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Open Access
Article
Publication date: 17 November 2023

Qi Xiao, Weidong Yu, Guangrong Tian and Fangxuan Li

This study aims to introduce the achievements and benefits of applying wheel/rail-force–based maintenance interval extension of the C80 series wagon in China.

Abstract

Purpose

This study aims to introduce the achievements and benefits of applying wheel/rail-force–based maintenance interval extension of the C80 series wagon in China.

Design/methodology/approach

Chinese wagons' existing maintenance strategy had left a certain safety margin for the characteristics of widely running range, unstable service environment and submission to transportation organization requirements. To reduce maintenance costs, China railway (CR) has attempted to extend the maintenance interval since 2020. The maintenance cycle of C80 series heavy haul wagons is extended by three months (no stable routing) or 50,000 km (regular routing). However, in the meantime, the alarming rate of the running state, a key index to reflect the severe degree of hunting stability, by the train performance detection system (TPDS) for the C80 series heavy haul wagons has increased significantly.

Findings

The present paper addresses a big data statistical way to evaluate the risk of allowing the C80 series heavy haul wagons to remain in operation longer than stipulated by the maintenance interval initial set. Through the maintenance and wayside-detector data, which is divided into three stages, the extension period (three months), the current maintenance period and the previous maintenance period, this method reveals the alarming rate of hunting was correlated with maintenance interval. The maintainability of wagons will be achieved by utilizing wagon performance degradation modeling with the state of the wheelset and the often-contact side bearing. This paper also proposes a statistical model to return to the average safety level of the previous maintenance period's baseline through correct alarming thresholds for unplanned corrective maintenance.

Originality/value

The paper proposes an approach to reduce safety risk due to maintenance interval extension by effective maintenance program. The results are expected to help the railway company make the optimal solution to balance safety and the economy.

Abstract

Details

Transportation and Traffic Theory in the 21st Century
Type: Book
ISBN: 978-0-080-43926-6

Article
Publication date: 15 March 2024

Phebe Hassana Obaka, Seyi Julian Adelegan and Leonard Shaibu

The level of deterioration of educational facilities, such as leaking classroom roofs, inadequate good seats, obsolete offices, broken shutters and doors, outdated school…

Abstract

Purpose

The level of deterioration of educational facilities, such as leaking classroom roofs, inadequate good seats, obsolete offices, broken shutters and doors, outdated school buildings, power plants and office equipment like ICT media, laboratories, offices and workshops, despite the involvement of Alumni association in the maintenance of educational facilities for the effective actualization of school objectives was a worrisome nightmare in Kogi state. This, therefore, prompted the researchers to explore the Alumni’s participation in plant maintenance for effective implementation of the universal basic education (UBE) programme in public junior secondary schools in Kogi state. The purpose of this study was guided by the research question which stated that to what extent does the Alumni Association participate in plant maintenance for effective implementation of the UBE programme in public junior secondary schools in Kogi state?

Design/methodology/approach

A quantitative research approach using a descriptive survey was adopted for the study. The sample was drawn using a proportionate stratified sampling technique comprising 387 participants which consisted of 191 (49%) urban junior secondary school principals and 196 (51%) rural principals in selected UBE junior secondary schools. Alumni’s Participation in Plant Maintenance Questionnaire was used as an instrument for data collection. The data were analysed with the aid of mean and standard deviation for the research question and z-test statistics at 0.05 level of significance and the value of z-crit. of 1.96 was used to determine the rejection or otherwise of the hypotheses.

Findings

The descriptive analysis revealed that the average mean set of 2.64 pointed to the fact that the respondents averagely agreed that there was a high extent to which Alumni participate in plant maintenance in urban than rural areas for effective implementation of the UBE programme in public junior secondary schools in Kogi state. This indicates that Alumni contribute to the management of UBE schools in Kogi state, especially in the areas of funding, infrastructural facilities, discipline, politics and quality control. This finding also shows that the contributions of the alumni to educational institutions are still unclear if they have made contributions to education in some areas and none in other areas making their relevance to plant maintenance unclear.

