement methods.

Design/methodology/approach

This paper uses a methodology for the reliability analysis based on the assessment of trends in maintenance data. The data required for reliability and LCC analysis are collected from the manufacturers and users of CNC turning center over a period of eight years. ReliaSoft’s Weibull++9 software has been used for verifying goodness of fit and estimating parameters of the distribution. The LCC of the system is estimated for five cost elements: acquisition cost, operation cost, failure cost, support cost and net salvage value.

Findings

The analysis shows that the spindle bearing, spindle belt, spindle drawbar, insert, tool holder, drive battery, hydraulic hose, lubricant hose, coolant hose and solenoid valve are the components with low reliability. With certain design changes and implementation of reliability-based maintenance policies, system reliability is improved, especially during warranty period. The reliability of the CNC turning center is improved by nearly 45 percent at the end of warranty period and system mean time between failure is increased from 15,000 to 17,000 hours. The LCC analysis reveals that the maintenance cost, operating cost and support costs dominate the LCC and contribute to the tune of 87 percent of the total LCC.

Research limitations/implications

The proposed methodology provides an excellent tool that can be utilized in industries, where safety, reliability, maintainability and availability of the system play a vital role. The approach may be improved by collecting data from more number of users of the CNC turning centers.

Practical implications

The approach presented in this paper is generic and can be applied to analyze the repairable systems. A real case study is presented to show the applicability of the approach.

Originality/value

The proposed methodology provides a practical approach for the analysis of time-to-failure and time-to-repair data based on the assessment of trends in the maintenance data. The methodology helps in selecting a proper approach of the analysis such as Bayesian method, parametric methods and nonparametric methods.

Details

International Journal of Quality & Reliability Management, vol. 34 no. 9
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 17 August 2010

Alireza Ahmadi, Peter Söderholm and Uday Kumar

The purpose of this paper is to present issues and challenges of scheduled maintenance task development within the maintenance review board (MRB) process, and to find…

Abstract

Purpose

The purpose of this paper is to present issues and challenges of scheduled maintenance task development within the maintenance review board (MRB) process, and to find potential areas of improvement in the application of the MSG‐3 methodology for aircraft systems.

Design/methodology/approach

The issues and challenges as well as potential areas of improvement have been identified through a constructive review that consists of two parts. The first part is a benchmarking between the Maintenance Steering Group (MSG‐3) methodology and other established and documented versions of reliability‐centred maintenance (RCM). This benchmarking focuses on the MSG‐3 methodology and compares it with some RCM standards to identify differences and thereby find ways to facilitate the application of MSG‐3. The second part includes a discussion about methodologies and tools that can support different steps of the MSG‐3 methodology within the framework of the MRB process.

Findings

The MSG‐3 methodology is closely related to the RCM methodology, in which the anticipated consequences of failure are considered for risk evaluation. However, MSG‐3 considers neither environmental effects of failures nor operational consequences of hidden failures. Furthermore, in MSG‐3, the operational check (failure‐finding inspection) is given priority before all other tasks, whereas in RCM it is considered as a default action, where there is no other applicable and effective option. While RCM allows cost‐effectiveness analysis for all failures that have no safety consequences, MSG‐3 just allows it for failures with economic consequences. A maintenance program that is established through the MRB process fulfils the requirements of continuous airworthiness, but there is no foundation to claim that it is the optimal or the most effective program from an operator's point‐of‐view. The major challenge when striving to achieve a more effective maintenance program within the MRB process is to acquire supporting methodologies and tools for adequate risk analysis, for optimal interval assignments, and for selection of the most effective maintenance task.

Originality/value

The paper presents a critical review of existing aircraft scheduled maintenance program development methodologies, and demonstrates the differences between MSG‐3 and other RCM methodologies.

Details

Journal of Quality in Maintenance Engineering, vol. 16 no. 3
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 29 May 2007

Rajiv Kumar Sharma, Dinesh Kumar and Pradeep Kumar

The aim of this paper is to permit system reliability analysts/managers/practitioners/engineers to analyse system failure behaviour more consistently and plan suitable…

Abstract

Purpose

The aim of this paper is to permit system reliability analysts/managers/practitioners/engineers to analyse system failure behaviour more consistently and plan suitable maintenance actions accordingly.

Design/methodology/approach

The paper adopted three important tools, namely, root cause analysis (RCA), failure mode effect analysis (FMEA), and non‐homogeneous Poisson point process (NHPPP), to build an integrated and helpful framework, able to facilitate the maintenance managers in decision making. The factors contributing to system unreliability were analysed using RCA and FMEA. The failure data related to the components are modelled using NHPPP models and are used to optimise maintenance decisions (repair or replacements) based on cost dimensions.

