Pub Date : 2021-04-29DOI: 10.1108/JQME-06-2020-0056
A. K. Abdul Jawwad, Ibrahim AbuNaffa
PurposeThe purpose of this paper is to help newly established plants with minimal or no historical machine data select best maintenance strategies that suit their specific working setup and at the same time satisfy relevant selection criteria.Design/methodology/approachAnalytical hierarchy process (AHP) was applied successfully in this study to select the maintenance strategy at a newly established chemical fertilizers plant. Implementation started by identifying main and sub-criteria pertinent to maintenance practice in this particular industry. Pair-wise comparisons and consistency calculations were carried out on the chosen criteria and then were used to assess candidate maintenance strategies through a special scoring process. The methodology included the use of surveys, brainstorming and expert consultation.FindingsThe results have shown that the most important main criteria are cost, resources, failures, management, operations, quality and safety. The final maintenance strategy selected for the plant under consideration included a mix of condition-based predictive maintenance (PDM), time-based preventive maintenance (PM) and corrective maintenance (CM). The best balance between the three maintenance activities, which satisfies the maintenance criteria with technical applicability, was found to be 50, 23 and 19% for PDM, PM and CM, respectively.Originality/valueThe present paper is a novel application of AHP coupled with deterministic application-specific ranking for devising a procedure for selecting viable and applicable comprehensive maintenance strategies for newly established chemical fertilizers plants with no historical data on machine failures.
{"title":"Applying analytical hierarchy process (AHP) in selecting best maintenance strategies for newly established chemical fertilizers plants","authors":"A. K. Abdul Jawwad, Ibrahim AbuNaffa","doi":"10.1108/JQME-06-2020-0056","DOIUrl":"https://doi.org/10.1108/JQME-06-2020-0056","url":null,"abstract":"PurposeThe purpose of this paper is to help newly established plants with minimal or no historical machine data select best maintenance strategies that suit their specific working setup and at the same time satisfy relevant selection criteria.Design/methodology/approachAnalytical hierarchy process (AHP) was applied successfully in this study to select the maintenance strategy at a newly established chemical fertilizers plant. Implementation started by identifying main and sub-criteria pertinent to maintenance practice in this particular industry. Pair-wise comparisons and consistency calculations were carried out on the chosen criteria and then were used to assess candidate maintenance strategies through a special scoring process. The methodology included the use of surveys, brainstorming and expert consultation.FindingsThe results have shown that the most important main criteria are cost, resources, failures, management, operations, quality and safety. The final maintenance strategy selected for the plant under consideration included a mix of condition-based predictive maintenance (PDM), time-based preventive maintenance (PM) and corrective maintenance (CM). The best balance between the three maintenance activities, which satisfies the maintenance criteria with technical applicability, was found to be 50, 23 and 19% for PDM, PM and CM, respectively.Originality/valueThe present paper is a novel application of AHP coupled with deterministic application-specific ranking for devising a procedure for selecting viable and applicable comprehensive maintenance strategies for newly established chemical fertilizers plants with no historical data on machine failures.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42746032","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-04-29DOI: 10.1108/JQME-09-2020-0095
A. Polenghi, I. Roda, M. Macchi, A. Pozzetti
The purpose of this work is to investigate industrial asset management (AM) in manufacturing. After depicting gaps for AM in this sector, the role of information as a key dimension is considered to realise a summary of challenges and advices for future development.,The work is grounded on an extensive systematic literature review. Considering the eligible documents, descriptive statistics are provided and a content analysis is performed, both based on a sector-independent normative-based framework of analysis.,AM principles, organisation and information are the dimensions defined to group ten areas of interest for AM in manufacturing. Information is the major concern for an effective AM implementation. Moreover, Internet of Things and big data management and analytics, as well as data modelling and ontology engineering, are the major technologies envisioned to advance the implementation of AM in manufacturing.,The identified challenges and advices for future development may serve to stimulate further research on AM in manufacturing, with special focus on information and data management. The sector-independent normative-based framework may also enable to analyse AM in different contexts of application, thus favouring cross-sectorial comparisons.,Industries with higher operational risk, like Oil&Gas and infrastructure, are advanced in AM, while others, like some in manufacturing, are laggard in this respect. This literature review is the first of a kind addressing AM in manufacturing and depicts the state-of-the-art to pave the way for future research and development.