Research limitations/implications

In terms of practical implications, the study has contributed to knowledge in that it is the first of this form of a study carried out in Kogi state, and as such the findings of the research will make contributions to the physique of information on plant maintenance for the profitable implementation of the UBE programme in Kogi state. Besides, the degree of plant preservation for the implementation of the UBE programme among applicable stakeholders in Kogi state is nevertheless at a low extent.

Originality/value

Researchers have conducted studies that show how non-state Alumni members contribute to the administration of education across different states. Some of these studies revealed that Alumni members have assisted schools in the provision of teaching and learning materials at the senior secondary or tertiary education level. There are no sufficient studies to show how these Alumni members have contributed to the implementation of the free education programme, especially in public junior secondary schools in Kogi state and this is the gap this study intends to fill.

Details

Facilities , vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0263-2772

Keywords

Article
Publication date: 18 March 2024

Nuno Miguel de Matos Torre and Andrei Bonamigo

Maintenance represents an indispensable role in the productive sector of the steel industry. The increasing use of operating with a high level of precision makes hydraulic systems…

Abstract

Purpose

Maintenance represents an indispensable role in the productive sector of the steel industry. The increasing use of operating with a high level of precision makes hydraulic systems one of the issues that require a high level of attention. This study aims to explore an empirical investigation for decreasing the occurrences of corrective maintenance of hydraulic systems in the context of Lean 4.0.

Design/methodology/approach

The maintenance model is developed based on action-research methodology through an empirical investigation, with nine stages. This approach aims to build a scenario to analyze and interpret the occurrences, seeking to implement and evaluate the actions to be performed. The undertaken initiatives demonstrate that this approach can be applied to optimize the maintenance of an organization.

Findings

The main contribution of this paper is to demonstrate that the applied method allows the overviewing results, with a qualitative approach concerning the maintenance actions and management processes to be considered, allowing a holistic understanding and contributing to the current literature. The results also indicated that Lean 4.0 has direct and mediating effects on maintenance performance.

Originality/value

This research intends to propose an evaluation framework with an interdimensional linkage between action research methodology and Lean 4.0, to explore an empirical investigation and contributing to understanding the actions to reduce the occurrences of hydraulic systems corrective maintenance in a production line in the steel industry.

Details

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

Keywords

Open Access
Article
Publication date: 28 February 2024

Hassan Th. Alassafi, Khalid S. Al-Gahtani, Abdulmohsen S. Almohsen and Abdullah M. Alsugair

Heating, ventilating, air-conditioning and cooling (HVAC) systems are crucial in daily health-care facility services. Design-related defects can lead to maintenance issues…

Abstract

Purpose

Heating, ventilating, air-conditioning and cooling (HVAC) systems are crucial in daily health-care facility services. Design-related defects can lead to maintenance issues, causing service disruptions and cost overruns. These defects can be avoided if a link between the early design stages and maintenance feedback is established. This study aims to use experts’ experience in HVAC maintenance in health-care facilities to list and evaluate the risk of each maintenance issue caused by a design defect, supported by the literature.

Design/methodology/approach

Following semistructured interviews with experts, 41 maintenance issues were identified as the most encountered issues. Subsequently, a survey was conducted in which 44 participants evaluated the probability and impact of each design-caused issue.

Findings

Chillers were identified as the HVAC components most prone to design defects and cost impact. However, air distribution ducts and air handling units are the most critical HVAC components for maintaining healthy conditions inside health-care facilities.

Research limitations/implications

The unavailability of comprehensive data on the cost impacts of all design-related defects from multiple health-care facilities limits the ability of HVAC designers to furnish case studies and quantitative approaches.

Originality/value

This study helps HVAC designers acquire prior knowledge of decisions that may have led to unnecessary and avoidable maintenance. These design-related maintenance issues may cause unfavorable health and cost consequences.

Article
Publication date: 13 February 2024

José Nogueira da Mata Filho, Antonio Celio Pereira de Mesquita, Fernando Teixeira Mendes Abrahão and Guilherme C. Rocha

This paper aims to explore the optimization process involved in the aircraft maintenance allocation and packing problem. The aircraft industry misses a part of the optimization…

Abstract

Purpose

This paper aims to explore the optimization process involved in the aircraft maintenance allocation and packing problem. The aircraft industry misses a part of the optimization potential while developing maintenance plans. This research provides the modeling foundation for the missing part considering the failure behavior of components, costs involved with all maintenance tasks and opportunity costs.

