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Article
Publication date: 30 May 2008

Salman T. Al‐Mishari and S.M.A. Suliman

The purpose of this paper is to develop a preventive maintenance (PM) model for auxiliary components whose failures may not necessarily correspond to system failure but…

Abstract

Purpose

The purpose of this paper is to develop a preventive maintenance (PM) model for auxiliary components whose failures may not necessarily correspond to system failure but rather to faster system degradation.

Design/methodology/approach

The concept of load sharing was utilized to build a suitable Markov model for the problem. Regression analysis was used to estimate the various transition rates of the model. A real field application was used to illustrate the model.

Findings

Models addressing the design of an optimal PM strategy for such a problem are rare in the literature. The load‐sharing concept was borrowed and found very useful to model this problem. Regression analysis based on real field data was also found to be useful to estimate the model transition rates.

Originality/value

This paper addresses a problem that is not given enough attention in the currently available literature. Available models assume that a PM activity will restore the equipment to an as new, or at least to a better, condition. There exist situations, however, where a PM activity does not amend any damage but instead slows down further deterioration.

Details

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

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Article
Publication date: 9 April 2020

Panagiotis Tsarouhas

The purpose of this paper is to implement the six sigma (SS) strategy in a bag sector under actual operating circumstances based on defining-measure-analyze-improve and…

Abstract

Purpose

The purpose of this paper is to implement the six sigma (SS) strategy in a bag sector under actual operating circumstances based on defining-measure-analyze-improve and control (DMAIC). During the project, several statistical tools and methods have been used efficiently to create inferences. Thus, to measure and enhance system efficiency, the author calculate reliability, availability and maintainability (RAM) indices. Based on this research, the author show how the SS method and RAM analysis are very helpful in determining maintenance intervals, as well as in planning and organizing the appropriate maintenance strategy.

Design/methodology/approach

This study introduces the step-by-step application of the DMAIC methodology for the identification and reduction of bag production line downtime and examines the present operations management. Thus, statistical techniques are used to analyze the failure and repair database. Pareto analysis, histograms and descriptive statistics at the machine and line-level of the historical data were conducted. Trend and serial correlation testing validated the hypothesis of independence and identical distribution of database was performed. In addition, with their best fit allocation, the RAM of both the bag production line and its machines was estimated at separate mission times.

Findings

The main goals of the applied method are to understand the nature of the downtime patterns and to accurately and quantitatively estimate the RAM characteristics of the bag production system. The assessment defines the production line's critical points, requiring further enhancement through an efficient maintenance approach. Therefore, by improving plant efficiency and safety, the author can decrease unplanned downtime and equipment failures.

Originality/value

This research is expected to serve as an attempt to conduct SS DMAIC methodology through RAM assessment and its impact on system efficiency under actual circumstances. The benefit of the methodology is that the manufacturing process is continuously monitored by suitable indicators, the use of which leads to a continuous improvement cycle.

Details

International Journal of Lean Six Sigma, vol. 12 no. 2
Type: Research Article
ISSN: 2040-4166

Keywords

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Article
Publication date: 10 March 2021

Ifeanyi Okpala, Chukwuma Nnaji and Ibukun Awolusi

This study aims to examine relationships between several key technology acceptance variables that predict workers’ wearable sensing devices (WSDs) acceptance in the…

Abstract

Purpose

This study aims to examine relationships between several key technology acceptance variables that predict workers’ wearable sensing devices (WSDs) acceptance in the construction industry by using technology acceptance model, theory of planned behavior and unified theory of acceptance and use of technology (UTAUT) model. The study proposes a hybrid conceptual model to measure construction field workers’ intentions to use WSDs and their usage behaviors. The study introduces variables that are instrumental in understanding and improving WSD acceptance in construction.

Design/methodology/approach

The study was carried out using a structured literature review, online survey and structural equation modeling. A total of 195 field workers across the USA, with experience in using WSDs, participated in the study.

Findings

Results indicate that all three theories predict WSD acceptance with variables explaining at least 89% of the variance in actual use, with the UTAUT outperforming other models (91%). However, the differences between the predictive power of these models were not statistically significant. A hybrid conceptual model is proposed using findings from the present study.

Practical implications

The study contributes to knowledge and practice by highlighting key variables that influence WSD acceptance. Findings from this study should provide stakeholders with critical insights needed to successfully drive WSD acceptance in the construction industry.