{"title":"Information as a key dimension to develop industrial asset management in manufacturing","authors":"A. Polenghi, I. Roda, M. Macchi, A. Pozzetti","doi":"10.1108/JQME-09-2020-0095","DOIUrl":"https://doi.org/10.1108/JQME-09-2020-0095","url":null,"abstract":"The purpose of this work is to investigate industrial asset management (AM) in manufacturing. After depicting gaps for AM in this sector, the role of information as a key dimension is considered to realise a summary of challenges and advices for future development.,The work is grounded on an extensive systematic literature review. Considering the eligible documents, descriptive statistics are provided and a content analysis is performed, both based on a sector-independent normative-based framework of analysis.,AM principles, organisation and information are the dimensions defined to group ten areas of interest for AM in manufacturing. Information is the major concern for an effective AM implementation. Moreover, Internet of Things and big data management and analytics, as well as data modelling and ontology engineering, are the major technologies envisioned to advance the implementation of AM in manufacturing.,The identified challenges and advices for future development may serve to stimulate further research on AM in manufacturing, with special focus on information and data management. The sector-independent normative-based framework may also enable to analyse AM in different contexts of application, thus favouring cross-sectorial comparisons.,Industries with higher operational risk, like Oil&Gas and infrastructure, are advanced in AM, while others, like some in manufacturing, are laggard in this respect. This literature review is the first of a kind addressing AM in manufacturing and depicts the state-of-the-art to pave the way for future research and development.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46471565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-04-01DOI: 10.1108/JQME-10-2020-0112
H. Pant, S. B. Singh
PurposeThe system encountering dormant failure subject to sequential inspections is modeled and the emphasis is made on determining the availability and long-run average cost rate for the model. The derived results are then utilized to obtain the optimal inspection period minimizing the cost.Design/methodology/approachExplicitly, a system with a functional and a failed state is taken into account. Inspections are performed to reveal the dormant failures and are assumed to be carried out at time T, T + aT, T + aT+a2 T, … where 0 < a = 1 in each cycle. Perfect repairs taking random times are performed if the system is found in a failed state during any inspection.FindingsSome theorems on the point availability, limiting availability and long-run average cost rate are obtained in the study. An illustration is shown to explain the results obtained in the proposed work. The effect of inspection time on the availability and cost rate is also analyzed graphically.Originality/valueThe availability and cost rate for a system with dormant failure under a sequential inspection policy are figured out unlike previous research.
目的对连续检查下遇到休眠故障的系统进行建模，重点确定模型的可用性和长期平均成本率。然后利用所得到的结果求出成本最小的最优检测周期。设计/方法学/方法明确地，一个具有功能和失败状态的系统被考虑在内。执行检查以显示休眠故障，并假定在时间T, T+ at, T+ at +a2 T，…进行检查，其中每个周期中的0 < a = 1。如果在任何检查过程中发现系统处于故障状态，则执行随机时间的完美维修。得到了一些关于点可用性、极限可用性和长期平均成本率的定理。给出了一个例子来解释在提出的工作中获得的结果。分析了检测时间对可用性和成本率的影响。不同于以往的研究，本文计算出了在顺序检查策略下具有休眠故障的系统的可用性和成本率。
{"title":"Availability and cost assessment of systems with dormant failure undergoing sequential inspections","authors":"H. Pant, S. B. Singh","doi":"10.1108/JQME-10-2020-0112","DOIUrl":"https://doi.org/10.1108/JQME-10-2020-0112","url":null,"abstract":"PurposeThe system encountering dormant failure subject to sequential inspections is modeled and the emphasis is made on determining the availability and long-run average cost rate for the model. The derived results are then utilized to obtain the optimal inspection period minimizing the cost.Design/methodology/approachExplicitly, a system with a functional and a failed state is taken into account. Inspections are performed to reveal the dormant failures and are assumed to be carried out at time T, T + aT, T + aT+a2 T, … where 0 < a = 1 in each cycle. Perfect repairs taking random times are performed if the system is found in a failed state during any inspection.FindingsSome theorems on the point availability, limiting availability and long-run average cost rate are obtained in the study. An illustration is shown to explain the results obtained in the proposed work. The effect of inspection time on the availability and cost rate is also analyzed graphically.Originality/valueThe availability and cost rate for a system with dormant failure under a sequential inspection policy are figured out unlike previous research.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42086931","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-03-25DOI: 10.1108/JQME-01-2020-0004
