Pub Date : 2021-10-13DOI: 10.1108/jqme-08-2020-0082
R. F. da Silva, G. D. de Souza
PurposeMaintenance management is perceived as fundamental for ensuring that physical assets contribute to business outcomes. In this context, the purpose of this paper is to elaborate a novel maintenance management framework for asset management (MMFAM) based on ISO 55000 series guidelines.Design/methodology/approachThe paper proposes an MMFAM that intends to translate the technical requirements set out in the ISO 550001 standard to the maintenance stage of asset management. First, the framework is modeled using consideration based on the analysis of the ISO 55000 series and the review of previous maintenance management frameworks. Then, support tools are presented that collaborate for the implementation of the processes and activities provided for in the MMFAM.FindingsThe proposed MMFAM was modeled using a Business Process Model and Notation since it is a standardized graphical notation for process modeling and contributes to the understanding of the framework. In addition, the applicable tools were presented for the practical implementation of MMFAM processes and activities.Practical implicationsThe paper is expected to contribute to maintenance practitioners and researchers in understanding and disseminating a novel maintenance management framework that is in line with asset management through the international ISO 55000 series.Originality/valueAs it is essentially multidisciplinary and complex, asset management has still been little explored. Moreover, the requirements for implementing an asset management system, as explained in the ISO 55001 standard, only provide what needs to be done, but not how to do it. Accordingly, the paper fills a gap in maintenance management literature, as it addresses the ISO 55000 series for asset management in depth.
{"title":"Modeling a maintenance management framework for asset management based on ISO 55000 series guidelines","authors":"R. F. da Silva, G. D. de Souza","doi":"10.1108/jqme-08-2020-0082","DOIUrl":"https://doi.org/10.1108/jqme-08-2020-0082","url":null,"abstract":"PurposeMaintenance management is perceived as fundamental for ensuring that physical assets contribute to business outcomes. In this context, the purpose of this paper is to elaborate a novel maintenance management framework for asset management (MMFAM) based on ISO 55000 series guidelines.Design/methodology/approachThe paper proposes an MMFAM that intends to translate the technical requirements set out in the ISO 550001 standard to the maintenance stage of asset management. First, the framework is modeled using consideration based on the analysis of the ISO 55000 series and the review of previous maintenance management frameworks. Then, support tools are presented that collaborate for the implementation of the processes and activities provided for in the MMFAM.FindingsThe proposed MMFAM was modeled using a Business Process Model and Notation since it is a standardized graphical notation for process modeling and contributes to the understanding of the framework. In addition, the applicable tools were presented for the practical implementation of MMFAM processes and activities.Practical implicationsThe paper is expected to contribute to maintenance practitioners and researchers in understanding and disseminating a novel maintenance management framework that is in line with asset management through the international ISO 55000 series.Originality/valueAs it is essentially multidisciplinary and complex, asset management has still been little explored. Moreover, the requirements for implementing an asset management system, as explained in the ISO 55001 standard, only provide what needs to be done, but not how to do it. Accordingly, the paper fills a gap in maintenance management literature, as it addresses the ISO 55000 series for asset management in depth.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-10-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45383451","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 : 2021-09-28DOI: 10.1108/jqme-02-2021-0017
P. Dhiman, Amit Kumar
PurposeThe purpose of this paper is to investigate the performance of a turbine structure of the oil and gas Egyptian company in terms of reliability, mean time to failure (MTTF), mean time to repair (MTTR) and mean time between failures (MTBF) under fuzzy environment and working criteria. This paper examines the impact of the failure of various components on the complete turbine structure of the oil and gas system.Design/methodology/approachTo overcome the problem of uncertain behavior of available data for various components, the right triangular generalized fuzzy number (RTrGFN) is proposed to be taken into the account to express the uncertainty which attains some tolerance in data. Furthermore, reliability indices are calculated with the help of the Lambda Tau method and the arithmetic operations on right generalized triangular fuzzy numbers (RTrGFN).FindingsThis paper explores the reliability of a repairable 3 out of 4 structure of turbines and along with the other parameters namely MTTF, MTTR and MTBF; under a fuzzy environment. Failure rates and repair times are expected to be exponential. The ranking of components of the structure is being found to decide the priority for maintenance.Originality/valueThis paper investigates the performance of the system with different spread/tolerance like 15%, 25% and 50% of crisp data. It helps to predict realistic results in the range value. To enhance the system's performance, the most important item of the system requires greater attention. For this, the authors find the sensitive part by ranking. For ranking, an extended approach has been developed to find the sensitive unit of the system by using the right triangular generalized fuzzy number. This paper explores the most and least sensitive component of the system, which helps the maintenance department to plan the maintenance action.