Originality/value

To the best of the authors’ knowledge, this is the first study that evaluates the predictive strength of multiple technology acceptance theories and models within the construction worker safety technology domain. Additionally, the study proposes a hybrid conceptual model which could provide practitioners and researchers with information pertinent to enhancing WSD acceptance.

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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

Keywords

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Article
Publication date: 14 June 2018

Omneya Kandil and Rasha Abd El Aziz

There is a great deal of concern among the Egyptian economy that small- and medium-sized enterprises’ (SMEs’) potentials are not fully used although they dominate it and…

Abstract

Purpose

There is a great deal of concern among the Egyptian economy that small- and medium-sized enterprises’ (SMEs’) potentials are not fully used although they dominate it and contribute to its success. The question is what challenges are preventing those SMEs from performing efficiently. This research aims to focus on examining the issues regarding the supply chain of Egyptian SMEs, exploring the areas that need improvement and assessing the impact of technology in enhancing their performance and whether they afford applying it.

Design/methodology/approach

In this research, semi-structured interviews were conducted at 14 Egyptian SMEs. Then, the business process at six of the fourteen SMEs was observed. After that, a representative sampling was applied and a company was chosen as a representative case company. Moreover, the selected company’s documents were analyzed to capture the full image of the current supply chain performance in Egyptian SMEs. Finally, the Six Sigma DMAIC approach was used to assess the effectiveness of the current supply chain and identify the problems faced and how to deal with these deficiencies.

Findings

The current process of the supply chain was analyzed and the result shows the obstacles and constrains facing SMEs in Egypt. Despite the clear benefits of radio frequency identification (RFID) technology, Egyptian SMEs still do not use it to solve their problems due to its high cost and their low budgets. However, the investigation concludes that SMEs in particular can benefit from the RFID technology and will be able to pay back the cost of the system applied after a certain period of time that is measured by calculating the breakeven point of having the RFID system against the current situation. As a result, improvements were realized and recommended for the organization.

Originality/value

This research develops a model that suits SMEs in the Egyptian market. The use of a case study approach with a quality measurement tool, namely, the Six Sigma DMAIC approach, especially after surveying several SMEs, and observing the business process at some of them, makes this a thorough investigation which proves that even SMEs can use the RFID technology despite its high cost that hinders its utilization. Thus, this research helps decision-makers in Egyptian SMEs make better informed decisions and guides them to when will they be able to pay back the cost of the system applied.

Details

International Journal of Lean Six Sigma, vol. 12 no. 1
Type: Research Article
ISSN: 2040-4166

Keywords

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Article
Publication date: 19 September 2019

Abdulrahim Shamayleh, Mahmoud Awad and Aidah Omar Abdulla

Medical technologies and assets are one of the main drivers of increasing healthcare cost. The rising number and complexity of medical equipment have forced hospitals to…

Abstract

Purpose

Medical technologies and assets are one of the main drivers of increasing healthcare cost. The rising number and complexity of medical equipment have forced hospitals to set up and regulate medical equipment management programs to ensure critical devices are safe and reliable. The purpose of this paper is to gain insights into maintenance management-related activities for medical equipment. The paper proposes applying a tailored reliability-centered maintenance (RCM) approach for maintenance activities selection for medical equipment. Such approach will support assets management teams in enhancing operation, decrease risk and cost, and ultimately improve health of patients served by these equipment.

Design/methodology/approach

The traditional RCM approach will be used with a focus on criticality reduction. By criticality, the authors refer to the severity of failures and occurrence. The proposed method relies on the use of reliability growth analysis for opportunity identification followed by a thorough failure mode and effect analysis to investigate major failure modes and propose ways to reduce criticality. The effectiveness of the proposed method will be demonstrated using a case of one of the leading obstetric and gynecological hospitals in United Arab Emirates and in the Gulf Cooperation Council region.

Findings

The case examines the relationship between the current practice of planned preventive maintenance and the failure rates of the equipment during its life span. Although a rigorous preventive maintenance program is implemented in the hospital under study, some critical equipment show an increasing failure rates. The analysis highlights the inability of traditional time-driven preventive maintenance alone in preventing failures. Thus, a systematic RCM approach focused on criticality is more beneficial and more time and cost effective than traditional time-driven preventive maintenance practices.