K. V. Sigsgaard, I. Soleymani, N. Mortensen, W. Khalid, K. B. Hansen
PurposeThis paper aims to investigate how the product architecture and service architecture methodology can be applied in strategic maintenance optimization to reduce the non-value-adding variance of maintenance, decrease the complexity and ensure alignment in maintenance practices in asset-intensive companies. The proposed maintenance architecture model will make it possible to make data-driven decisions regarding how the equipment should be grouped and maintained.Design/methodology/approachThe research approach is considered exploratory, and the main research strategy is a case study. The maintenance architecture model is developed based on the product architecture methodology and then tested in three different cases in the oil and gas sector.FindingsThrough the maintenance architecture model, it is possible to pair a quantitative data-driven approach with qualitative understanding of dependencies between equipment, maintenance actions and maintenance work management processes, enabling a more holistic and top-down data-driven approach to improving maintenance, than what currently exists in literature.Originality/valueThe proposed model provides a contribution to the understanding of maintenance and is positioned at a detailed level, different from other maintenance improvement models. This model is focused on the main drivers of maintenance that can be utilized at the strategic level compared to optimization of maintenance for individual pieces of equipment.
{"title":"Toward a framework for a maintenance architecture","authors":"K. V. Sigsgaard, I. Soleymani, N. Mortensen, W. Khalid, K. B. Hansen","doi":"10.1108/JQME-01-2020-0004","DOIUrl":"https://doi.org/10.1108/JQME-01-2020-0004","url":null,"abstract":"PurposeThis paper aims to investigate how the product architecture and service architecture methodology can be applied in strategic maintenance optimization to reduce the non-value-adding variance of maintenance, decrease the complexity and ensure alignment in maintenance practices in asset-intensive companies. The proposed maintenance architecture model will make it possible to make data-driven decisions regarding how the equipment should be grouped and maintained.Design/methodology/approachThe research approach is considered exploratory, and the main research strategy is a case study. The maintenance architecture model is developed based on the product architecture methodology and then tested in three different cases in the oil and gas sector.FindingsThrough the maintenance architecture model, it is possible to pair a quantitative data-driven approach with qualitative understanding of dependencies between equipment, maintenance actions and maintenance work management processes, enabling a more holistic and top-down data-driven approach to improving maintenance, than what currently exists in literature.Originality/valueThe proposed model provides a contribution to the understanding of maintenance and is positioned at a detailed level, different from other maintenance improvement models. This model is focused on the main drivers of maintenance that can be utilized at the strategic level compared to optimization of maintenance for individual pieces of equipment.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48856770","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-03-24DOI: 10.1108/JQME-09-2020-0099
Rodrigo Martins, F. B. Fernandes, V. Infante, A. R. Andrade
PurposeThe purpose of this paper is to describe an integer linear programming model to schedule the maintenance crew and the maintenance tasks in a bus operating company.Design/methodology/approachThe proposed methodology relies on an integer linear programming model that finds feasible maintenance schedules. It minimizes the costs associated with maintenance crew and the costs associated with unavailability. The model is applied in a real-world case study of a Portuguese bus operating company. A constructive heuristic approach is put forward, based on solving the maintenance scheduling problem for each bus separately.FindingsThe heuristic finds better solutions than the exact methods (based on branch-and-bound techniques) in a much lower computational time.Practical implicationsThe results suggest the relevance of such heuristic approaches for maintenance scheduling in practice.Originality/valueThis proposed model is an effective decision-making support method that provides feasible maintenance schedules for the maintenance technicians and for the maintenance tasks in a fleet of buses. It also complies with several operational, technical and labour constraints.
