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Article
Publication date: 28 July 2020

Antti Salonen and Maheshwaran Gopalakrishnan

The purpose of this study was to assess the readiness of the Swedish manufacturing industry to implement dynamic, data-driven preventive maintenance (PM) by identifying…

Abstract

Purpose

The purpose of this study was to assess the readiness of the Swedish manufacturing industry to implement dynamic, data-driven preventive maintenance (PM) by identifying the gap between the state of the art and the state of practice.

Design/methodology/approach

An embedded multiple case study was performed in which some of the largest companies in the discrete manufacturing industry, that is, mechanical engineering, were surveyed regarding the design of their PM programmes.

Findings

The studied manufacturing companies make limited use of the existing scientific state of the art when designing their PM programmes. They seem to be aware of the possibilities for improvement, but they also see obstacles to changing their practices according to future requirements.

Practical implications

The results of this study will benefit both industry professionals and academicians, setting the initial stage for the development of data-driven, diversified and dynamic PM programmes.

Originality/Value

First and foremost, this study maps the current state and practice in PM planning among some of the larger automotive manufacturing industries in Sweden. This work reveals a gap between the state of the art and the state of practice in the design of PM programmes. Insights regarding this gap show large improvement potentials which may prove important for academics as well as practitioners.

Details

Journal of Quality in Maintenance Engineering, vol. 27 no. 2
Type: Research Article
ISSN: 1355-2511

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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…

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2919

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: 19 October 2012

Premaratne Samaranayake and Senevi Kiridena

The purpose of this paper is to examine how certain limitations of the current approaches to planning and scheduling of aircraft heavy maintenance can be addressed using a…

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2988

Abstract

Purpose

The purpose of this paper is to examine how certain limitations of the current approaches to planning and scheduling of aircraft heavy maintenance can be addressed using a single integrated framework supported by unified data structures.

Design/methodology/approach

The “unitary structuring technique”, originally developed within the context of manufacturing planning and control, is further enhanced for aircraft heavy maintenance applications, taking into account the uncertainty associated with condition‐based maintenance. The proposed framework delivers the advanced functionalities required for simultaneous and dynamic forward planning of maintenance operations, as well as finite loading of resources, towards optimising the overall maintenance performance.

Findings

Execution of maintenance operations under uncertainty involves materials changes, rectification and re‐assembly. It is shown that re‐scheduling of materials (spare‐parts), resources and operations can be taken care of by simultaneous and dynamic forward planning of materials and operations with finite loading of resources, using the integrated framework.

Research limitations/implications

As part of adopting the proposed framework in practice, it needs to be guided by an overall methodology appropriate for application‐specific contexts.

Practical implications

The potential direct benefits of adopting the proposed framework include on‐time project completion, reduced inventory levels of spare‐parts and reduced overtime costs.

Originality/value

Existing approaches to aircraft maintenance planning and scheduling are limited in their capacity to deal with contingencies arising out of inspections carried out during the execution phase of large maintenance projects. The proposed integrated approach is, capable of handling uncertainty associated with condition‐based maintenance, due to the added functionalities referred to above.

Details

Journal of Quality in Maintenance Engineering, vol. 18 no. 4
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 4 March 2014

Shixiong Zhao, Liya Wang and Yu Zheng

Making decisions on production and maintenance separately, as is often done in practice and research literature, may not result in overall optimization. This paper aims to…

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2574

Abstract

Purpose

Making decisions on production and maintenance separately, as is often done in practice and research literature, may not result in overall optimization. This paper aims to propose a joint method that better integrates production planning and maintenance at the tactical level. The potential of improving the performance of the classic planning method is also explored.

Design/methodology/approach

An integrated production planning and maintenance model is proposed. The production capacity losses resulted from both preventive and corrective maintenance activities are considered. Meanwhile, the reliability deterioration of the machine is considered to be operation dependent. An iterative approach is presented to find a solution for the nonlinear model through iteratively solving a sequence of mixed integer linear programming instances, accompanied by modification of some parameters prior to each iteration. Computational experiments are conducted to evaluate the performance of the proposed method compared with three other methods, including two methods based on separate planning and one integrated model.

Findings

The superiority of the proposed method compared with all the other three methods is demonstrated. Thus, the values of both integrated planning and considering operation-dependent failures are testified. The advantage of the proposed method is highlighted in the cases of high capacity utilization, long maintenance durations and low maintenance costs. The performance of the two methods based on separate planning is sensitive to the system utilization, and when utilization is high, the one with an availability-sensitive objective function defined for the maintenance problem performs better.