{"title":"Fuzzy reliability of a turbines structure system using the right triangular fuzzy number","authors":"P. Dhiman, Amit Kumar","doi":"10.1108/jqme-02-2021-0017","DOIUrl":"https://doi.org/10.1108/jqme-02-2021-0017","url":null,"abstract":"PurposeThe purpose of this paper is to investigate the performance of a turbine structure of the oil and gas Egyptian company in terms of reliability, mean time to failure (MTTF), mean time to repair (MTTR) and mean time between failures (MTBF) under fuzzy environment and working criteria. This paper examines the impact of the failure of various components on the complete turbine structure of the oil and gas system.Design/methodology/approachTo overcome the problem of uncertain behavior of available data for various components, the right triangular generalized fuzzy number (RTrGFN) is proposed to be taken into the account to express the uncertainty which attains some tolerance in data. Furthermore, reliability indices are calculated with the help of the Lambda Tau method and the arithmetic operations on right generalized triangular fuzzy numbers (RTrGFN).FindingsThis paper explores the reliability of a repairable 3 out of 4 structure of turbines and along with the other parameters namely MTTF, MTTR and MTBF; under a fuzzy environment. Failure rates and repair times are expected to be exponential. The ranking of components of the structure is being found to decide the priority for maintenance.Originality/valueThis paper investigates the performance of the system with different spread/tolerance like 15%, 25% and 50% of crisp data. It helps to predict realistic results in the range value. To enhance the system's performance, the most important item of the system requires greater attention. For this, the authors find the sensitive part by ranking. For ranking, an extended approach has been developed to find the sensitive unit of the system by using the right triangular generalized fuzzy number. This paper explores the most and least sensitive component of the system, which helps the maintenance department to plan the maintenance action.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49575093","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 : 2021-09-27DOI: 10.1108/jqme-10-2020-0104
M. Demichela, Lorenzo Comberti, G. Baldissone
PurposeThe purpose of the research was to verify if there was an alignment between the risk assessed and the risk perceived or if some inconsistencies arise that could affect the safety of the operators. In fact, eventual inconsistencies should be analysed, interpreted and managed to maximise the information and training process, if needed.Design/methodology/approachThe adopted approach in this work relies on the collection of the perception of the operators about the level of risk in a work environment and its comparison with the level of risk assessed by the company. The collection of data was performed through a survey designed ad hoc, subministrated to all the workers in the area under study, being them involved in the production and in the maintenance. The survey’s structure and aim were described to the operator by the researchers and returned by the operators in a voluntary and anonymous way.FindingsThe information collected allowed identifying a gap between the risk assessed and the risk perceived by the plant operators. For example, for the use of personal protective equipments, the data highlighted a discrepancy between the knowledge about their need and the behaviour in using them, which resulted in the revision of both communication and training processes, with the adoption of a more participatory approach.Originality/valueThe originality of the work is in the data set, originally collected for this study, in the data collection form, also devised specifically for the case under study, despite it can be easily adapted for other work environment, and in the purpose itself, aimed at pushing risk assessment towards a personalised and adaptive approach.