{"title":"Simultaneous scheduling of maintenance crew and maintenance tasks in bus operating companies: a case study","authors":"Rodrigo Martins, F. B. Fernandes, V. Infante, A. R. Andrade","doi":"10.1108/JQME-09-2020-0099","DOIUrl":"https://doi.org/10.1108/JQME-09-2020-0099","url":null,"abstract":"PurposeThe purpose of this paper is to describe an integer linear programming model to schedule the maintenance crew and the maintenance tasks in a bus operating company.Design/methodology/approachThe proposed methodology relies on an integer linear programming model that finds feasible maintenance schedules. It minimizes the costs associated with maintenance crew and the costs associated with unavailability. The model is applied in a real-world case study of a Portuguese bus operating company. A constructive heuristic approach is put forward, based on solving the maintenance scheduling problem for each bus separately.FindingsThe heuristic finds better solutions than the exact methods (based on branch-and-bound techniques) in a much lower computational time.Practical implicationsThe results suggest the relevance of such heuristic approaches for maintenance scheduling in practice.Originality/valueThis proposed model is an effective decision-making support method that provides feasible maintenance schedules for the maintenance technicians and for the maintenance tasks in a fleet of buses. It also complies with several operational, technical and labour constraints.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45886826","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-03-15DOI: 10.1108/JQME-10-2020-0105
S. Dellagi, M. N. Darghouth
PurposeIn this paper, a maintenance strategy based on improved imperfect maintenance actions with stochastic repair times for multiperiod randomly failing equipment is developed. The main objective is to minimize the total maintenance cost by jointly finding the optimal preventive maintenance (PM) cycle and planning horizon.Design/methodology/approachA model based on the mathematical theory of reliability is developed to minimize the total maintenance cost by jointly finding the optimal couple: PM cycle T* and planning horizon H*. The proposed model aims to characterize the evolutionary impact of imperfect PM actions on the equipment failure rate and the resulting mean number of failures. The conventional threshold accepting (TA) algorithm is implemented to solve the proposed model. A numerical example for a given set of input parameters is presented in order to show the usefulness of the proposed model. A sensitivity analysis of some of the key parameters is performed to demonstrate the coherence of the developed maintenance policy.FindingsThe obtained results showed a sensitive trade-off between PM frequency and the total maintenance cost. Performing PM actions more frequently helps significantly to reduce the expected number of corrective maintenance actions and the corresponding total cost. It has also been found that improving the efficiency of the PM actions allows for maintaining the equipment less frequently by increasing the time between successive PM actions.Research limitations/implicationsGiven the complexity of the objective function to be minimized and the stochastic nature of the model's parameters, the authors limited this study to equally cyclic production periods over the planning horizon.Practical implicationsThe present model aims to provide an integrated maintenance/production comprehensive framework to assist planners in establishing maintenance schedules considering multiperiod randomly failing production systems and the evolutionary impact of imperfect PM actions on the equipment failure rate.Originality/valueContrary to the majority of existing works in the literature dealing with maintenance strategies, the authors consider that repair times are stochastic to provide a more realistic framework. In addition, the developed model considers the impact of imperfect maintenance on the equipment's mean time to failure. Thus, the evolutionary impact of imperfect PM actions on the equipment failure rate and the resulting mean number of failures is characterized. Simultaneously, the production planning horizon along with the length of each PM cycle is optimized in order to minimize the total maintenance cost over the planning horizon.