Practical implications

The study highlights the need for utilizing RCM approach with criticality as the most important prioritization criterion in healthcare. A proper RCM implementation will decrease criticality and minimize the risk of failure, accidents and possible loss of life. In addition to that, it will increase the availability of equipment, and reduce cost and time.

Originality/value

This paper proposes a maintenance methodology that can help healthcare management to improve availability and decrease the risk of critical medical equipment failures. Current practices in healthcare facilities have difficulty identifying the optimal maintenance strategy. Literature focused on medical maintenance approach selection is rather limited, and this paper will help in this discussion. In addition to that, the Association for the Advancement of Medical Instrumentation supports the initiative of adopting RCM on a large scale in healthcare. Therefore, this paper address the gap in the literature for medical equipment maintenance and the work is in line with the recommendation of leading healthcare association. The paper also presents statistical review of the total number of received maintenance work orders during one full year in the hospital under study. The analysis supports the need for more research to examine current practice and propose more effective maintenance approaches.

Details

Journal of Quality in Maintenance Engineering, vol. 26 no. 2
Type: Research Article
ISSN: 1355-2511

Keywords

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Article
Publication date: 10 May 2019

Fatemeh Shaker, Arash Shahin and Saeed Jahanyan

The purpose of this paper is to propose an integrative approach for improving failure modes and effects analysis (FMEA).

Abstract

Purpose

The purpose of this paper is to propose an integrative approach for improving failure modes and effects analysis (FMEA).

Design/methodology/approach

An extensive literature review on FMEA has been performed. Then, an integrative approach has been proposed based on literature review. The proposed approach is an integration of FMEA and quality function deployment (QFD). The proposed approach includes a two-phase QFD. In the first phase, failure modes are prioritized based on failure effects and in the second phase, failure causes are prioritized based on failure modes. The proposed approach has been examined in a case example at the blast furnace operation of a steel-manufacturing company.

Findings

Results of the case example indicated that stove shell crack in hot blast blower, pump failure in cooling water supply pump and bleeder valves failed to operate are the first three important failure modes. In addition, fire and explosion are the most important failure effects. Also, improper maintenance, over pressure and excess temperature are the most important failure causes. Findings also indicated that the proposed approach with the consideration of interrelationships among failure effects, failure mode and failure causes can influence and adjust risk priority number (RPN) in FMEA.

Research limitations/implications

As manufacturing departments are mostly dealing with failure effects and modes of machinery and maintenance departments are mostly dealing with causes of failures, the proposed model can support better coordination and integration between the two departments. Such support seems to be more important in firms with continuous production lines wherein line interruption influences response to customers more seriously. A wide range of future study opportunities indicates the attractiveness and contribution of the subject to the knowledge of FMEA.

Originality/value

Although the literature indicates that in most of studies the outcomes of QFD were entered into FMEA and in some studies the RPN of FMEA was entered into QFD as importance rating, the proposed approach is a true type of the so-called “integration of FMEA and QFD” because the three main elements of FMEA formed the structure of QFD. In other words, the proposed approach can be considered as an innovation in the FMEA structure, not as a data provider prior to it or a data receiver after it.

Details

International Journal of Quality & Reliability Management, vol. 36 no. 8
Type: Research Article
ISSN: 0265-671X

Keywords

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Article
Publication date: 26 August 2014

Alireza Shokri, David Oglethorpe and Farhad Nabhani

The purpose of this paper is to investigate the implementation of the Six Sigma methodology as a systematic business strategy and quality initiative to improve the…

Abstract

Purpose

The purpose of this paper is to investigate the implementation of the Six Sigma methodology as a systematic business strategy and quality initiative to improve the critical logistical measures within small-to-medium-sized food distributors.

Design/methodology/approach

The first stage was the conducting of structured questionnaires to verify the applicability in terms of capability, resources and culture in the targeted industry. The second stage was the implementation of two industrial case studies to investigate the impacts of Six Sigma on logistical measures.

Findings

It was found that Six Sigma is applicable and beneficial in small-to-medium-sized food distributors. It was also found that required training, personal characteristics of managers, size of the organisation, education level and workplace of the employees are the most effective elements to adopt Six Sigma for these organisations.