{"title":"Operators’ risk awareness towards operations’ risk assessment: a field study in the motor vehicle field","authors":"M. Demichela, Lorenzo Comberti, G. Baldissone","doi":"10.1108/jqme-10-2020-0104","DOIUrl":"https://doi.org/10.1108/jqme-10-2020-0104","url":null,"abstract":"PurposeThe purpose of the research was to verify if there was an alignment between the risk assessed and the risk perceived or if some inconsistencies arise that could affect the safety of the operators. In fact, eventual inconsistencies should be analysed, interpreted and managed to maximise the information and training process, if needed.Design/methodology/approachThe adopted approach in this work relies on the collection of the perception of the operators about the level of risk in a work environment and its comparison with the level of risk assessed by the company. The collection of data was performed through a survey designed ad hoc, subministrated to all the workers in the area under study, being them involved in the production and in the maintenance. The survey’s structure and aim were described to the operator by the researchers and returned by the operators in a voluntary and anonymous way.FindingsThe information collected allowed identifying a gap between the risk assessed and the risk perceived by the plant operators. For example, for the use of personal protective equipments, the data highlighted a discrepancy between the knowledge about their need and the behaviour in using them, which resulted in the revision of both communication and training processes, with the adoption of a more participatory approach.Originality/valueThe originality of the work is in the data set, originally collected for this study, in the data collection form, also devised specifically for the case under study, despite it can be easily adapted for other work environment, and in the purpose itself, aimed at pushing risk assessment towards a personalised and adaptive approach.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47041276","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 : 2021-09-21DOI: 10.1108/jqme-09-2020-0096
Navid Nazhand, R. Dashti, A. Ahmadi
PurposeThe purpose of this paper is to describe a novel method to compromise between planned (regulated) maintenance and outage initiation and unplanned (unregulated) maintenance and to find an economic model using which one can perform maintenance adequately and in the most optimal state.Design/methodology/approachIn this paper, a system consisting of similar components is considered, and the role of each component in the system is explained. Then, the cost pertaining to failure in each asset is determined. Costs such as energy not supplied, penalties, human resources to resolve the defect and replacing assets are taken into account. Finally, a new comprehensive objective is proposed, and optimization is performed for a sample system.FindingsIn this paper, some graphs have been plotted from which plenty of information may be extracted. This is mentioned in the Conclusion.Originality/valueIn this paper, some graphs have been plotted from which plenty of information may be extracted. This is mentioned in the Conclusion.
{"title":"Economic study of maintenances and outage resolution in an electricity distribution network using the continuous-time Markov chain","authors":"Navid Nazhand, R. Dashti, A. Ahmadi","doi":"10.1108/jqme-09-2020-0096","DOIUrl":"https://doi.org/10.1108/jqme-09-2020-0096","url":null,"abstract":"PurposeThe purpose of this paper is to describe a novel method to compromise between planned (regulated) maintenance and outage initiation and unplanned (unregulated) maintenance and to find an economic model using which one can perform maintenance adequately and in the most optimal state.Design/methodology/approachIn this paper, a system consisting of similar components is considered, and the role of each component in the system is explained. Then, the cost pertaining to failure in each asset is determined. Costs such as energy not supplied, penalties, human resources to resolve the defect and replacing assets are taken into account. Finally, a new comprehensive objective is proposed, and optimization is performed for a sample system.FindingsIn this paper, some graphs have been plotted from which plenty of information may be extracted. This is mentioned in the Conclusion.Originality/valueIn this paper, some graphs have been plotted from which plenty of information may be extracted. This is mentioned in the Conclusion.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42501629","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 : 2021-09-03DOI: 10.1108/jqme-09-2020-0101
Z. Ismail
PurposeThe conventional methods practiced by Development and Facilities Management Unit (UPPF) faced issues due to management deficiencies and negligent staffs to handle operation and maintenance processes of Chemical Facility (CFs) management at Malaysian Polytechnic. The prime objective of this paper is to improve the conventional methods which tend to be both cumbersome and ineffective in the Maintenance Management Systems (MMS) for UPPF at Malaysian Polytechnic.Design/methodology/approachPrimary data was gathered through the interview to develop the proposed system. The major conclusion drawn from the interview results was that there is a lack of comprehensive MMS that integrate operation and maintenance processes of CF management and software programming that provide the guides for decision-making processes. The interview results also revealed irregularities within the Malaysian Polytechnic's maintenance management database.FindingsThe conventional methods had significantly little emphasis on defect diagnosis tools. It had also increased the inadequate strategic decision making to analyse information in improving the maintenance project outcomes for Malaysian Polytechnic's building. New MMS tools is suggested from findings and lessons learned as a good practice to reduce the frequent overhauling and repairs on the durability's performance and design of building control instrument.Originality/valueThe new MMS potentially transform operation and maintenance processes of CF management into one of the most sophisticated technologies by providing access to all information published by all Malaysian Polytechnics institutions. This is in order to foster financial cooperation, the idea that being that Polytechnics who compete with one another become financially independent towards successful achievements of CF management for laboratory building and equipment.
