Maintenance and Availability Study of a Manufacturing Company: Case Study of a Flour Mill Company

2013 ◽  
Vol 824 ◽  
pp. 584-594
Author(s):  
Ralph O. Edokpia ◽  
P.C. Oparah
Keyword(s):  
Preventive Maintenance ◽  
Maintenance Strategy ◽  
Production Ratio ◽  
Optimal Replacement ◽  
Equipment Availability ◽  
Flour Mill ◽  
Manufacturing Company ◽  
Maintenance Activities

The focus of this study is to carry out a maintenance and availability study of a manufacturing company using a flour mill company as a case study. To properly evaluate the maintenance activities of the company, some sets of performance ratios were used. The performance ratios used in the assessment include; equipment availability, maintenance to production ratio, equipment shutdown intensity, overall equipment effectiveness. The result obtained showed that equipment availability was 93.7%, 93.38%, 93.18%, 92.42%, 91.28%, for year 2006, 2007, 2008, 2009 and 2010 respectively. Maintenance to production ratio was 0.03, 0.04, 0.04, 0.05, and 0.06 for year 2006, 2007, 2008, 2009 and 2010 respectively. Intensity of shutdown ranged from 0.07, 0.7, 0.07, 0.08, and 0.10 for year 2006, 2007, 2008, 2009 and 2010 respectively. Overall equipment effectiveness was 86.30%, 85.10%, 84.92%, 83.33%, 81.40% for year 2006, 2007, 2008, 2009 and 2010 respectively. Comparing the results obtained, revealed the following; the availability of the mill declined with age, from 93.7% in 2006 to 91.28% in 2010. The proportion of time spent on maintenance as against production was on the increase from 0.03 in 2006 to 0.06 in 2010. The intensity of shutdown of the mill increased by the years from 0.07 in 2006 to 0.10 in 2010. The overall equipment effectiveness of the mill was unsatisfactory from the year when optimal replacement was supposed to have been done (year 2009), according to existing standards. OEE was 83.33% in 2009 and 81.40% in 2010. Further study also revealed that an average of 244 million was lost annually due to down time. For optimal availability, the most effective maintenance strategy needs to be adopted and preventive maintenance is recommended.

An evaluation of preventive maintenance framework in an Italian manufacturing company

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Kaustav Kundu ◽  
Fabiana Cifone ◽  
Federica Costa ◽  
Alberto Portioli-Staudacher ◽  
Matteo Rossini
Keyword(s):  
Preventive Maintenance ◽  
Management Plan ◽  
Added Value ◽  
Content Type ◽  
Starting Point ◽  
Manufacturing Company ◽  
World Class ◽  
Maintenance Model ◽  
First Time

PurposeThe purpose of this paper is to provide the description of an original framework for maintenance management plan development. The research aims to use in an integrated way different World Class Manufacturing (WCM)-based tools, in order to obtain a model which can be used for preventive maintenance in different industrial contexts.Design/methodology/approachIn this research, a conceptual framework of preventive maintenance was described and then it was evaluated through a qualitative study in an Italian company. The company was chosen based on an initial interview with the operations team and the model area was selected. Then, the location was reorganized in order to obtain a green field which could sustain the implementation of the framework tools.FindingsThe case study was carried out in a small-medium manufacturing company which produces quick-release couplings and multiconnections, ranging from medium to ultra-high pressure. The defined framework has proved to be easy to implement in a company with a corrective maintenance plan, allowing the maintenance department to embrace the preventive maintenance culture. The maintenance model has been well received from the employees.Practical implicationsThe framework allows a standardization of maintenance plans. Firstly, the standardization design itself allows finding previous wastes and consequent improvement areas. Then, it brings the improvement of a single machine which impacts all other machines in its family.Originality/valueThe added value of this study is the ability to integrate different WCM-based tools. Since the framework depicts a step-by-step process; it is also a starting point for companies that want to approach preventive maintenance for the first time.

scholarly journals Preventive maintenance features specific to offset printing machines

2021 ◽  
Vol 343 ◽  
pp. 08012
Author(s):  
Emilia Bălan ◽  
Liviu Berculescu ◽  
Răzvan-George Răcheru ◽  
Dorin Vasile Piţigoi ◽  
Lucia Adăscăliţa
Keyword(s):  
Preventive Maintenance ◽  
Offset Printing ◽  
Printing Process ◽  
Machine Performance ◽  
Continuous Quality ◽  
Study Results ◽  
Maintenance Activities ◽  
Printing Processes