Design/methodology/approach

The study models the cost-effectiveness of support against the availability to come up with an optimization problem. The mathematical problem was solved with an exact algorithm. Experiments were performed with real field and synthetically generated data, to validate the correctness of the model and its potential to provide more accurate and better engineered maintenance plans.

Findings

The solution procedure provided excellent results by enhancing the overall arrangement of the tasks, resulting in higher availability rates and a substantial decrease in total maintenance costs. In terms of situational awareness, it provides the user with the flexibility to better manage resource constraints while still achieving optimal results.

Originality/value

This is an innovative research providing a state-of-the-art mathematical model and an algorithm for efficiently solving a task allocation and packing problem by incorporating components’ due flight time, failure probability, task relationships, smart allocation of common preparation tasks, operational profile and resource limitations.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 9 January 2024

Fadoua Benhamza Hlihel, Youness Chater and Abderrazak Boumane

Competencies are significant predictors of employee outcome. Nowadays, new technologies are changing maintenance processes and workflow. The role of employees and their…

Abstract

Purpose

Competencies are significant predictors of employee outcome. Nowadays, new technologies are changing maintenance processes and workflow. The role of employees and their competencies will therefore undergo decisive changes in the future. Therefore, a well-designed competency model for maintenance departments is important. The purpose of this paper is to develop a maintenance 4.0 competency model applicable to all industrial sectors by adapting it to the specificities of each sector.

Design/methodology/approach

The research methods consist of a comprehensive literature review on the main characteristics of the competency model and the individual competencies needed for the maintenance 4.0 employees. Interviews were conducted in order to validate and prioritize the required competencies for maintenance 4.0 employees identified in the literature.

Findings

The maintenance 4.0 competency model combines the required competencies in maintenance 4.0 and crosses the three hierarchical levels: managers, engineers and technicians. These competencies are organized in terms of four categories: technical, personal, social and methodological. In addition, a degree of importance for each competency is assigned as very important, moderately important and slightly important. As a result, this study identified the essential competencies for maintenance 4.0 stakeholders, where 12 competencies are considered very important for maintenance 4.0 technicians, 19 for engineers and 18 for managers.

Research limitations/implications

This work has some limitations. First, although the articles related to competencies and their classification were selected very carefully, it is difficult to eliminate the probability of overlooking publications. Second, the limitation of the study is based on the difficulty of implementing the model in a case study, given that a minority of industrial companies have implemented maintenance 4.0 technologies in Morocco.

Practical implications

This work has practical implications for both individuals and institutions (companies and academies) to cope with new competency requirements in maintenance 4.0. Organizations can use the model in the recruitment process and for the identification of training needs. The results of the research will also contribute to identifying the scope of competencies of the maintenance 4.0 actors (engineer, manager and technician), which, in practice, contributes to the creation of requirements for the candidates applying for a job in the maintenance department. Additionally, educational institutions should make the necessary changes to their curricula to suitably prepare students for the required maintenance 4.0 competencies.

Social implications

The social implications of the article result from the contribution to the development of maintenance competencies. Individuals can use this model for their own personal development. Furthermore, companies can use this model to define job profiles for vacancies in M4.0. Therefore, using the model for training program implementation has a positive effect on employee job satisfaction and employees ’morale.

Originality/value

This research develops a novel maintenance 4.0 competency model by categorizing the maintenance workforce into three hierarchical levels: managers, engineers and technicians. In addition, the competency requirement is prioritized to three degrees: very important, moderately important and slightly important. According to the previous studies conducted on maintenance 4.0 and employees' competencies, this study revealed that no research has developed a competency model for maintenance 4.0. Hence, this model is unique, generic and integrative since it presents the most relevant competencies for the three hierarchical levels. Moreover, this work combines the results of the literature review and the experts' returns. This model can be useful in the recruitment of new maintenance employees, the evaluation of their performance and the identification of training needs to cope with new changes in maintenance competencies.

