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Article
Publication date: 1 July 1999

Hans Löfsten

One of the main problems, when choosing between preventive or corrective maintenance for the production and maintenance departments in the eight firms studied, is to…

Abstract

One of the main problems, when choosing between preventive or corrective maintenance for the production and maintenance departments in the eight firms studied, is to attempt to establish the state of a particular production system or individual production line. In order to carry out a cost analysis it is imperative to be able to measure how preventive maintenance will both reduce the deterioration of the state of the object and improve the state of the object at the point in time that the maintenance is carried out. This can be explained by the fact that the departments lack methods for measuring and estimating the effects. The model presented in this paper determines whether to schedule preventive maintenance and the model trades off the capital costs of preventive maintenance and the sum of corrective maintenance and down‐time costs based on the production line’s state.

Details

International Journal of Operations & Production Management, vol. 19 no. 7
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 12 April 2018

Shirley Jin Lin Chua, Najilah Bt Zubbir, Azlan Shah Ali and Cheong Peng Au-Yong

Preventive maintenance is an effective maintenance strategy to ensure the constant and efficient usage of building systems and their components. The reactive-based…

Abstract

Purpose

Preventive maintenance is an effective maintenance strategy to ensure the constant and efficient usage of building systems and their components. The reactive-based maintenance as the main strategy in high-rise residential buildings is a concern as the maintenance output resulting from the strategy could not achieve the standard level of performance. The purpose of this paper is to identify the characteristics of preventive maintenance and establish the relationship with maintenance performance in high-rise residential buildings.

Design/methodology/approach

The characteristics of preventive maintenance and maintenance performance parameters were identified through the literature review. A quantitative approach was adopted, where a questionnaire was distributed to the maintenance personnel of high-rise residential buildings. Then, ranking analysis and correlation were conducted to produce findings that help to achieve the research objectives.

Findings

The research findings indicate that there are seven maintenance characteristics significantly correlated with maintenance performance indicators (maintenance costs deviation, time variance of maintenance work, customer service and downtime rate). It is recommended that these characteristics are considered during the execution of preventive maintenance as they have a significant effect on the maintenance performance.

Originality/value

The extensive literature suggests the relationship between the characteristics of preventive maintenance and maintenance performance, but is still questionable. Thus, this research investigates the relationship between preventive maintenance characteristic and maintenance performance for high-rise residential buildings in Malaysia. The findings of the research can act as a guide for maintenance personnel to optimise maintenance performance by focusing on the highlighted preventive maintenance characteristics.

Details

International Journal of Building Pathology and Adaptation, vol. 36 no. 2
Type: Research Article
ISSN: 2398-4708

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Article
Publication date: 28 September 2010

Slah Samet, Anis Chelbi and Fayçal Ben Hmida

The purpose of this paper is to study the evolution of a system stationary availability and determine the optimal preventive maintenance period, which maximises it in a…

Abstract

Purpose

The purpose of this paper is to study the evolution of a system stationary availability and determine the optimal preventive maintenance period, which maximises it in a context where preventive and corrective maintenance actions are imperfect and have non‐negligible durations.

Design/methodology/approach

The quasi‐renewal process approach and a (p, q) rule are respectively used to model corrective and preventive maintenance. Considering the durations of the preventive and corrective maintenance actions as well as their respective efficiency extents, a mathematical model and a numerical algorithm are developed in order to compute the system stationary availability.

Findings

It has been proven that for any given situation regarding the system, the repair and preventive maintenance efficiency extents, and the downtime durations for preventive and corrective maintenance, there is necessarily a finite optimal period T* of preventive maintenance which maximises the system stationary availability. A sufficient condition for the uniqueness of the optimal solution has also been derived. Numerical examples illustrated how preventive and corrective maintenance efficiency extents affect simultaneously the system optimal availability.

Practical implications

The study considers a general industrial framework where preventive and corrective maintenance actions are imperfect. In fact, neither the best‐qualified technicians nor the most suitable tools or spare parts are found to carry out maintenance actions. In such a context for a large variety of technical systems, when implementing preventive maintenance policies one should take into account the efficiency extents of maintenance actions as well as their durations in order to evaluate and optimise the system availability. The paper provides maintenance managers with a decision model allowing not only the computation and optimisation of system availability, but also the investigation of how preventive and corrective maintenance efficiency extents affect simultaneously the system optimal availability. The proposed model also allows one to find to what extent corrective actions ineffectiveness should be tolerated without having an important availability loss.

Originality/value

The paper proposes a modified formulation of the quasi‐renewal process taking into account the non‐negligible duration of corrective maintenance actions and periodic preventive maintenance. A new numerical algorithm is also developed in this context to compute the quasi‐renewal function that it is impossible to find in closed form. This allowed the computation and optimisation of system stationary availability.