{"title":"An improved imperfect maintenance strategy for multiperiod randomly failing equipment with stochastic repair times","authors":"S. Dellagi, M. N. Darghouth","doi":"10.1108/JQME-10-2020-0105","DOIUrl":"https://doi.org/10.1108/JQME-10-2020-0105","url":null,"abstract":"PurposeIn this paper, a maintenance strategy based on improved imperfect maintenance actions with stochastic repair times for multiperiod randomly failing equipment is developed. The main objective is to minimize the total maintenance cost by jointly finding the optimal preventive maintenance (PM) cycle and planning horizon.Design/methodology/approachA model based on the mathematical theory of reliability is developed to minimize the total maintenance cost by jointly finding the optimal couple: PM cycle T* and planning horizon H*. The proposed model aims to characterize the evolutionary impact of imperfect PM actions on the equipment failure rate and the resulting mean number of failures. The conventional threshold accepting (TA) algorithm is implemented to solve the proposed model. A numerical example for a given set of input parameters is presented in order to show the usefulness of the proposed model. A sensitivity analysis of some of the key parameters is performed to demonstrate the coherence of the developed maintenance policy.FindingsThe obtained results showed a sensitive trade-off between PM frequency and the total maintenance cost. Performing PM actions more frequently helps significantly to reduce the expected number of corrective maintenance actions and the corresponding total cost. It has also been found that improving the efficiency of the PM actions allows for maintaining the equipment less frequently by increasing the time between successive PM actions.Research limitations/implicationsGiven the complexity of the objective function to be minimized and the stochastic nature of the model's parameters, the authors limited this study to equally cyclic production periods over the planning horizon.Practical implicationsThe present model aims to provide an integrated maintenance/production comprehensive framework to assist planners in establishing maintenance schedules considering multiperiod randomly failing production systems and the evolutionary impact of imperfect PM actions on the equipment failure rate.Originality/valueContrary to the majority of existing works in the literature dealing with maintenance strategies, the authors consider that repair times are stochastic to provide a more realistic framework. In addition, the developed model considers the impact of imperfect maintenance on the equipment's mean time to failure. Thus, the evolutionary impact of imperfect PM actions on the equipment failure rate and the resulting mean number of failures is characterized. Simultaneously, the production planning horizon along with the length of each PM cycle is optimized in order to minimize the total maintenance cost over the planning horizon.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46188305","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-03-02DOI: 10.1108/JQME-08-2020-0089
Amit Kumar, Pardeep Kumar
PurposeThis paper presents the performance analysis of the automatic ticket vending machine (ATVM) through the functioning of its different hardware and software failures.Design/methodology/approachFrequent failures in the working of ATVM have been observed; therefore, the authors of the paper intend to analyze the performance measures of the same. Authors have developed a mathematical model based on different hardware and software failures/repairs, which may occur during the operation, with the help of the Markov process. The developed model has been solved for two kinds of failure/repair rates namely variable failures (very much similar to real-time failure) and constant failures. Lagrange's method and Laplace transformation are used for the solution of the developed model.FindingsReliability and mean time to failure of the ATVM are determined. Sensitivity analysis for ATVM is also carried out in the paper. Critical components of the ATVM, which affect the performance of the same, in terms of reliability and MTTF are also identified.Originality/valueA mathematical model based on different hardware and software failures/repairs of ATVM has been developed to analyze its performance, which has not been done in the past.
{"title":"Reliability assessment for multi-state automatic ticket vending machine (ATVM) through software and hardware failures","authors":"Amit Kumar, Pardeep Kumar","doi":"10.1108/JQME-08-2020-0089","DOIUrl":"https://doi.org/10.1108/JQME-08-2020-0089","url":null,"abstract":"PurposeThis paper presents the performance analysis of the automatic ticket vending machine (ATVM) through the functioning of its different hardware and software failures.Design/methodology/approachFrequent failures in the working of ATVM have been observed; therefore, the authors of the paper intend to analyze the performance measures of the same. Authors have developed a mathematical model based on different hardware and software failures/repairs, which may occur during the operation, with the help of the Markov process. The developed model has been solved for two kinds of failure/repair rates namely variable failures (very much similar to real-time failure) and constant failures. Lagrange's method and Laplace transformation are used for the solution of the developed model.FindingsReliability and mean time to failure of the ATVM are determined. Sensitivity analysis for ATVM is also carried out in the paper. Critical components of the ATVM, which affect the performance of the same, in terms of reliability and MTTF are also identified.Originality/valueA mathematical model based on different hardware and software failures/repairs of ATVM has been developed to analyze its performance, which has not been done in the past.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-03-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42465673","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-02-11DOI: 10.1108/JQME-08-2020-0086
Rodrigo E. Peimbert-García, Jesús Isaac Vázquez-Serrano, J. Limón-Robles
PurposeLiterature shows that the economics of early failures in maintenance and electric utilities have not been deeply analyzed. This study aims to focus on quantifying the economic impact that early failures in current transformers have on total maintenance costs. The empirical study is conducted in a regional transmission division of an electric utility located in Mexico.Design/methodology/approachThe utility's database was accessed to collect 219 maintenance records. Clustering techniques were used to identify early failures from a bimodal distribution of failures. Confirmatory goodness-of-fit procedures followed the analysis, and finally, direct and opportunity costs were estimated by adapting the cost-of-quality (PAF) Model.FindingsAround 11% of all maintenance activities are triggered by early failures, and they account for up to US$2.2m during the eight-year period under study, which represents 16% of total maintenance costs. Additionally, opportunity costs represent close to two-thirds of the total costs due to early failures. This was obtained after finding and validating a clear-cut border of 3.5 months between early failures and the rest.Originality/valueFailures in energy grids and power transmission can have a large economic impact on the power industry and the society in general. Thus, the maintenance function in equipment such as current transformers is a crucial entry of the budget of any electric utility. This study is one of the very few that highlights the magnitude and importance of direct and opportunity costs derived from early failures.
