A New Approach on Preventive Maintenance in Industry

2017

Modern manufacturing industries uses high level of automation with complex machines. The function of automated machines is to achieve higher production rate with better quality. Therefore machines must remain in operating condition in order to achieve the desired result or goal. The failures or breakdown of machineries cause disruptions in production resulting in a loss of availability of the existing system. This further increases the cost of maintenance. Because of this, to face a greater competition in the market, industrial engineers always try to improve productivity continuously. One way to increase the productivity is to increase the operational availability of existing machines. This paper highlights recent research work carried out and a case study conducted in leading automobile industry with results obtained to increase machines operational availability or up time by implementing effective preventive maintenance schedule. Finding suggest that after implementing proper pre...

Scientific Bulletin

The use and maintenance of technical systems throughout their lifecycle aims at achieving goals that allow for high values of productivity and availability characteristics of these systems. In the economic policy of each state or private organization or state institution, there is the right to determine the type of adequate maintenance system within the maintenance strategy adopted. Thus, the types of maintenance systems recognized in the technical domain are analyzed from the point of view of the two previously-mentioned features, productivity and availability, thus making the predictive maintenance system, derived from the preventively-planned one, advantageous for all organizations. It is obvious that the current trend is to spread this predictive maintenance system, according to which the interventions will be carried out before the malfunction occurs, depending on the periodically measured values of global pressure, flow, energy consumption, temperature, current, voltage, vibra...

Journal of Production Engineering

Since the beginning of the current millennium, various professional organizations, research institutes, scientific papers in journals and various conferences around the world, address the issue of maintenance, generically speaking, both theoretically, directly or tangentially and by examples of benefits in industry for various production processes, machines and installations. However, recent studies and reports reveal that even in highly industrially developed countries, company management aims to improve maintenance in only about 15% of cases for the next plan year. Why, this is the question? This paper will try to provide answers and even propose possible solutions to increase the applicability in industry of new concepts and theories of maintenance. The arguments used are less oriented on the technical side, they are mainly focused on the “money” indicator, close to the understanding of the company's senior management, i.e. on how huge material benefits can be obtained compar...

1999

The paper considers effective maintenance management vis-a-vis improving productivity. The scope of effective management was dealt with and the relationship between management techniques and availability, reliability and maintainability. An attempt was made to clearly defme important terminologies . The paper profers that increased productivity is impossible without effective maintenance of plant, equipment and labour.

The International Journal of Science & Technoledge, 2021

All equipment/machinery are designed to carry out specific function and to last for a period of time called the design life span, but in real sense, they are unreliable as they degrade with age and fails when it no longer has the capacity to deliver required service or product. Failure of equipment/ machinery result not only in productivity loss but also delay of services, cause loss of life and environmental problems. The cautiousness of resilient equipment/machinery maintenance is continuously increasing since they are the fundamental component in the operation of critical infrastructure, but the constraints are in adequate strategic maintenance management and policies, untrained personnel, lack of spare-parts, substandard maintenance workshops, etc. This paper, therefore, examines strategies for effective maintenance management of machineries to promote resilient infrastructures. To achieve this objective, the paper takes a look at the components of engineering infrastructure, the available maintenance strategies and policies, the benefit of strategic maintenance management, the factors affecting equipment/machinery performance and service life and the strategies that promote resilient equipment/machinery life and performance. It also identifies the usual maintenance problems and proffers strategies to tackle them. The study finds that, selecting a successful maintenance strategy requires a good knowledge of equipment failure, behavior and management practice.

Applied Sciences, 2021

Preventive maintenance (PM) in the production industry is one of the most essential measures to eliminate accidental machinery failures by replacing/repairing worn out machines or parts. The decision of when and where to perform preventive maintenance is non-trivial due to the complex and stochastic nature of the industry where PM is implemented. This article deals with the theoretical and practical implementation of preventive maintenance based on a unique modification of the total productive maintenance (TPM) methodology. The innovative approach of preventive maintenance management was implemented in the real production hall of ITT (Czech Republic) and has been verified. Within preventive maintenance, the new concept brings in an innovative method of managing the maintenance process as a whole, from abstract methodical conception to practical usage. The whole new approach has been verified and implemented on industrial equipment. A challenging task while implementing Industry 4.0 ...

International journal of production economics, 1992

In this paper, a preventive maintenance (PM) planning and control system designed and implemented in a large foundry İs presented. The system designed and implemented is part of the measures taken by the top management to İncrease the scope and effectiveness of PM actiüties within the production facility. In this paper, first, shortcomings of the previous system are stated. Then, a systematic approach to bring about a well functioning and effective maintenance planning and control system İs presented. The heart ofthe new system is a custom tailored software containing data management, PM task scheduling and performance evaluation modules, and these are discussed in the paper. Furthermore, a priority function developed for the selection ofthe PM tasks for scheduling is also introduced and discussed.