Originality/value

Few studies have been carried out to integrate decisions on production lot and maintenance. Their considerations are either incomplete or not realistic enough. A more comprehensive and realistic integrated model is proposed in this paper, along with an iterative solution algorithm for it. A potential way to improve the performance of the classic planning method with its simplicity preserved is also presented.

Details

Industrial Management & Data Systems, vol. 114 no. 2
Type: Research Article
ISSN: 0263-5577

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Article
Publication date: 30 January 2019

Umar Al-Turki, Salih Duffuaa and M. Bendaya

Turnaround maintenance (TAM) is a planned stoppage of production for conducting a comprehensive maintenance of equipment or plant with the purpose of improving plant…

Abstract

Purpose

Turnaround maintenance (TAM) is a planned stoppage of production for conducting a comprehensive maintenance of equipment or plant with the purpose of improving plant availability and performance. The purpose of this paper is to investigate trends in the operation and management of TAM, as reported in the literature, and identify gaps, in the context of a system approach that views a plant as part of a network of a supply chain.

Design/methodology/approach

This literature review is based on over 80 subject-relevant papers and uses content analysis. The literature subjects are classified into several managerial areas that include organization, planning, scope and risk analysis, execution, performance measurement and learning. The gap in the literature is identified in light of the proposed system view for TAM.

Findings

The system view of TAM opens new opportunities for new research areas for improving the operation and management of TAM. These areas include optimizing TAM scheduling and developing methods for managing risks along the entire business supply chain. In addition, new approaches for collaboration, sharing knowledge, best practices and expertise within the supply chain become necessary for effective TAM planning and control.

Originality/value

This paper reviews the literature and provides a new classification of TAM. It adopts the system view for TAM that has brought new insights in the operation and management of TAM. New trends for research in the area of TAM are identified.

Details

Journal of Quality in Maintenance Engineering, vol. 25 no. 2
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 1 December 2020

Zul-Atfi Ismail

Most green building (GB) materials, which are used widely in the construction sector in Malaysia, perform poorly in terms of energy efficiency and sustainability…

Abstract

Purpose

Most green building (GB) materials, which are used widely in the construction sector in Malaysia, perform poorly in terms of energy efficiency and sustainability. Nevertheless, during maintenance planning of these materials, the focus is often directed towards comfort and design instead. However, as GB material construction projects grow in scale and complexity, interconnections between the activities and processes can be noticed during problematic planning performance management to monitor the GB material components for corrective and preventive maintenance actions.

Design/methodology/approach

The concept of GB material maintenance planning for sustainable development and the main features of information and communication technology tools and techniques are based on analysis of literature reviews of GB material scenarios.

Findings

The results show how decision-making support in maintenance planning can be unsuccessful and how planning decisions can frame the content of an integrated system to analyse information and reduce risks of GB material failure.

Originality/value

The paper concludes that implementing a research framework for developing such a system can help improve the sustainable performance of maintenance planning of GB material economic, social and environmental issues.

Details

Journal of Financial Management of Property and Construction , vol. 26 no. 1
Type: Research Article
ISSN: 1366-4387

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Article
Publication date: 16 August 2011

Carles Sitompul and El‐Houssaine Aghezzaf

The purpose of this study is to propose and formulate an integrated hierarchical production, and maintenanceplanning model.

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1249

Abstract

Purpose

The purpose of this study is to propose and formulate an integrated hierarchical production, and maintenanceplanning model.

Design/methodology/approach

The proposed model is formulated mathematically and tested for some hypothetical cases. A two‐level planning is proposed to address the hierarchical planning problem, i.e. aggregate planning and detailed planning. A preventive maintenance planning is integrated into the aggregate planning, while machine breakdowns, which require corrective maintenance actions, are investigated in the detailed planning. The proposed general preventive maintenance model is tested against cyclical preventive maintenance models for some cases, and for evaluating the performance of the models, in terms of costs, and service levels.

Findings

The proposed general preventive maintenance model gives a better solution in terms of cost than the cyclical maintenance model (i.e. 6 per cent less costly), if the maintenance planning is executed separately from the production planning. In terms of service level, however, both models perform equally well with average service levels equal to 97.6 per cent. The effect of tight capacity, long maintenance duration, and small machine parameters similarly tightens the capacity. In these cases, it is shown that a stable level of capacity is more beneficial to achieve a better service level, which is gained if the preventive maintenance actions are carried out monthly.

Practical implications

At the aggregate level, the proposed preventive maintenance model considers a non‐cyclical planning, which means that the preventive maintenance periods do not necessarily fall at equally distant times. The inventory movement constraints at the aggregate level decouple machines to operate independently; hence the detailed level problem can be solved separately for each machine. In a rolling horizon approach, only the first period of the aggregate plan is implemented and disaggregated into the production of items at the detailed level.

