Phogat 2017
Phogat 2017
Phogat 2017
(2017),"Preventive Maintenance (PM) planning: a review", Journal of Quality in Maintenance Engineering, Vol. 23 Iss 2 pp. -
http://dx.doi.org/10.1108/JQME-04-2016-0014
(2017),"Prognosis of degradation based on a new dynamic method for Remaining Useful Life prediction", Journal of Quality
in Maintenance Engineering, Vol. 23 Iss 2 pp. - http://dx.doi.org/10.1108/JQME-03-2016-0012
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Abstract
Purpose – In the present era of rapid globalization, maintenance of manufacturing systems is
extremely important. Different organizations are facing various problems in maintenance
management. Therefore the purpose of the paper is to identify the main problems of maintenance
operations and compare them with the problems in manufacturing operations, deduced from the
available literature of effective maintenance.
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1. Introduction
Due to the briskly changing scenario of globalized markets, most of the organizations around the
globe are worried due to the increasing competitors and changing consumers’ demands for
quality products at the lowest costs (Chandra and Shastry, 1998). In this context, many local
firms are losing their market (Khanna and Sharma, 2011). Singh and Sharma (2015) and
Phusavat and Kanchana (2008) have noticed that various factors to gain competitiveness are:
flexibility, quality, reliability, ability to meet demand and supply requirements. Most of the
organizations are trying to improve manufacturing flexibility (Singh and Sharma, 2014). So it is
essential for such firms to spotlight on effective maintenance systems. Alsyouf (2007) and
Ahmed et al. (2005) have noticed that cost reduction can be achieved by increasing the level of
automation in different operations. Automation decreases the requirement of man power
significantly but since the complex machinery is involved in it, maintenance has a significant
role here (Ahuja and Khamba, 2008; Hansson and Backlund, 2003; Garg and Deshmukh, 2006).
Thus there is requirement of responsive maintenance department if they want to do extremely
well in service and subsequently want to raise their market share.
Due to the increasing technical advancements, the stimulus of productivity and quality, is
moving from man to machine. Productivity and quality may be increased only by implementing
well developed and organized maintenance system. So it is significant to understand the
problems faced by the organizations and they should be managed by the experienced
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“All the activities of the management that determine the maintenance aims or priorities (defined
as targets assigned and accepted by the management and maintenance department), strategies
(defined as a management method required to achieve maintenance objectives), and
responsibilities and implement them by the help of maintenance planning, maintenance control
and supervision, and several improving methods including economic aspects in the
organization.”
Dhillon (2006) defines maintenance as “a collection of actions executed on an asset with the aim
of keeping an asset in, or restoring it to, a specified condition”. The maintenance function is an
essential part of any asset of an intensive organization, and needs to maintain the organization’s
business objectives.
2.2.1 Corrective maintenance: This option support technique is likewise called putting out
fires upkeep, disappointment based support or breakdown upkeep. In the remedial
support procedure, upkeep is not executed until the disappointment happens (Swanson,
2001). Restorative support is the well known upkeep technique found in industry
(Waeyenbergh and Pintelon, 2002; Mechefske and Wang, 2003). It is considered as an
appropriate approach in the cases where profit margins are large (Sharma et al., 2005). In
any case, such a putting out fires technique for upkeep regularly causes genuine harm to
related facilities, work force and environment. Further it, increments worldwide rivalry
and little overall revenues have constrained support supervisors to apply more powerful
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Recently, the smart maintenance system was described by Djurdjanovic et al. (2003), focusing
on mistake prognostic techniques and aimed towards achieving near-zero-downtime performance
of equipments. It is significant mentioning that the equipment failures and corrective procedures
of maintenance cannot be skipped completely when preventive maintenance approaches
(including the time-based, condition- based and predictive maintenance) are applied. This is due
to the stochastic nature of the equipment failure. However, the equipment failure can be reduced
if the preventive maintenance approaches are correctly selected and implemented.
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Chan, 2000; Hansson and Backlund, 2003). Due to lack of communication and information,
not flow laterally, workforce of organization are not capable to report and identify the
sources of reliability and maintenance; and are not capable to put their precious suggestions
for enhancement (Hansson and Backlund, 2003).
performed when the whole business unit works towards a common goal, or else sub-
optimization will effects in unachieved targets (Rolfsen and Langeland, 2012).
3.5 Lack of effective performance measures:- For maintenance systems’ effectiveness, apart
from OEE, other performance measures are also equally important. Due to the substantial
cost of maintenance as compared to operational cost, measuring of good performance
becomes most important to survive competition and still being cost effective. Usually
maintenance measures are not the part of performance framework. In favor of this, framed
audits can be voted for to measure efficiency and to recognize area of enhancement (Raouf,
1994; Raouf and Ben-Daya, 1995). To monitor and to take timely decisions, the information
about the output of machine is most important and shortage of this information causes
ineffective and inefficient maintenance process (Parida and Kumar, 2009).
3.7 Lack of training:- Effective working of maintenance department requires that the managers
and employees have the appropriate knowledge, skills and expertise in the field of quality
management (Mosadeghrad, 2014). It helps in changing the mind set of employees from
traditional maintenance approach to the new and modern approach. It further aides in
lessening the maintenance crew and expands the adaptability as the little maintenance job
could then be done by the normal maintenance staff or the work floor specialists (Nembhard,
2014). It also increases the commitment and brings about the positive behavioural changes.