{"title":"The requirements for maintenance management systems (MMS) at Malaysian polytechnic: a case study","authors":"Z. Ismail","doi":"10.1108/jqme-09-2020-0101","DOIUrl":"https://doi.org/10.1108/jqme-09-2020-0101","url":null,"abstract":"PurposeThe conventional methods practiced by Development and Facilities Management Unit (UPPF) faced issues due to management deficiencies and negligent staffs to handle operation and maintenance processes of Chemical Facility (CFs) management at Malaysian Polytechnic. The prime objective of this paper is to improve the conventional methods which tend to be both cumbersome and ineffective in the Maintenance Management Systems (MMS) for UPPF at Malaysian Polytechnic.Design/methodology/approachPrimary data was gathered through the interview to develop the proposed system. The major conclusion drawn from the interview results was that there is a lack of comprehensive MMS that integrate operation and maintenance processes of CF management and software programming that provide the guides for decision-making processes. The interview results also revealed irregularities within the Malaysian Polytechnic's maintenance management database.FindingsThe conventional methods had significantly little emphasis on defect diagnosis tools. It had also increased the inadequate strategic decision making to analyse information in improving the maintenance project outcomes for Malaysian Polytechnic's building. New MMS tools is suggested from findings and lessons learned as a good practice to reduce the frequent overhauling and repairs on the durability's performance and design of building control instrument.Originality/valueThe new MMS potentially transform operation and maintenance processes of CF management into one of the most sophisticated technologies by providing access to all information published by all Malaysian Polytechnics institutions. This is in order to foster financial cooperation, the idea that being that Polytechnics who compete with one another become financially independent towards successful achievements of CF management for laboratory building and equipment.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42445360","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 : 2021-09-03DOI: 10.1108/jqme-08-2020-0083
Maheswar Singha Mahapatra, Dinesh Shenoy
PurposeMaintenance organizations continue to be under pressure to systematically eliminate maintenance wastes and deliver services that their customers value. To this end, maintenance managers are implementing lean maintenance practices. But how does one consistently estimate the leanness of these practices in their organization? The purpose of this paper is to develop a framework for a metrics – referred to as the lean maintenance index (LMI) that can help managers estimate the leanness of maintenance practices.Design/methodology/approachBased on a comprehensive review of literature in the domain, this study identifies four factors and nineteen subfactors that are essential for the success of a lean maintenance program. A fuzzy-set-theory-based assessment framework is developed that can be used by an in-house team to measure the degree of implementation of lean maintenance practices in their organization. The authors applied the framework to a maintenance workshop that services diesel engines and other prime movers.FindingsThe framework provides maintenance managers valuable insights to help identify the strengths and weaknesses of their organization vis-à-vis their maintenance practices, thus enabling them come up with a firm action plan for future process improvements.Originality/valueThis paper adapts the concept of agility and readiness to maintenance work. A key contribution of this study is the identification of factors and subfactors that forms the basis to estimate the leanness of maintenance practices in an organization. Another contribution is its application to a large maintenance workshop that demonstrates the ease of its implementation. Future research in this area can help identify more factors and subfactors and thus improve the estimation of leanness.