{"title":"The impact of early failures on maintenance costs: an empirical study in Latin America","authors":"Rodrigo E. Peimbert-García, Jesús Isaac Vázquez-Serrano, J. Limón-Robles","doi":"10.1108/JQME-08-2020-0086","DOIUrl":"https://doi.org/10.1108/JQME-08-2020-0086","url":null,"abstract":"PurposeLiterature shows that the economics of early failures in maintenance and electric utilities have not been deeply analyzed. This study aims to focus on quantifying the economic impact that early failures in current transformers have on total maintenance costs. The empirical study is conducted in a regional transmission division of an electric utility located in Mexico.Design/methodology/approachThe utility's database was accessed to collect 219 maintenance records. Clustering techniques were used to identify early failures from a bimodal distribution of failures. Confirmatory goodness-of-fit procedures followed the analysis, and finally, direct and opportunity costs were estimated by adapting the cost-of-quality (PAF) Model.FindingsAround 11% of all maintenance activities are triggered by early failures, and they account for up to US$2.2m during the eight-year period under study, which represents 16% of total maintenance costs. Additionally, opportunity costs represent close to two-thirds of the total costs due to early failures. This was obtained after finding and validating a clear-cut border of 3.5 months between early failures and the rest.Originality/valueFailures in energy grids and power transmission can have a large economic impact on the power industry and the society in general. Thus, the maintenance function in equipment such as current transformers is a crucial entry of the budget of any electric utility. This study is one of the very few that highlights the magnitude and importance of direct and opportunity costs derived from early failures.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43859718","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-26DOI: 10.1108/JQME-12-2019-0111
Akhilesh Nautiyal, S. Sharma
PurposeA large number of roads have been constructed in the rural areas of India to connect habitations with the nearest major roads. With time, the pavements of these roads have deteriorated and they need some kind of maintenance, although they all do not need maintenance at the same time, as they have all not deteriorated to the same level. Hence, they have to be prioritized for maintenance.Design/methodology/approachIn order to present a scientific methodology for prioritizing pavement maintenance, the factors affecting prioritization and the relative importance of each were identified through an expert survey. Analytic Hierarchy Process (AHP) was used to scientifically establish weight (importance) of each factor based on its relative importance over other factors. The proposed methodology was validated through a case study of 203 low volume rural roads in the state of Himachal Pradesh in India. Ranking of these roads in order of their priority for maintenance was presented as the final result.FindingsThe results show that pavement distresses, traffic volume, type of connectivity and the socioeconomic facilities located along a road are the four major factors to be considered in determining the priority of a road for maintenance.Research limitations/implicationsThe methodology provides a comprehensive, scientific and socially responsible pavement maintenance prioritization method which will automatically select roads for maintenance without any bias.Practical implicationsTimely maintenance of roads will also save budgetary expenditure of restoration/reconstruction, leading to enhancement of road service life. The government will not only save money but also provide timely benefit to the needy population.Social implicationsRoad transportation is the primary mode of inland transportation in rural areas. Timely maintenance of the pavements will be of great help to the socioeconomic development of rural areas.Originality/valueThe proposed methodology lays special emphasis on rural roads which are small in length, but large in number. Instead of random, a scientific method for selection of roads for maintenance will be of great help to the public works department for better management of rural road network.