Training is required with adequate measure of reasonable learning; generally representatives
have a tendency to overlook what they were taught (Hansson and Backlund, 2003). For
example a untrained planner would not be capable to determine job content, duration,
number of workers required, number of spare parts required, etc. (Raouf and Ben-daya,
1995).
3.8 Lack of proper strategic planning and implementation:- Strategies set directions for
deciding operations functions to ensure competitiveness (Singh et al., 2010). These are the
functions that help in integrating the quality requirement with the business activities (Chin et
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al., 2002). These are the behaviors to identify and develop the barriers in achieving the most
wanted goals (Hartman, 1992; Hipkin and Lockett, 1995; Shin et al., 1998). They help in
encouraging the subsequent meet-ups and checking the accomplishments like association of
employees and comprehension amongst administration and worker by setting objectives, and
identifying solutions (Abraham et al., 1999; Schawn and Khan, 1994). It also relates
maintenance works with organization’s vision, mission and strategies (Bardoel and Sohal,
1999; Riis et al., 1997). It is observed that lack of proper strategic planning and
implementation can prove to be a bottleneck due to the unclear picture of benefits to
organization from these improvements (Abreu et al., 2013).
3.9 Lack of top management support:- Atkinson (1990) and Jaehn (2000) have analyzed that
maximum number of firms fail due to lack of top management support. Implementation of
maintenance actions in organizations requires major resources like human resources, money
and time. Top management is accountable for providing these resources (Shin et al., 1998;
Hansson and Backlund, 2003). It has become very important to change traditional methods
and organization structure to the new and modern one (Singh et al., 2008). Therefore one of
the major job of top management in current context of business environment is to reorganize
the established organization reporting structure to obtain the maintenance quality and
reliability information on timely basis (Hansson and Backlund, 2003). Major assets need
proper accomplishment and clear perceptive of methodologies and objectiveness of
maintenance systems (Clark, 1991; Hipkin and Lockett, 1995). Genuine objective of
maintenance is to expand OEE and not to decrease the work tally. Asjad et al. (2013) have
recommended supportability based contract options for operating life of mechanical
frameworks. As indicated by them supportability for a client is the capacity of the maker to
execute all the bolster exercises that are required for maintenance of the system, in its best
effective and auspicious way all through the operating life of the equipment, at whatever
point and wherever required.
3.10 Lack of empowerment:- For viable maintenance administration and manufacturing
operations, worker strengthening for taking diverse choices at own levels are critical.
Strengthening intends to build up the groups and to fabricate a developed staff (Mohamed,
2005). Representatives ought to be dynamic members and fulfilled by their employment with
sentiment possession (Hansson and Backlund, 2003; Aghazadeh, 2002; Yamashina, 2000).
To utilize maintenance for upper hand, associations ought to engage workers to adjust forms
according to natural changes (Douglas and Judge, 2001). Lack of empowerment means latent
interest of workers hence there is decrement in effectiveness of maintenance procedure and
productivity.
3.11 Lack of awareness about safety and health:- For the success of any enterprise an
important prerequisite is the safety of people, environment and assets (Narayan, 2012).
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According to survey of European agency of health and safety at work in year 2000, 10-15%
of fatal accidents and 15-20% of all accidents were associated with maintenance work. Thus
maintenance is usually regarded as important to operators. They are extra exposed to variety
of hazards with potential harm to their health (Grusenmeyer, 2010). Thusly one of the
principle works of the maintenance department office ought to be to make a safe working
environment with most extreme significance of safety in the plant (Singh et al., 2013). Safety
in plant alludes to individual security and additionally handle of safety. Personal safety is
significant in the industries, but the more important factor is the process safety (Narayan,
2012). Therefore health and safety at workplace should be everyone’s concern.
4. Concluding remarks
Due to the rising competition in the global market and local markets, firms are progressively
realizing the significance of effective maintenance management. This can be helpful in
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enhancing the market profit by improving product quality, decreasing rejection, reducing cost,
increasing productivity and by providing best service to the consumers. A lot of models such as
RCM, CBM and TPM are used in the organization to solve maintenance-related problems.
Successful implementation of these models involves many difficulties. This study has identified
main problems of maintenance operations in the accomplishment of efficient maintenance
management organization in the manufacturing operations. These problems are lack of
communication, lack of benchmarking, lack of empowerment, lack of commitment of employees
towards maintenance, lack of teamwork, lack of training, lack of proper strategic planning, lack
of top management support, lack of proper OEE, lack of awareness about safety and health and
lack of effective performance measurement. Managers should focus on these problems
effectively to contain a positive impact of the manufacturing and maintenance operations on the
performance of the industry.
Analysis and findings from the review shows that lack of top management support, lack of focus
on OEE and lack of strategic planning and implementation are the most common problems of
maintenance operations and manufacturing operations in effective maintenance and production
management. Whereas lack of benchmarking is ranked lower than the other problems but it
cannot be fully ignored. These problems can only be reduced by the will and a powerful
leadership which really wants to construct a quality-oriented culture in the industry. These
findings will help management to formulate maintenance and manufacturing strategies. Be that
as it may, before summing up these findings, some observational and contextual investigations
might be completed as a future extent of study.
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