{"title":"Lean maintenance index: a measure of leanness in maintenance organizations","authors":"Maheswar Singha Mahapatra, Dinesh Shenoy","doi":"10.1108/jqme-08-2020-0083","DOIUrl":"https://doi.org/10.1108/jqme-08-2020-0083","url":null,"abstract":"PurposeMaintenance organizations continue to be under pressure to systematically eliminate maintenance wastes and deliver services that their customers value. To this end, maintenance managers are implementing lean maintenance practices. But how does one consistently estimate the leanness of these practices in their organization? The purpose of this paper is to develop a framework for a metrics – referred to as the lean maintenance index (LMI) that can help managers estimate the leanness of maintenance practices.Design/methodology/approachBased on a comprehensive review of literature in the domain, this study identifies four factors and nineteen subfactors that are essential for the success of a lean maintenance program. A fuzzy-set-theory-based assessment framework is developed that can be used by an in-house team to measure the degree of implementation of lean maintenance practices in their organization. The authors applied the framework to a maintenance workshop that services diesel engines and other prime movers.FindingsThe framework provides maintenance managers valuable insights to help identify the strengths and weaknesses of their organization vis-à-vis their maintenance practices, thus enabling them come up with a firm action plan for future process improvements.Originality/valueThis paper adapts the concept of agility and readiness to maintenance work. A key contribution of this study is the identification of factors and subfactors that forms the basis to estimate the leanness of maintenance practices in an organization. Another contribution is its application to a large maintenance workshop that demonstrates the ease of its implementation. Future research in this area can help identify more factors and subfactors and thus improve the estimation of leanness.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45678562","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 : 2021-09-01DOI: 10.1108/jqme-09-2020-0098
R. Singh, Amulya Gurtu
PurposeThis paper aims to prioritize the factors for the successful implementation of total productive maintenance (TPM).Design/methodology/approachThe technique used for prioritization is the analytical hierarchy process (AHP).FindingsThe commitment and involvement of the top management, i.e. the leadership team, is the most critical success factor in the successful implementation of TPM. Employee training is another vital factor. Top management should also encourage a culture favorable for information flow, equipment ownership, the involvement of people and quality management throughout the organization.Research limitations/implicationsManufacturing organizations interested in improving productivity through the implementation of TPM should first involve the leadership team and seek their full support and train all the employees in this philosophy. However, the findings cannot be generalized for global application due to the inputs taken from experts in AHP from limited geography.Practical implicationsReducing production costs is a universal expectation of business leaders. TPM can be used as a long-term strategy to improve productivity by the organization.Social implicationsAll employees have to be trained in this philosophy, and as part of the training and the implementation of TPM, they feel empowered and committed to the organization.Originality/valueThis study has illustrated the use of AHP for the prioritization of success factors. Prioritization of success factors will help in strategy formulation by management for effective maintenance. It will help in improving the productivity and performance of the organization.
