Preventive Maintenance Strategies : Literature Review and Directions

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...

2018

Journal of Quality in Maintenance Engineering, 2006

Purpose -The purpose of this paper is to review the literature on maintenance management and suggest possible gaps from the point of view of researchers and practitioners. Design/methodology/approach -The paper systematically categorizes the published literature and then analyzes and reviews it methodically. Findings -The paper finds that important issues in maintenance management range from various optimization models, maintenance techniques, scheduling, and information systems etc. Within each category, gaps have been identified. A new shift in maintenance paradigm is also highlighted. Practical implications -Literature on classification of maintenance management has so far been very limited. This paper reviews a large number of papers in this field and suggests a classification in to various areas and sub areas. Subsequently, various emerging trends in the field of maintenance management are identified to help researchers specifying gaps in the literature and direct research efforts suitably. Originality/value -The paper contains a comprehensive listing of publications on the field in question and their classification according to various attributes. The paper will be useful to researchers, maintenance professionals and others concerned with maintenance to understand the importance of maintenance management

This paper presents a special case of integration of the preventive maintenance into the repair/replacement policy of a failure-prone system. The machine of the considered system exhibits increasing failure intensity and increasing repair times. To reduce the failure rate and subsequent repair times following a failure, there is an incentive to perform preventive maintenance on the machine before failure. When a failure occurs, the machine can be repaired or replaced by a new one. Thus the machine's mode at any time can be classified as either operating, in repair, in replacement or in preventive maintenance. The decision variables of the system are the repair/replacement switching age or number of failures at the time of the machine's failure and the preventive maintenance rate. The problem of determining the repair/replacement and preventive maintenance policies is formulated as a semi-Markov decision process and numerical methods are given in order to compute optimal policies which minimize the average cost incurred by preventive maintenance, repair and replacement over an infinite planning horizon. As expected, the decisions to repair or to replace the machine upon a failure are modified by performing preventive maintenance. A numerical example is given and a sensitivity analysis is performed to illustrate the proposed approach and to show the impact of various parameters on the control policies thus obtained.

International Journal of Supply Chain Management, 2017

Maintenance has become an important aspect in the manufacturing environment. There are a number of new technology and advancement in the manufacturing industry which can improve daily operations and production. In order to ensure smooth daily operations, the aspect of maintenance must be given a priority. A quality-oriented preventive maintenance practices such as preventive maintenance team, preventive maintenance strategy and planned maintenance can help to avoid any potential stoppages and disruptions of equipment from occurring in their daily operations. Preventive maintenance (PM), utilises total employee involvement in the maintenance activities. Operators and all employees should be actively involved in a maintenance programme that enable to avoid any disruptions, breakdowns, stoppages, failures, and so forth in order to improve manufacturing performance. Therefore, in the highly competitive manufacturing industries, the ability and reliability of equipment that well-maintain...

International Journal of Software Engineering & Applications, 2011

In the past several decades, maintenance and replacement problems have been extensively studied in the literature. Thousands of maintenance and replacement models have been created. However, all these models can fall into some categories of maintenance policies: age replacement policy, block replacement policy, periodic preventive maintenance policy, failure limit policy, sequential preventive maintenance policy, repair cost limit policy, repair time limit policy, repair number counting policy, reference time policy, mixed age policy, group maintenance policy, opportunistic maintenance policy, etc. Each kind of policy has different characteristics, advantages and disadvantages with lot of contributions from Research scientist, Technologists... This survey summarizes, classifies, and compares various existing maintenance policies Around 170 Authors and their research works are presented in the Reference section. It will help to look into the different policies which is appropriate to the organization and for further study the reference section will be helpful for the researchers for further knowledge

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...