Originality/value

The paper proposes an integrated model of hierarchical production and maintenance planning. A general preventive maintenance is integrated into the aggregate planning, while machine breakdowns are investigated in the detailed planning. To the best of one's knowledge, such a hierarchical view of production planning and maintenance has not been addressed adequately.

Details

Journal of Quality in Maintenance Engineering, vol. 17 no. 3
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 2 October 2009

Bernt E. Tysseland

The purpose of this paper is to determine how a small country's military force and a small country's non‐governmental organization (NGO) plan for and set up equipment…

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1244

Abstract

Purpose

The purpose of this paper is to determine how a small country's military force and a small country's non‐governmental organization (NGO) plan for and set up equipment maintenance, spare parts inventories in connection with man‐made humanitarian disasters. Additionally, it seeks to determine how the physical context, organizational structure and governance affect the planning and set‐up.

Design/methodology/approach

A research model that combines organizational theory with spare parts inventory theory is developed. Case study research methodology is used and observations and findings are discussed within the research model in order to answer predefined hypotheses.

Findings

Regarding planning procedures, as well as how the maintenance concept and spare parts inventory are set up, the research concludes that the organizational structure and governance of the organization contributing to the humanitarian operation in question are more important than physical context of the operation itself. Further it is concluded that the maturity level, when it comes to inventory control issues, is different for the two cases in question. None of the cases, however, utilize modern optimization methods and tools.

Research limitations/implications

Qualitative data from the two case studies give the possibility for in depth analysis of the case study findings. Lack of quantitative data means that it has not been possible to statistically reject or accept the hypotheses. More research is needed to present a template and/or processes based on the findings in the research.

Practical implications

By applying the research model developed in this study, organizations that contribute to humanitarian disasters could more easily assess their own possibility for effective maintenance and spare parts inventory planning and set up.

Originality/value

The study of the planning and set up of maintenance and spare parts inventories for both military and NGO players in connection with a man‐made humanitarian disaster is new. Further, the development of spare parts inventory theory into organizational theory is relatively new. Limited research is available within this field. The paper should be of interest to both practitioners and researchers within the field of maintenance and spare parts inventories in general, and in connection with humanitarian disasters in particular.

Details

Management Research News, vol. 32 no. 11
Type: Research Article
ISSN: 0140-9174

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Article
Publication date: 31 May 2011

Umar Al‐Turki

The purpose of this study is to introduce a framework for developing a maintenance strategic plan that links the maintenance function with the corporate strategy and…

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7316

Abstract

Purpose

The purpose of this study is to introduce a framework for developing a maintenance strategic plan that links the maintenance function with the corporate strategy and integrates it with other functional areas. Within the proposed framework, a systematic process for maintenance strategic planning is described and key success factors that need special attention are identified.

Design/methodology/approach

An analytical methodology is adopted to develop a systematic approach for implementing the framework

Findings

The study finds that the involvement of major stakeholders as well as top management commitment is essential for the successful development of a maintenance strategic plan. The process of development of the strategic plan in maintenance differs from other areas because of its intangible benefits to the organization and special type of stakeholders. More emphasis should be put into handling senior management and other partners within the organization.

Practical implications

Senior maintenance managers and strategy developers may benefit from this study in developing their own plans. The process of developing the plan is well explained in a systematic manner that will drive the developers throughout the whole process.

Originality/value

The literature of strategic management and strategic issues in maintenance is summarized to set the foundation for the framework and to enrich the process of strategic planning with alternative strategies for different issues that will help in selecting the most appropriate strategy. The value of the paper is in its framework that puts elements of strategic planning together in an integrated framework.

Details

Journal of Quality in Maintenance Engineering, vol. 17 no. 2
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 8 May 2017

Harald Rødseth and Per Schjølberg

The purpose of this paper is to develop a novel model for maintenance backlog (MB) of physical assets and structure it in a framework for integrated planning (IPL).

Abstract

Purpose

The purpose of this paper is to develop a novel model for maintenance backlog (MB) of physical assets and structure it in a framework for integrated planning (IPL).

Design/methodology/approach

Reliability theory principles for modelling MB are used. Furthermore, to structure a framework for IPL, literature study combined with earlier case studies is used.

Findings

The framework for IPL facilitates the model of MB. In addition to providing real-time diagnosis indicators, MB is regarded as valuable information for decision support in IPL.

Originality/value

Development of MB applied to IPL.

Details

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

Keywords

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