{"title":"Prioritizing success factors for implementing total productive maintenance (TPM)","authors":"R. Singh, Amulya Gurtu","doi":"10.1108/jqme-09-2020-0098","DOIUrl":"https://doi.org/10.1108/jqme-09-2020-0098","url":null,"abstract":"PurposeThis paper aims to prioritize the factors for the successful implementation of total productive maintenance (TPM).Design/methodology/approachThe technique used for prioritization is the analytical hierarchy process (AHP).FindingsThe commitment and involvement of the top management, i.e. the leadership team, is the most critical success factor in the successful implementation of TPM. Employee training is another vital factor. Top management should also encourage a culture favorable for information flow, equipment ownership, the involvement of people and quality management throughout the organization.Research limitations/implicationsManufacturing organizations interested in improving productivity through the implementation of TPM should first involve the leadership team and seek their full support and train all the employees in this philosophy. However, the findings cannot be generalized for global application due to the inputs taken from experts in AHP from limited geography.Practical implicationsReducing production costs is a universal expectation of business leaders. TPM can be used as a long-term strategy to improve productivity by the organization.Social implicationsAll employees have to be trained in this philosophy, and as part of the training and the implementation of TPM, they feel empowered and committed to the organization.Originality/valueThis study has illustrated the use of AHP for the prioritization of success factors. Prioritization of success factors will help in strategy formulation by management for effective maintenance. It will help in improving the productivity and performance of the organization.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44477485","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 : 2021-08-18DOI: 10.1108/jqme-12-2020-0122
S. Babaeimorad, P. Fattahi, H. Fazlollahtabar
PurposeThe purpose of this paper is to present an integrated strategy for inventory control and preventive maintenance planning for a single-machine production system with increasing failure rates.Design/methodology/approachThere are three scenarios for solving presented model. The strategy is such that the production component is placed under maintenance as soon as it reaches the m level or in the event of a malfunction earlier than m. Maintenance completion time is not predictable. As a result of periodic maintenance, a buffer stock h is held and the production component starts to produce from period A with the maximum throughput to satisfy demand and handle the shortage. A numerical algorithm to find the optimal policy is developed. The algorithm is implemented using MATLAB software.FindingsThe authors discovered that joint optimization mainly reduces production system costs. Cs is holding cost of a product unit during a unit of time. The authors consider two values for Cs, consist of, Cs = 1 and Cs = 2. By comparing the two cases, it is concluded that by reducing the cost from Cs = 2 to Cs = 1, the optimal scenario does not differ. The amount of decision variables decreases.Originality/valueThis paper is the provision of a model in which the shortage of back order type is considered, which greatly increases the complexity of the problem compared to similar issues. The methods for solving such problems are provided by the numerical algorithm, and the use of buffers as a way to compensate for the shortage in the event of a complete shutdown of the production line which is a very effective and efficient way to deal with customer loss.
{"title":"Integrated maintenance scheduling inventory policy adjustment considering back order disruptions using joint optimization approach","authors":"S. Babaeimorad, P. Fattahi, H. Fazlollahtabar","doi":"10.1108/jqme-12-2020-0122","DOIUrl":"https://doi.org/10.1108/jqme-12-2020-0122","url":null,"abstract":"PurposeThe purpose of this paper is to present an integrated strategy for inventory control and preventive maintenance planning for a single-machine production system with increasing failure rates.Design/methodology/approachThere are three scenarios for solving presented model. The strategy is such that the production component is placed under maintenance as soon as it reaches the m level or in the event of a malfunction earlier than m. Maintenance completion time is not predictable. As a result of periodic maintenance, a buffer stock h is held and the production component starts to produce from period A with the maximum throughput to satisfy demand and handle the shortage. A numerical algorithm to find the optimal policy is developed. The algorithm is implemented using MATLAB software.FindingsThe authors discovered that joint optimization mainly reduces production system costs. Cs is holding cost of a product unit during a unit of time. The authors consider two values for Cs, consist of, Cs = 1 and Cs = 2. By comparing the two cases, it is concluded that by reducing the cost from Cs = 2 to Cs = 1, the optimal scenario does not differ. The amount of decision variables decreases.Originality/valueThis paper is the provision of a model in which the shortage of back order type is considered, which greatly increases the complexity of the problem compared to similar issues. The methods for solving such problems are provided by the numerical algorithm, and the use of buffers as a way to compensate for the shortage in the event of a complete shutdown of the production line which is a very effective and efficient way to deal with customer loss.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44768877","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 : 2021-08-05DOI: 10.1108/jqme-10-2020-0113