Details

Journal of Quality in Maintenance Engineering, vol. 16 no. 4
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 1 April 2000

Michael Vineyard, Kwasi Amoako‐Gyampah and Jack R. Meredith

This paper presents the results of a case/simulation study that evaluated a number of potential maintenance policies for a flexible manufacturing system (FMS). Empirical…

Abstract

This paper presents the results of a case/simulation study that evaluated a number of potential maintenance policies for a flexible manufacturing system (FMS). Empirical data were used to structure the operation of the FMS, and to simulate its failures and repairs on the shop floor. Five maintenance policies – corrective, 30‐day preventive, 90‐day preventive, on‐failure opportunistic, and 30‐day opportunistic – were compared on four performance criteria: equipment utilization, machine downtime, through‐put, and average flow time. The “30‐day opportunistic” policy performed best overall, although the “corrective” policy was a close second, outperformed only in the area of equipment utilization. The “on‐failure opportunistic” policy performed poorly on every measure of system performance.

Details

International Journal of Operations & Production Management, vol. 20 no. 4
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 7 October 2014

Behnam Emami-Mehrgani, Sylvie Nadeau and Jean-Pierre Kenné

The analysis of the optimal production and preventive maintenance with lockout/tagout planning problem for a manufacturing system is presented in this paper. The…

Abstract

Purpose

The analysis of the optimal production and preventive maintenance with lockout/tagout planning problem for a manufacturing system is presented in this paper. The considered manufacturing system consists of two non-identical machines in passive redundancy producing one type of part. These machines are subject to random breakdowns and repairs. The purpose of this paper is to minimize production, inventory, backlog and maintenance costs over an infinite planning horizon; in addition, it aims to verify the influence of human reliability on the inventory levels for illustrating the importance of human error during the maintenance and lockout/tagout activities.

Design/methodology/approach

This paper is different compared to other research projects on preventive maintenance and lockout/tagout. The influence of human error on lockout/tagout as well as on preventive maintenance activities are presented in this paper. The preventive maintenance policy depends on the machine age. For the considered manufacturing system the optimality conditions are provided, and numerical methods are used to obtain machine age-dependent optimal control policies (production and preventive maintenance rates with lockout/tagout). Numerical examples and sensitivity analysis are presented to illustrate the usefulness of the proposed approach. The system capacity is described by a finite-state Markov chain.

Findings

The proposed model taking into account the preventive maintenance activities with lockout/tagout and human error jointly, instead of taking into account separately. It verifies the influence of human error during preventive maintenance and lockout/tagout activities on the optimal safety stock levels using an extension of the hedging point structure.

Practical implications

The model proposed in this paper might be extended to manufacturing systems, but a number of conditions must be met to make effective use of it.

Originality/value

The originality of this paper is to consider the preventive maintenance activities with lockout/tagout and human error simultaneously. The control policy is obtained in order to find the solution for the considered manufacturing system. This paper also brings a new vision on the importance of human reliability during preventive maintenance and lockout/tagout activities.

Details

Journal of Quality in Maintenance Engineering, vol. 20 no. 4
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 26 October 2010

Divya Pandey, Makarand S. Kulkarni and Prem Vrat

The purpose of this paper is to develop a model that incorporates the effect of rejection cost on optimal maintenance planning decisions. Such a model will help in further…

Abstract

Purpose

The purpose of this paper is to develop a model that incorporates the effect of rejection cost on optimal maintenance planning decisions. Such a model will help in further modelling the interrelationships between preventive maintenance and quality control policy.

Design/methodology/approach

In this paper a model is developed for obtaining optimal preventive maintenance interval based on block replacement policy to incorporate the effect of rejection cost. An illustrative example is presented to compare economic performance of the proposed model (M2) and the conventional model (M1). Model M1 stands for optimal preventive maintenance interval without considering the rejection cost and model M2 stands for optimal preventive maintenance interval considering the rejection cost. The comparison is done for different production rates, costs of rejection and cost of lost production. The impact of control chart parameters on preventive maintenance decision is also studied.

Findings

In this paper it is found that model M2 gives better results as compared to model M1. The improvements are more significant at higher production rate, lower cost of lost production and higher rejection cost. The impact of control chart parameters on preventive maintenance planning decision becomes significant as the cost of rejection increases.

Research limitations/implications

Conventionally only the down time cost and the cost of repair/replacement are considered for optimal maintenance interval determination. However in the case of machine tools, failure may not always bring the system immediately under complete breakdown but may lead to the functioning of system with degraded performance like process shift from in‐control state to out‐of‐control state. It results into poor quality and thus may lead to higher rejection cost. The cost of rejections may be significantly high in some production systems and, if not incorporated properly during maintenance planning decision may adversely affect the effectiveness of the maintenance planning. Hence the approach presented in this paper gives a better way of maintenance planning. Though the work presented here is illustrated through a simple example considering a single component operating as a part of machine, the approach can be extended to multi‐component system.