Research limitations/implications

Cultural factors including high level of secrecy in information exchange, ambiguity and lack of knowledge, sampling population and requirement of ISO9000 were found as key issues in implications of this research programme.

Practical implications

Six Sigma programme can be used as a problem solving practice, a performance measurement tool and a business strategy in small food distributors through more simplified approach to improve the ultimate food supply chain.

Originality/value

This research paper studies the application of Six Sigma in food logistics SME sector by having integrated research approach, and also provides a practical scientific and rigorous quality and profitability improvement methodology for smaller food distribution organisations with limited resources.

Details

Journal of Manufacturing Technology Management, vol. 25 no. 7
Type: Research Article
ISSN: 1741-038X

Keywords

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Article
Publication date: 6 August 2010

B. Tjahjono, P. Ball, V.I. Vitanov, C. Scorzafave, J. Nogueira, J. Calleja, M. Minguet, L. Narasimha, A. Rivas, A. Srivastava, S. Srivastava and A. Yadav

The purpose of the work presented in this paper is to capture the current state of Six Sigma as well as to document the current practices of Six Sigma through a systematic…

Abstract

Purpose

The purpose of the work presented in this paper is to capture the current state of Six Sigma as well as to document the current practices of Six Sigma through a systematic literature review so as to extend and update the previous work of Brady and Allen.

Design/methodology/approach

The approach to this paper is to answer the questions such as “what is Six Sigma?”, “what are the applications of the Six Sigma?”, “what are the main enablers and barriers to its application?” and “what are the emerging trends?” These questions are used to guide the search of papers from various publication databases even if it is expected that existing literature might not be sufficiently developed to translate each question directly into a finding. The literature is then analysed and the major emerging themes are presented.

Findings

Seven key findings (topics on which the views of the authors converged) and two issues (topics on which authors had differing views) have been established. These include the interpretation of Six Sigma, tools and techniques, implementation of Six Sigma, benefits, adoption, enablers and links to other disciplines.

Originality/value

The systematic literature review approach used in this paper allows emerging trends and issues in Six Sigma to be highlighted in a structured and thematic manner, enabling the future work to progress as Six Sigma continues to develop and evolve. The findings also open up new opportunities to apply Six Sigma in the fields that are not widely explored before for instance sustainability and product‐service systems.

Details

International Journal of Lean Six Sigma, vol. 1 no. 3
Type: Research Article
ISSN: 2040-4166

Keywords

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Article
Publication date: 25 January 2011

A.J. Thomas, J. Chard, E. John, A. Davies and M. Francis

The purpose of this paper is to propose a bearing replacement strategy which employs the Monte Carlo simulation method. In this contribution the method is used to estimate…

Abstract

Purpose

The purpose of this paper is to propose a bearing replacement strategy which employs the Monte Carlo simulation method. In this contribution the method is used to estimate the economic impact on the selection of a particular bearing change strategy. The simulation demonstrates that it is possible to identify the most cost‐effective approach and thus suggests a suitable bearing replacement policy, which in turn allows engineers to develop the appropriate maintenance schedules for their company.

Design/methodology/approach

The paper develops the Monte Carlo method through a case study approach. Three case studies are presented. The first study is detailed and chronicles the design, development and implementation of the Monte Carlo method as a means of defining a bearing replacement strategy within a subject company. The second and third cases outline the application of the Monte Carlo method in two different environments. These applications made it possible to obtain proof of concept and also to further prove the effectiveness of the Monte Carlo simulation approach.

Findings

An effective development of the Monte Carlo approach is proposed and the effectiveness of the method is subsequently evaluated, highlighting the benefits to the host organization and how the approach led to significant improvement in machinery reliability through a bearing replacement strategy.

Practical implications

The design, development and implementation of a bearing replacement strategy provide a simple yet effective approach to achieving significant improvements in system reliability and performance through less downtime and greater cost savings. The paper offers practising maintenance managers and engineers a strategic framework for increasing productive efficiency and output.

Originality/value

The proposed bearing replacement strategy contributes to the existing knowledge base on maintenance systems and subsequently disseminates this information in order to provide impetus, guidance and support towards increasing the development companies in an attempt to move the UK manufacturing sector towards world‐class manufacturing performance.

Details

International Journal of Quality & Reliability Management, vol. 28 no. 2
Type: Research Article
ISSN: 0265-671X

Keywords

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