Details

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

Keywords

Article
Publication date: 23 January 2024

Chinedu Onyeme and Kapila Liyanage

This study investigates the integration of Industry 4.0 (I4.0) technologies with condition-based maintenance (CBM) in upstream oil and gas (O&G) operations, focussing on…

49

Abstract

Purpose

This study investigates the integration of Industry 4.0 (I4.0) technologies with condition-based maintenance (CBM) in upstream oil and gas (O&G) operations, focussing on developing countries like Nigeria. The research identifies barriers to this integration and suggests solutions, intending to provide practical insights for improving operational efficiency in the O&G sector.

Design/methodology/approach

The study commenced with an exhaustive review of extant literature to identify existing barriers to I4.0 implementation and contextualise the study. Subsequent to this foundational step, primary data are gathered through the administration of carefully constructed questionnaires targeted at professionals specialised in maintenance within the upstream O&G sector. A semi-structured interview was also conducted to elicit more nuanced, contextual insights from these professionals. Analytically, the collected data were subjected to descriptive statistical methods for summarisation and interpretation with a measurement model to define the relationships between observed variables and latent construct. Moreover, the Relative Importance Index was utilised to systematically prioritise and rank the key barriers to I4.0 integration to CBM within the upstream O&G upstream sector.

Findings

The most ranked obstacles in integrating I4.0 technologies to the CBM strategy in the O&G industry are lack of budget and finance, limited engineering and technological resources, lack of support from executives and leaders of the organisations and lack of competence. Even though the journey of digitalisation has commenced in the O&G industry, there are limited studies in this area.

Originality/value

The study serves as both an academic cornerstone and a practical guide for the operational integration of I4.0 technologies within Nigeria's O&G upstream sector. Specifically, it provides an exhaustive analysis of the obstacles impeding effective incorporation into CBM practices. Additionally, the study contributes actionable insights for industry stakeholders to enhance overall performance and achieve key performance indices (KPIs).

Details

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

Keywords

Open Access
Article
Publication date: 25 December 2023

Anna Trubetskaya, Alan Ryan, Daryl John Powell and Connor Moore

Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk…

Abstract

Purpose

Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity.

Design/methodology/approach

Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season.

Findings

Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in €8.9m additional value to the business and a reduction of 36% in the duration of the overhaul.

Practical implications

The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls.

Originality/value

To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting.

Details

International Journal of Lean Six Sigma, vol. 15 no. 8
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 30 January 2024

Mahnaz Ensafi, Walid Thabet and Deniz Besiktepe

The aim of this paper was to study current practices in FM work order processing to support and improve decision-making. Processing and prioritizing work orders constitute a…

Abstract

Purpose

The aim of this paper was to study current practices in FM work order processing to support and improve decision-making. Processing and prioritizing work orders constitute a critical part of facilities and maintenance management practices given the large amount of work orders submitted daily. User-driven approaches (UDAs) are currently more prevalent for processing and prioritizing work orders but have challenges including inconsistency and subjectivity. Data-driven approaches can provide an advantage over user-driven ones in work-order processing; however, specific data requirements need to be identified to collect and process the functional data needed while achieving more consistent and accurate results.

Design/methodology/approach

This paper presents the findings of an online survey conducted with facility management (FM) experts who are directly or indirectly involved in processing work orders in building maintenance.

Findings

The findings reflect the current practices of 71 survey participants on data requirements, criteria selection, rankings, with current shortcomings and challenges in prioritizing work orders. In addition, differences between criteria and their ranking within participants’ experience, facility types and facility sizes are investigated. The findings of the study provide a snapshot of the current practices in FM work order processing, which aids in developing a comprehensive framework to support data-driven decision-making and address the challenges with UDAs.

Originality/value

Although previous studies have explored the use of selected criteria for processing and prioritizing work orders, this paper investigated a comprehensive list of criteria used by various facilities for processing work orders. Furthermore, previous studies are focused on the processing and prioritization stage, whereas this paper explored the data collected following the completion of the maintenance tasks and the benefits it can provide for processing future work orders. In addition, previous studies have focused on one specific stage of work order processing, whereas this paper investigated the common data between different stages of work order processing for enhanced FM.

Details

Facilities , vol. 42 no. 5/6
Type: Research Article
ISSN: 0263-2772

Keywords

1 – 10 of over 76000