Maintenance policy selection model – a case study in the palm oil industry

Purpose – An optimal maintenance policy is key to the improvement of the availability and reliability of a system at an acceptable level without a significant increase in investment. However, the selection process is a complicated task because it requires in-depth knowledge on maintenance policies and on the technical requirements of maintenance. The difficulties and complexity of the selection process arise from the combination of conflicting maintenance constraints such as available spares, size of workforce, and maintenance skills. The paper aims to discuss these issues. Design/methodology/approach – The proposed maintenance policy selection (MPS) model is separated into three major phases. The first phase identifies the critical system (CS) based on failure frequency. The failure mechanism in the CS is then analyzed by using a failure mode and effect analysis in the second phase. In the third phase, a multi-criteria decision making method, called the technique for order of preference by similarity to ideal solution, is adopted to identify an optimal maintenance policy that can minimize the failures. Findings – Through a case study, preventive maintenance was selected as the optimal maintenance policy for the reduction of system failures. The results obtained from the case study not only provide evidence of the feasibility and practicability of the developed model, but also test the acceptability and rationale of the developed model from the industry perspective. Valuable knowledge and experience from employees were extracted and utilized through the proposed model to rank the optimal maintenance policy based on the capability to reduce failure. Originality/value – The practicality of the MPS model is justified through an implementation in the palm oil industry. The application of the MPS model can also be extended to other manufacturing industries.

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Imperfect maintenance model for estimating aircraft fleet availability

Aircraft Engineering and Aerospace Technology ◽

10.1108/aeat-10-2015-0221 ◽

2017 ◽

Vol 89 (2) ◽

pp. 338-346 ◽

Cited By ~ 5

Author(s):

Aleksandar Knezevic ◽

Ljubisa Vasov ◽

Slavisa Vlacic ◽

Cedomir Kostic

Keyword(s):

Intermediate Level ◽

Imperfect Maintenance ◽

Maintenance Policy ◽

Content Type ◽

Reliability Parameters ◽

Optimal Maintenance ◽

Maintenance Policies ◽

Optimal Maintenance Policy ◽

Maintenance Model

Purpose The purpose of this paper is to define conditions under which improved availability of fleet of G-4 jet trainers is obtained, and optimization of intermediate-level maintenance through imperfect maintenance model application. This research has been conducted based on available knowledge, and experience gained by performing intermediate-level maintenance of Serbian Air Force aircrafts. Design/methodology/approach Analysis of the data collected from daily maintenance reports, and the analysis of maintenance technology and organization, was performed. Based on research results, a reliability study was performed. Implementation of imperfect maintenance with its models of maintenance policies (especially a quasi-renewal process and its treating of reliability and optimal maintenance) was proposed to define new maintenance parameters so that the greater level of availability could be achieved. Findings The proposed methodology can potentially be applied as a simple tool to estimate the present maintenance parameters and to quickly point out some deficiencies in the analyzed maintenance organization. Validation of this process was done by conducting a reliability case study of G-4 jet trainer fleet, and numerical computations of optimal maintenance policy. Research limitations/implications The methodology of the availability estimation when reliability parameters were not tracked by the maintenance organization, and optimization of intermediate-level maintenance, has so far been applied on G-4 jet trainers. Moreover, it can be potentially applied to other aircraft types. Originality/value Availability estimation and proposed optimization of intermediate maintenance is based on a survey of data for three years of aircraft fleet maintenance. It enables greater operational readiness (due to a military rationale) with possible cost reduction as a consequence but not as a goal.

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Opportunistic maintenance (OM) as a new advancement in maintenance approaches

Journal of Quality in Maintenance Engineering ◽

10.1108/jqme-04-2013-0018 ◽

2014 ◽

Vol 20 (2) ◽

pp. 98-121 ◽

Cited By ~ 42

Author(s):

Hasnida Ab-Samat ◽

Shahrul Kamaruddin

Keyword(s):

Current Trend ◽

Replacement Policy ◽

Practical Significance ◽

Clear Understanding ◽

Maintenance Policy ◽

Opportunistic Maintenance ◽

Content Type ◽

Research Areas ◽

Optimal Maintenance ◽

Optimal Maintenance Policy

Purpose – This paper reviews the literature on opportunistic maintenance (OM) as new advance maintenance approach and policy. The purpose of this paper is to conceptually identify common principle and thereby provide absolute definition, concept and characteristics of this policy. Design/methodology/approach – A conceptual analysis was conducted on various literatures to clarify a number of principle and concepts as a method for understanding information on OM. The analysis involves the process of separating the compound terms used in the literatures into a few parts, analyse them and then recombining them to have more clear understanding of the policy. Findings – The paper discussed the maintenance approach, genealogy, principle, concept and applications of OM both in numerical analysis and real industry. OM policy is developed based on combination of age replacement policy and block replacement policy and in practical; OM is applied as the combination of corrective maintenance which is applied when any failure occurred, with preventive maintenance (PM) – a planned and scheduled maintenance approach to prevent failure to happen. Any machine shutdown or stoppages due to failure is the “opportunity” to conduct PM even though it is not as planned. The characterization of OM was provided in order to present its theoretical novelty for researchers and practical significance for industries. Practical implications – To date, there is no publication that reviews the OM in-depth and provides clear understanding on the topic. Therefore, this paper aims to show lineage of OM and the current trend in researches. This discussion will pave the way of new research areas on this optimal maintenance policy. Clear definition and principle of OM provided in this paper will trigger interest in its practicality as well as aid industries to understand and conduct OM in operation plant. Originality/value – This paper discussed the available literature about OM in various perspectives and scopes for further understanding of the topic by maintenance management professionals and researchers. Therefore, OM can be widely studied and applied in real industry as it is an effective and optimal maintenance policy.

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Development of a model for optimal maintenance policy selection

European J of Industrial Engineering ◽

10.1504/ejie.2014.059349 ◽

2014 ◽

Vol 8 (1) ◽

pp. 50 ◽

Cited By ~ 7

Author(s):

Siew Hong Ding ◽

Shahrul Kamaruddin ◽

Ishak Abdul Azid

Keyword(s):

Maintenance Policy ◽

Policy Selection ◽

Optimal Maintenance ◽

Optimal Maintenance Policy

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Development of opportunistic maintenance policy towards optimal maintenance system (OPTOMS) model

Journal of Quality in Maintenance Engineering ◽

10.1108/jqme-07-2018-0057 ◽

2019 ◽

Vol 26 (1) ◽

pp. 129-165

Author(s):

Hasnida Ab-Samat ◽

Shahrul Kamaruddin

Keyword(s):

Support System ◽

Model Development ◽

Maintenance Policy ◽

Opportunistic Maintenance ◽

Effect Analysis ◽

Content Type ◽

Maintenance System ◽

Machine Reliability ◽

Optimal Maintenance

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.

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