Originality/value

The outcome is of significant value as it opens up a new perspective into the development of integrated model for maintenance planning and quality control decisions for reducing the operating costs associated with the manufacturing processes.

Details

Journal of Advances in Management Research, vol. 7 no. 2
Type: Research Article
ISSN: 0972-7981

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Article
Publication date: 1 April 1991

Festus O. Olorunniwo and Ariwodo Izuchukwu

Although each maintenance task performed on an item of equipment may enhance its reliability, neither preventive nor overhaul maintenance can return the equipment to…

Abstract

Although each maintenance task performed on an item of equipment may enhance its reliability, neither preventive nor overhaul maintenance can return the equipment to good‐as‐new condition. Applying the concept of maintenance improvement factors to both types of maintenance, mathematical models are developed that are used to generate preventive and overhaul maintenance schedules. Examples are provided to demonstrate the sensitivity of the schedules to model parameters.

Details

International Journal of Quality & Reliability Management, vol. 8 no. 4
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 1 June 2001

Hajime Yamashina and Shunsuke Otani

The purpose of this paper is to properly plan the preventive maintenance schedule for multiple elevators and optimize the number of maintenance workers.The total amount of…

Abstract

The purpose of this paper is to properly plan the preventive maintenance schedule for multiple elevators and optimize the number of maintenance workers.The total amount of the maintenance cost consisting of the labor cost, the part cost, and the quality cost (the loss evaluated in terms of cost, to be incurred when an elevator breaks down) is to be minimized.The method is presented of setting up the optimal preventive maintenance schedule on a long‐term basis by rescheduling the contents of schedule dynamically and flexibly in accordance with the ever‐changing maintenance conditions, taking the possibility of the future occurrence of failure into consideration. From numerical experiments, the validity of the proposal procedure for planning the preventive maintenance schedule and the effectiveness of considering the possibility of the future occurrence of failure in planning the schedule are shown, and the optimal number of maintenance workers can be decided.

Details

Journal of Quality in Maintenance Engineering, vol. 7 no. 2
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 17 August 2010

Kamran S. Moghaddam and John S. Usher

This paper seeks to develop and present a new mathematical formulation to determine the optimal preventive maintenance and replacement schedule of a system.

Abstract

Purpose

This paper seeks to develop and present a new mathematical formulation to determine the optimal preventive maintenance and replacement schedule of a system.

Design/methodology/approach

The paper divides the maintenance‐planning horizon into discrete and equally‐sized intervals and in each period decide on one of three possible actions: maintain the system, replace the system, or do nothing. Each decision carries a specific cost and affects the failure pattern of the system. The paper models the cases of minimizing total cost subject to a constraint on system reliability, and maximizing the system reliability subject to a budgetary constraint on total cost. The paper presents a new mathematical function to model an improvement factor based on the ratio of maintenance and repair costs, and show how it outperforms fixed improvement factor models by analyzing the effectiveness in terms of cost and reliability of the system.

Findings

Optimal decisions in each period over a planning horizon are sought such that the objectives and the requirements of the system can be achieved.

Practical implications

The developed mathematical models for this improvement factor can be used in theoretical and practical situations.

Originality/value

The presented models are effective decision tools that find the optimal solution of the preventive maintenance and replacement scheduling problem.

Details

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

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Article
Publication date: 30 May 2008

Anis Chelbi, Nidhal Rezg and Mehdi Radhoui

The purpose of this study is to propose and model an integrated production‐maintenance strategy for unreliable production systems producing conforming and non‐conforming items.

Abstract

Purpose

The purpose of this study is to propose and model an integrated production‐maintenance strategy for unreliable production systems producing conforming and non‐conforming items.

Design/methodology/approach

The proposed integrated policy is defined and modeled mathematically.

Findings

The paper focuses on finding simultaneously the optimal values of the lot size Q and the age T at which preventive maintenance must be performed. These values minimize the total average cost per time unit over an infinite horizon.

Practical implications

The paper attempts to integrate in a single model the three main aspects of any manufacturing system: production, maintenance, and quality. It deals with the lot‐sizing problem for a production system which may randomly shift to an out‐of‐control state and produce non‐conforming units. The system is submitted to an age‐based preventive maintenance policy. The effect of performing preventive maintenance on quality‐ and inventory‐related costs is shown through a numerical example.

Originality/value

The paper proposes an integrated model that links EMQ, quality and an age‐based preventive maintenance policy. It is shown that performing preventive maintenance yields reduction in inventory‐ and quality‐related costs.

Details

Journal of Quality in Maintenance Engineering, vol. 14 no. 2
Type: Research Article
ISSN: 1355-2511

Keywords

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