In this research, a mathematical model was deployed that improves the effectiveness of maintenance planning for manufacturing systems. It utilizes operational data as obtained from industrial equipment to monitor the reliability and availability of the test equipment. A parametric test was conducted on the model by varying the input parameters to ascertain their effects on the overall system. For each case, varied values of failure rates and repair rates at given states are used to calculate the state probabilies considering the discrete states of the equipment under study. Continuing, this evaluation, gives an insight to the most appropriate maintenance action to undertake at any given time so as to improve on the reliability and availability of the equipment. The prescribed procedure, assists in planning preventive maintenance, which stands preferred to having a corrective maintenance action on manufacturing systems as it makes for increased operational life cycle, cost effectiveness, improving availability and reliability of such systems.

International Journal of Research, 2019

The aim of this study is to implement Total Productive Maintenance (TPM) in a continuous injection molding industry. By implementing TPM, the industry can increase their Overall Equipment Effectiveness (OEE) and productivity. Before implementing TPM, overall equipment efficiency, availability rate, performance rate, and quality rate of the injection molding machine were 74.9%, 88.54%, 88.5%, and 95.6%, respectively. It needs to be improved for good operating condition of machines. In this paper, some tools are suggested to improve their productivity and maintenance procedure. These tools are cause and effect diagram, Pareto chart, WWBLA, and preventive maintenance schedule. TPM program is to change the culture of the company maintenance policy with involvement of all employees toward the maintenance system of the company. Through the proper planning of maintenance schedule, productivity can be improved. This schedule helps to maintain machines in good operating conditions as well as...

Global Journal of Enterprise Information System, 2017

Too much “Maintenance” is a necessary evil. It is considered as a cost centre. It is therefore, the general tendency to avoid maintenance to reduce the cost. This was considered to be fine few years back when the cost of equipment was not so high and the competition in the market was not stiff, people could afford to maintain any production cost. In the present scenario, market competition is such that companies can only afford production at lowest cost. The cost of production equipment is going up with more sophistication. The increasing cost of production goes hand in hand with the increase in downtime cost. Therefore all attention is focused on the equipment availability and reliability and reaping profits out of maintenance is becoming a common trend. It is a positive paradigm shift in thinking that maintenance is should no longer be considered as a group of people undertaking repairs rather than it is a group of people who avoid the breakdown of equipment. Maintenance is now be...

The International Journal of Business Review (The Jobs Review), 2019

The object of research is the engine maintenance system that is on the CV. Fajar Offset. The production process is often disrupted by the high amount of damage, which results in maintenance costs. Machines that often experience damage affect the printed product to be produced. The amount of downtime will affect the profits that will have an effect on the swollen maintenance costs of the budget that has been prepared. The purpose of this study is to analyze the cost of machine maintenance with corrective method and preventive method against increase production result. The results showed that machine maintenance was done by corrective method and preventive method proven to have an effect on increase production result.

Plant optimization is a sound fiscal decision and this is a key attribute of good operational management. The decision to adhere strictly to the maintenance measurements, controls and efficiencies necessary for optimum performance not only enhances the plant operations, it quite often produces a safer operating facility and protects plant asset or investment. Plant operations rely on dependable acquired knowledge, skills, equipment and maintenance programs for an assured performance whiles strategies are required to be in place for equipment optimum availability to ensure system operational integrity in order to reduce costs which affect production. This optimized system would ideally give meaning to effective maintenance practice of plant equipment and accepted best maintenance management system. This paper presents a comprehensive review of characteristics of plant equipment and maintenance strategies and proposes sustainable maintenance management performance criteria. Thereby improving business, safety, equipment efficiency and sustain the environment. The goal is to achieve optimum availability and optimum operating condition of the equipment life cycle in a cost optimized approach.

IFAC-PapersOnLine, 2018

With continued global market growth and increased equipments complexity, professional access to maintenance plays a key role to be competitive in the market and increase productivity of production. Advanced production systems are related to the wider use of information technology in maintenance management, staff training, professional staff engagement in maintenance, and wider use of preventive maintenance. In this paper will be presented results from research on maintenance management and the importance of maintenance in manufacturing enterprises in Kosovo.

International Journal of Science and Research (IJSR)

The study specifically, focused on identifying maintenance factors affecting productivity of the primary machines, identifying potential causes of primary machines failures and develop Maintenance Model and Maintenance Management System (MMS). The study was conducted through adoption of qualitative approach for data collection and quantitative for quantifying the problem. The most significant factors were found to be: organization and human resources, management, material management and equipment & machinery. Model development, test and validation by using most significant identified factors were analysed using Statistical Package for Social Sciences (SPSS). Validation of the model confirmed that, the developed models are valid and reliable because the variation between actual and predicted productivities from the year 2012/13 and year 2013/14 are very small; account to 3% & 2% and 5% & 4% respectively. The researchers recommend maintenance management system for the best practise at the workshops. From the findings, the study recommends that, the responsible organization can adopt the developed maintenance model and system in order to improve productivity of the primary machines at the workshops.

The purpose of this paper is to develop a strategy for maintenance of mine hydraulic excavators and its various forms. These excavators are finding increasing applications in mining operations.