Youn Ji Lee, Hyuk Jun Kwon, Y. Seok, S. Hong
PurposeThe purpose of this paper is to demonstrate industrial Internet of Things (IIoT) solution to improve the equipment condition monitoring with equipment status data and process condition monitoring with plasma optical emission spectroscopy data, simultaneously. The suggested research contributes e-maintenance capability by remote monitoring in real time.Design/methodology/approachSemiconductor processing equipment consists of more than a thousand of components, and unreliable condition of equipment parts leads to the failure of wafer production. This study presents a web-based remote monitoring system for physical vapor deposition (PVD) systems using programmable logic controller (PLC) and Modbus protocol. A method of obtaining electron temperature and electron density in plasma through optical emission spectroscopy (OES) is proposed to monitor the plasma process. Through this system, parts that affect equipment and processes can be controlled and properly managed. It is certainly beneficial to improve the manufacturing yield by reducing errors from equipment parts.FindingsA web-based remote monitoring system provides much of benefits to equipment engineers to provide equipment data for the equipment maintenance even though they are physically away from the equipment side. The usefulness of IIoT for the e-maintenance in semiconductor manufacturing domain with the in situ monitoring of plasma parameters is convinced. The authors found the average electron temperature gradually with the increase of Ar carrier gas flow due to the increased atomic collisions in PVD process. The large amount of carrier gas flow, in this experimental case, was 90 sccm, dramatically decreasing the electron temperature, which represents kinetic energy of electrons.Research limitations/implicationsSemiconductor industries require high level of data security for the protection of their intellectual properties, and it also falls into equipment operational condition; however, data security through the Internet communication is not considered in this research, but it is already existing technology to be easily adopted by add-on feature.Practical implicationsThe findings indicate that crucial equipment parameters are the amount of carrier gas flow rate and chamber pressure among the many equipment parameters, and they also affect plasma parameters of electron temperature and electron density, which directly affect the quality of metal deposition process result on wafer. Increasing the gas flow rate beyond a certain limit can yield the electron temperature loss to have undesired process result.Originality/valueSeveral research studies on data mining with semiconductor equipment data have been suggested in semiconductor data mining domain, but the actual demonstration of the data acquisition system with real-time plasma monitoring data has not been reported. The suggested research is also valuable in terms of high cost and complicated equipment manufacturing.
{"title":"IOT-based in situ condition monitoring of semiconductor fabrication equipment for e-maintenance","authors":"Youn Ji Lee, Hyuk Jun Kwon, Y. Seok, S. Hong","doi":"10.1108/jqme-10-2020-0113","DOIUrl":"https://doi.org/10.1108/jqme-10-2020-0113","url":null,"abstract":"PurposeThe purpose of this paper is to demonstrate industrial Internet of Things (IIoT) solution to improve the equipment condition monitoring with equipment status data and process condition monitoring with plasma optical emission spectroscopy data, simultaneously. The suggested research contributes e-maintenance capability by remote monitoring in real time.Design/methodology/approachSemiconductor processing equipment consists of more than a thousand of components, and unreliable condition of equipment parts leads to the failure of wafer production. This study presents a web-based remote monitoring system for physical vapor deposition (PVD) systems using programmable logic controller (PLC) and Modbus protocol. A method of obtaining electron temperature and electron density in plasma through optical emission spectroscopy (OES) is proposed to monitor the plasma process. Through this system, parts that affect equipment and processes can be controlled and properly managed. It is certainly beneficial to improve the manufacturing yield by reducing errors from equipment parts.FindingsA web-based remote monitoring system provides much of benefits to equipment engineers to provide equipment data for the equipment maintenance even though they are physically away from the equipment side. The usefulness of IIoT for the e-maintenance in semiconductor manufacturing domain with the in situ monitoring of plasma parameters is convinced. The authors found the average electron temperature gradually with the increase of Ar carrier gas flow due to the increased atomic