In the printing industry, where production never stops, it is very important to continuously maintain machine performance. If a machine breaks down, the production will stop and it will disturb the production process. Therefore, the maintenance system must be managed efficiently to solve those problems. The paper presents the study results on continuous quality improvement of offset printing using preventive maintenance features. Offset printing is a process that involves a multitude of variables, independent and interdependent factors. The offset printing process was analyzed and the factors that have a significant influence on the quality of the process and the products made were identified. The defects that may occur during the printing process and the causes thereof have also been identified and the types of non-conformities of the end products were estabilished. The experimental method was used. The case study was conducted on Manroland 508. For the planning of preventive maintenance activities, the duration of the maintenance works necessary to ensure the proper functioning of the offset printing machines was established. Finally, maintenance activities that would guarantee and continuously improve the quality of the printing processes and the printed products were issued.

scholarly journals Application of system analysis and preventive maintenance on cigarette packer line

2021 ◽  
Vol 12 (2) ◽  
pp. 439-449
Author(s):  
Mohamed fathi Karoui ◽  
Mohamed Najeh Lakhoua
Keyword(s):  
Preventive Maintenance ◽  
System Analysis ◽  
Decision Support Tool ◽  
Support Tool ◽  
Industrial Manufacturing ◽  
Repair Costs ◽  
Equipment Availability ◽  
Optimal Maintenance ◽  
Production Group

The use of system analysis and preventive maintenance in today’s industry becomes a necessity as it increases equipment availability. These methods reduce the frequency of failures. The objective of this article is to present a case study for improving the reliability and availability of a production group in an industrial enterprise. Next, we present an improvement in maintenance. Finally, we present and discuss the application of preventive maintenance. Through an industrial manufacturing model, we will combine three tools; SADT modelling, the FMECA analysis and the Pareto diagram to arrive at an optimal maintenance approach that will be a decision support tool in order to minimize the repair costs and the downtime of the system. 

Criticality analysis for preventive maintenance optimization purposes in gas network infrastructures

2018 ◽  
Vol 232 (4) ◽  
pp. 464-472
Author(s):  
Javier Serra Parajes ◽  
Adolfo Crespo Márquez ◽  
Antonio Sola Rosique
Keyword(s):  
Preventive Maintenance ◽  
Maintenance Optimization ◽  
Maintenance Strategy ◽  
Maintenance Strategies ◽  
Gas Network ◽  
Operation And Maintenance ◽  
Relative Value ◽  
Criticality Analysis ◽  
Corporate Level

Identification and quantification of cost and value of industrial assets is a field in which much terminology has been developed. When we try to analyze the importance of an asset for our business, the discussion about its costs should not be separated from the value provided by the asset. Most of the time, managers use the term “cost” because it seems to be more objective. The concept of value is more subjective and more difficult to define. However, we shall henceforth use definitions as amortization, inflation, or replacement value in order to simplify the concept of “value” to improve our decisions. The economic retribution of the facilities is based on a legal normative for regulated companies, so the concept of “cost” may turn out to be quite useless. Therefore, it is important to use a methodology that allows us to estimate the value of our assets. We have developed a criticality analysis of our infrastructure in order to assess the relative value of these items for the company. The target is to optimize the operation and maintenance strategies at a corporate level. This must have a relevant impact on the OPEX of our company, and there may also be an impact on future CAPEX. This article is a case study of the methodology and presents clear examples of how operation and maintenance strategy is transformed according to criticality assessments.

Improvements in Web Based ERP Software Architecture as Implemented on the Cloud

2017 ◽  
Vol 7 (11) ◽  
pp. 22
Author(s):  
Shruti Makarand Kanade
Keyword(s):  
Health Care ◽  
Information Technology ◽  
Cloud Computing ◽  
Software Architecture ◽  
Enterprise Resource Planning ◽  
Resource Planning ◽  
Web Based ◽  
Manufacturing Company ◽  
Erp Software

 Cloud computing is the buzz word in today’s Information Technology. It can be used in various fields like banking, health care and education. Some of its major advantages that is pay-per-use and scaling, can be profitably implemented in development of Enterprise Resource Planning or ERP. There are various challenges in implementing an ERP on the cloud. In this paper, we discuss some of them like ERP software architecture by considering a case study of a manufacturing company.

Assessing Pruning Knowledge towards Effective Tree Maintenance: A case study of four Local Authorities in Malaysia

2020 ◽  
Vol 5 (13) ◽  
pp. 223
Author(s):  
Norainiratna Badrulhisham ◽  
Noriah Othman
Keyword(s):  
Publishing House ◽  
Knowledge Level ◽  
Local Authorities ◽  
The Public ◽  
Risk Of Injury ◽  
International Publishing ◽  
Maintenance Activities ◽  
Tree Pruning ◽  
Open Access Article