International Journal of Mechanical Engineering Technologies and Applications, 2023

In the modern world, a company pays serious attention to productivity and efficiency. Several sectors in the manufacturing world are starting to carry out business transformation, particularly those leading to industry 4.0. This circumstance is driven by efforts to achieve higher productivity and an efficient process, mainly after being economically hit by the Covid-19 pandemic. To maintain efficiency, a manufacturing company should maintain its machine and equipment. Total productive maintenance is a system based on the concept of preventive and predictive maintenance. It is designed to prevent loss resulting from many factors, e.g. production interruption due to failures and adjustments, speed loss due to minor stops and speed reductions, and loss due to defects. Total productive maintenance also provides a tool to measure the level of effectiveness of a machine, i.e. overall equipment effectiveness. This review article focusses on the application of total productive maintenance and overall equipment effectiveness to determine the effectiveness of equipment and eliminate the factors that affect the effectiveness of the equipment.

E3S web of conferences, 2024

PT ABC which is a manufacturing company that produces steel pipes. The last period there was an XYZ machine that often downtime and disrupted the production process. The breakdowns indicate the ineffectiveness of machine. It was necessary to identify and analyze the problems that occurred and the factors that caused the problem. Measurement of machine effectiveness dan it caused is carried out using the OEE method. To avoid the recurrence of machine ineffectiveness, machine maintenance is carried out in a preventive manner according to the spare parts classification (there are 3 classifications of spare parts based on price, namely A under Rp.250,000, B between Rp.250,000-Rp.500,000 and C above Rp.500,000). The results obtained for the average value of OEE for 1 year is 68%, which shows a value below the ideal OEE standard (85%) and needs to be evaluated. From the calculation of the largest losses value is in the reduce speed losses factor of 67%, it is necessary to minimize the difference in ideal cycle time with actual time (operation time). The best scheduling results is using the preventive maintenance policy method with the schedule of maintenance are: for classification A spare parts the maintenance every 3 months, class B every 5 months, and class C every 6 months.

Complexity

The considerable increase in the complexity associated with the formulation of maintenance plans has enabled the development of new techniques to bring maintenance scheduling optimization models to more realistic environments. In this sense, a previous optimization model was proposed considering the use of time windows for the formation of grouping schemes under an opportunistic strategy for maintenance activities considering non-negligible execution times, thus offering the possibility of analysing scenarios with limited resources. This article proposes a risk analysis based on the failure probability of each component involved in the maintenance scheduling optimization model, which has the particularity of enabling a greater number of combinations of grouped PM activities. Moreover, it seeks to identify the general behaviour of the optimization model against different scenarios of periodicities and execution times of each maintenance activity. The proposed optimization model is fo...

2018

General preventive maintenance model for the components of a system, which improves the reliability to ‘as good as new,’ was used to optimize the maintenance cost. The cost function of a maintenance policy was minimized under given availability constraint. On the other hand, in order to ensure appropriate reliability and availability, the development of the optimal maintenance policy is the one of the main issues in system to perform preventive maintenance (PM) in equipment. In this paper, maintenance characteristics of a typical flexible manufacturing system (FMS) have been determined. These characteristics can be used to understand and prevent the complex reality of failures and repairs. Also, an optimal model for the preventive maintenance management of a FMS has been presented based on preview literature in order to enhance availability and reliability of this system and to reduce the cost of maintenance tasks. Finally, proposed framework has been applied for a robot paint spray...

2020

Abstract: Organisations nowadays are placing more emphasis on availability and reliability of systems, including safety in production plants. The uptime of production systems substantially contributes to an organisation’s productiveness, and the organisation's ability to become or remain competitive; for this reason, maintenance is now known to be compulsory and necessary. Companies are now changing their organisational maintenance policy from that of being reactive to more preventative strategies. This research was conducted at ArcelorMittal South Africa, which is situated in Vanderbijlpark, Gauteng province. The research aims to address the issues concerning maintenance that are occurring at ArcelorMittal South Africa, through assessing the maintenance planning policy which is being applied at the ArcerlorMittal plant so that the organisation can move toward a more preventative environment. Currently, the organisation has an operative preventative maintenance policy, though th...

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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.

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.