collisions in PVD process. The large amount of carrier gas flow, in this experimental case, was 90 sccm, dramatically decreasing the electron temperature, which represents kinetic energy of electrons.Research limitations/implicationsSemiconductor industries require high level of data security for the protection of their intellectual properties, and it also falls into equipment operational condition; however, data security through the Internet communication is not considered in this research, but it is already existing technology to be easily adopted by add-on feature.Practical implicationsThe findings indicate that crucial equipment parameters are the amount of carrier gas flow rate and chamber pressure among the many equipment parameters, and they also affect plasma parameters of electron temperature and electron density, which directly affect the quality of metal deposition process result on wafer. Increasing the gas flow rate beyond a certain limit can yield the electron temperature loss to have undesired process result.Originality/valueSeveral research studies on data mining with semiconductor equipment data have been suggested in semiconductor data mining domain, but the actual demonstration of the data acquisition system with real-time plasma monitoring data has not been reported. The suggested research is also valuable in terms of high cost and complicated equipment manufacturing.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48497726","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 : 2021-07-26DOI: 10.1108/jqme-08-2019-0075
G. Sharma, R. Rai
PurposeDegradation of repairable components may not be similar after each maintenance activity; thus, the classic (traditional-time based) maintenance policies, which consider preventive maintenance (PM), age-based maintenance and overhauls to be done at fixed time interval, may fail to monitor the exact condition of the component. Thus, a progressive maintenance policy (PMP) may be more appropriate for the industries that deal with large, complex and critical repairable systems (RS) such as aerospace industries, nuclear power plants, etc.Design/methodology/approachA progressive maintenance policy is developed, in which hard life, PM scheduled time and overhaul period of the system are revised after each service activity by adjusting PM interval and mean residual life (MRL) such that the risk of failure is not increased.FindingsA comparative study is then carried out between the classic PM policy and developed PMP, and the improvement in availability, mean time between failures and reduction in maintenance cost is registered.Originality/valueThe proposed PMP takes care of the equipment degradation more efficiently than any other existing maintenance policies and is also flexible in its application as the policy can be continuously amended as per the failure profile of the equipment. Similar maintenance policies assuming lifetime distributions are available in the literature, but to ascertain that the proposed PMP is more suitable and applicable to the industries, this paper uses Kijima-based imperfect maintenance models. The proposed PMP is demonstrated through a real-time data set example.
{"title":"Progressive maintenance policy for multiple repairable systems with imperfect maintenance","authors":"G. Sharma, R. Rai","doi":"10.1108/jqme-08-2019-0075","DOIUrl":"https://doi.org/10.1108/jqme-08-2019-0075","url":null,"abstract":"PurposeDegradation of repairable components may not be similar after each maintenance activity; thus, the classic (traditional-time based) maintenance policies, which consider preventive maintenance (PM), age-based maintenance and overhauls to be done at fixed time interval, may fail to monitor the exact condition of the component. Thus, a progressive maintenance policy (PMP) may be more appropriate for the industries that deal with large, complex and critical repairable systems (RS) such as aerospace industries, nuclear power plants, etc.Design/methodology/approachA progressive maintenance policy is developed, in which hard life, PM scheduled time and overhaul period of the system are revised after each service activity by adjusting PM interval and mean residual life (MRL) such that the risk of failure is not increased.FindingsA comparative study is then carried out between the classic PM policy and developed PMP, and the improvement in availability, mean time between failures and reduction in maintenance cost is registered.Originality/valueThe proposed PMP takes care of the equipment degradation more efficiently than any other existing maintenance policies and is also flexible in its application as the policy can be continuously amended as per the failure profile of the equipment. Similar maintenance policies assuming lifetime distributions are available in the literature, but to ascertain that the proposed PMP is more suitable and applicable to the industries, this paper uses Kijima-based imperfect maintenance models. The proposed PMP is demonstrated through a real-time data set example.","PeriodicalId":16938,"journal":{"name":"Journal of Quality in Maintenance Engineering","volume":" ","pages":""},"PeriodicalIF":1.5,"publicationDate":"2021-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42672745","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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