Findings

The paper finds that the in‐depth analysis of a system using RCA and FMEA helps to create a knowledge base to deal with problems related to process/product unreliability. From the results it is observed that NHPPP models adequately analyse time‐dependent rate of occurrence of failures. Thus, assisting the maintenance analyst in development of suitable maintenance strategy by properly understanding the mechanism of failure (through modeling of failure data); adopting adequate aging management actions (such as predictive or periodic testing) to predict or detect the degradation of components; and performing cost analysis.

Originality/value

The contemporaneous adoption of the three proposed techniques for failure analysis will help system reliability engineers/managers/practitioners not only to understand the failure behaviour of component(s) in the system, but also to plan/adapt suitable maintenance practices to improve system reliability and availability.

Details

International Journal of Quality & Reliability Management, vol. 24 no. 5
Type: Research Article
ISSN: 0265-671X

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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…

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: 7 February 2019

Rajkumar Bhimgonda Patil

Reliability, maintainability and availability of modern complex engineered systems are significantly affected by four basic systems or elements: hardware, software…

Abstract

Purpose

Reliability, maintainability and availability of modern complex engineered systems are significantly affected by four basic systems or elements: hardware, software, organizational and human. Computerized Numerical Control Turning Center (CNCTC) is one of the complex machine tools used in manufacturing industries. Several research studies have shown that the reliability and maintainability is greatly influenced by human and organizational factors (HOFs). The purpose of this paper is to identify critical HOFs and their effects on the reliability and maintainability of the CNCTC.

Design/methodology/approach

In this paper, 12 human performance influencing factors (PIFs) and 10 organizational factors (OFs) which affect the reliability and maintainability of the CNCTC are identified and prioritized according to their criticality. The opinions of experts in the fields are used for prioritizing, whereas the field failure and repair data are used for reliability and maintainability modeling.

Findings

Experience, training, and behavior are the three most critical human PIFs, and safety culture, problem solving resources, corrective action program and training program are the four most critical OFs which significantly affect the reliability and maintainability of the CNCTC. The reliability and maintainability analysis reveals that the Weibull is the best-fit distribution for time-between-failure data, whereas log-normal is the best-fit distribution for Time-To-Repair data. The failure rate of the CNCTC is nearly constant. Nearly 66 percent of the total failures and repairs are typically due to the hardware system. The percentage of failures and repairs influenced by HOFs is nearly only 16 percent; however, the failure and repair impact of HOFs is significant. The HOFs can increase the mean-time-to-repair and mean-time-between-failure of the CNCTC by nearly 65 and 33 percent, respectively.

Originality/value

The paper uses the field failure data and expert opinions for the analysis. The critical sub-systems of the CNCTC are identified using the judgment of the experts, and the trend of the results is verified with published results.

Details

Journal of Quality in Maintenance Engineering, vol. 26 no. 1
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 2 May 2019

Hasnida Ab-Samat and Shahrul Kamaruddin

Opportunistic maintenance (OM) policy is a prospective maintenance approach that instigates for a more effective and optimized system. The purpose of this paper is to…

Abstract

Purpose

Opportunistic maintenance (OM) policy is a prospective maintenance approach that instigates for a more effective and optimized system. The purpose of this paper is to provide the steps and methods used in model development processes for the application of the OM policy.

Design/methodology/approach

Dubbed as opportunistic principle toward optimal maintenance system (OPTOMS) for OM policy toward optimal maintenance system, the model is devised as a decision support system model and contains five phases. The motivation and focus of the model resolve around the need for a practical framework or model of maintenance policy for the application in an industry. In this paper, the OPTOMS model was verified and validated to ensure that the model is applicable in the industry and robust as a support system in decision making for the optimal maintenance system.

Findings

From the verification steps conducted in a case study company, it was found that the developed model incorporated simple but practical tools like check sheet, failure mode and effect analysis (FMEA), control chart that has been commonly used in the industry.

Practical implications

This paper provides the general explanations of the developed model and tools used for each phase in implementing OM to achieve an optimal maintenance system. Based on a case study conducted in a semiconductor company, the OPTOMS model can align and prepare the company in increasing machine reliability by reducing machine downtime.

Originality/value

The novelty of this paper is based on the in-depth discussion of all phases and steps in the model that emphasize on how the model will become practical theories in conducting an OM policy in a company. The proposed methods and tools for data collection and analysis are practical and commonly used in the industry. The framework is designed for practical application in the industry. The users would be from the Maintenance and Production Department.

Details

Journal of Quality in Maintenance Engineering, vol. 26 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

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