Pruning is one of the most crucial tree maintenance activities which give an impact on the tree's health and structure. Besides, improper pruning will contribute to the risk of injury to property and the public. This study aims to assess pruning knowledge among four Local authorities in Malaysia. Results found that 69.3 percent of tree pruning workers have a Good pruning knowledge level. However, Topping, pruning types and pruning cut dimension shows the lowest mean percentage of the correct answer. The findings also show that there is a significant positive relationship between pruning knowledge and education level and frequency attending pruning courses.Keywords: Tree pruning; knowledge; sustainable practices; urban treeseISSN: 2398-4287 © 2020. The Authors. Published for AMER ABRA cE-Bs by e-International Publishing House, Ltd., UK. This is an open access article under the CC BYNC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer–review under responsibility of AMER (Association of Malaysian Environment-Behaviour Researchers), ABRA (Association of Behavioural Researchers on Asians) and cE-Bs (Centre for Environment-Behaviour Studies), Faculty of Architecture, Planning & Surveying, Universiti Teknologi MARA, Malaysia.DOI: https://doi.org/10.21834/e-bpj.v5i13.2054 

scholarly journals Life Cycle Costing: Understanding How It Is Practised and Its Relationship to Life Cycle Management—A Case Study

2020 ◽  
Vol 12 (8) ◽  
pp. 3252 ◽  
Author(s):  
Marianna Lena Kambanou
Keyword(s):  
Life Cycle ◽  
Life Cycle Management ◽  
Life Cycle Costing ◽  
Methodological Choices ◽  
Manufacturing Company

Despite the existence of many life cycle costing (LCC) methods, LCC is not widely adopted and LCC methods are usually further tailored by practitioners. Moreover, little is known about how practising LCC improves life cycle management (LCM) especially if LCM is considered emergent and constantly developing. In a manufacturing company, LCC is prescriptively introduced to improve LCM. In the first part, this study describes how various methodological choices and other aspects of practising LCC were the outcome of contestation and conformity with extant practices and not only the best way to fulfil the LCC’s objective. This contestation can even influence if LCC is adopted. In the second part of the research, the implications of practising LCC on LCM are explored. LCC is found to positively propel LCM in many ways e.g., by spreading the life cycle idea, but may lead to a narrower understanding of the term life cycle resulting in the sustainability focus of LCM being overridden. The article also discusses how the findings can be taken into consideration when researchers develop LCC methods and when industry practises LCC.

Optimizing preventive maintenance over a finite planning horizon in a semi-Markov framework

2020 ◽  
Author(s):  
Antonio Sánchez Herguedas ◽  
Adolfo Crespo Márquez ◽  
Francisco Rodrigo Muñoz
Keyword(s):  
Preventive Maintenance ◽  
Recurrence Relations ◽  
Direct Calculation ◽  
Planning Horizon ◽  
Practical Implementation ◽  
Practical Application ◽  
Mathematical Solution ◽  
Accumulated Reward ◽  
Finite Planning Horizon

Abstract This paper describes the optimization of preventive maintenance (PM) over a finite planning horizon in a semi-Markov framework. In this framework, the asset may be operating, and providing income for the asset owner, or not operating and undergoing PM, or not operating and undergoing corrective maintenance following failure. PM is triggered when the asset has been operating for τ time units. A number m of transitions specifies the finite horizon. This system is described with a set of recurrence relations, and their z-transform is used to determine the value of τ that maximizes the average accumulated reward over the horizon. We study under what conditions a solution can be found, and for those specific cases the solution τ* is calculated. Despite the complexity of the mathematical solution, the result obtained allows the analyst to provide a quick and easy-to-use tool for practical application in many real-world cases. To demonstrate this, the method has been implemented for a case study, and its accuracy and practical implementation were tested using Monte Carlo simulation and direct calculation.

scholarly journals STANDARDISING MAINTENANCE JOBS TO IMPROVE GROUPING DECISION MAKING

2021 ◽  
Vol 1 ◽  
pp. 2701-2710
Author(s):  
Julie Krogh Agergaard ◽  
Kristoffer Vandrup Sigsgaard ◽  
Niels Henrik Mortensen ◽  
Jingrui Ge ◽  
Kasper Barslund Hansen ◽  
...  
Keyword(s):  
Decision Making ◽  
Tacit Knowledge ◽  
True Variance ◽  
Complex Decision ◽  
Maintenance Decision ◽  
Maintenance Activities

AbstractMaintenance decision making is an important part of managing the costs, effectiveness and risk of maintenance. One way to improve maintenance efficiency without affecting the risk picture is to group maintenance jobs. Literature includes many examples of algorithms for the grouping of maintenance activities. However, the data is not always available, and with increasing plant complexity comes increasingly complex decision requirements, making it difficult to leave the decision making up to algorithms.This paper suggests a framework for the standardisation of maintenance data as an aid for maintenance experts to make decisions on maintenance grouping. The standardisation improves the basis for decisions, giving an overview of true variance within the available data. The goal of the framework is to make it simpler to apply tacit knowledge and make right decisions.Applying the framework in a case study showed that groups can be identified and reconfigured and potential savings easily estimated when maintenance jobs are standardised. The case study enabled an estimated 7%-9% saved on the number of hours spent on the investigated jobs.

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