{"title":"Scientific approach using AHP to prioritize low volume rural roads for pavement maintenance","authors":"Akhilesh Nautiyal, S. Sharma","doi":"10.1108/JQME-12-2019-0111","DOIUrl":"https://doi.org/10.1108/JQME-12-2019-0111","url":null,"abstract":"PurposeA large number of roads have been constructed in the rural areas of India to connect habitations with the nearest major roads. With time, the pavements of these roads have deteriorated and they need some kind of maintenance, although they all do not need maintenance at the same time, as they have all not deteriorated to the same level. Hence, they have to be prioritized for maintenance.Design/methodology/approachIn order to present a scientific methodology for prioritizing pavement maintenance, the factors affecting prioritization and the relative importance of each were identified through an expert survey. Analytic Hierarchy Process (AHP) was used to scientifically establish weight (importance) of each factor based on its relative importance over other factors. The proposed methodology was validated through a case study of 203 low volume rural roads in the state of Himachal Pradesh in India. Ranking of these roads in order of their priority for maintenance was presented as the final result.FindingsThe results show that pavement distresses, traffic volume, type of connectivity and the socioeconomic facilities located along a road are the four major factors to be considered in determining the priority of a road for maintenance.Research limitations/implicationsThe methodology provides a comprehensive, scientific and socially responsible pavement maintenance prioritization method which will automatically select roads for maintenance without any bias.Practical implicationsTimely maintenance of roads will also save budgetary expenditure of restoration/reconstruction, leading to enhancement of road service life. The government will not only save money but also provide timely benefit to the needy population.Social implicationsRoad transportation is the primary mode of inland transportation in rural areas. Timely maintenance of the pavements will be of great help to the socioeconomic development of rural areas.Originality/valueThe proposed methodology lays special emphasis on rural roads which are small in length, but large in number. Instead of random, a scientific method for selection of roads for maintenance will be of great help to the public works department for better management of rural road network.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44807045","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-21DOI: 10.1108/JQME-03-2020-0016
M. Bengtsson, L. Andersson, Pontus Ekström
Purpose – The purpose of the study is to test if it, by the use of a survey methodology, is possible to measure managers’ awareness on, and specifically if there exist preconceived beliefs on, overall equipment effectiveness (OEE) results. The paper presents the design of the survey methodology as well as a test of the survey in one case company. Design/methodology/approach – Actual OEE logs from a case company are collected and a survey on the data is designed and managers at the same case company are asked to answer the survey. The survey results are followed-up by an interview study in order to get deeper insights to both the results of the survey as well as the OEE strategy at the case company. Findings – The findings show that the managers at this particular case company, on a general level, does not suffer too much from preconceived beliefs. However, it is clear that the managers have a preconceived belief that lack of material is logged as a loss much more often than what it actually is. Research limitations/implications – The test has only been performed with data from one case company within the automotive manufacturing industry and only the managers at that case company has been active in the test. Practical implications –The surveymethodology can be replicated and used by other companies to find out how aware their employees are on their OEE results and if possible preconceived beliefs exists. Originality/value – To the authors’ knowledge, this is the first attempt at measuring if preconceived beliefs on OEE results exist.
{"title":"Measuring preconceived beliefs on the results of overall equipment effectiveness – A case study in the automotive manufacturing industry","authors":"M. Bengtsson, L. Andersson, Pontus Ekström","doi":"10.1108/JQME-03-2020-0016","DOIUrl":"https://doi.org/10.1108/JQME-03-2020-0016","url":null,"abstract":"Purpose – The purpose of the study is to test if it, by the use of a survey methodology, is possible to measure managers’ awareness on, and specifically if there exist preconceived beliefs on, overall equipment effectiveness (OEE) results. The paper presents the design of the survey methodology as well as a test of the survey in one case company. Design/methodology/approach – Actual OEE logs from a case company are collected and a survey on the data is designed and managers at the same case company are asked to answer the survey. The survey results are followed-up by an interview study in order to get deeper insights to both the results of the survey as well as the OEE strategy at the case company. Findings – The findings show that the managers at this particular case company, on a general level, does not suffer too much from preconceived beliefs. However, it is clear that the managers have a preconceived belief that lack of material is logged as a loss much more often than what it actually is. Research limitations/implications – The test has only been performed with data from one case company within the automotive manufacturing industry and only the managers at that case company has been active in the test. Practical implications –The surveymethodology can be replicated and used by other companies to find out how aware their employees are on their OEE results and if possible preconceived beliefs exists. Originality/value – To the authors’ knowledge, this is the first attempt at measuring if preconceived beliefs on OEE results exist.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":null,"pages":null},"PeriodicalIF":1.5,"publicationDate":"2021-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42761892","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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