A methodology was developed that accurately and flexibly determines the auxiliary (AU) and value-added electricity in manufacturing operations. A tool was developed for production engineers which allows for the verification of machine efficiency in relation to their energy consumption. Historical production and electricity consumption data were collected for a period of three months from four different machines in a value stream at a manufacturing facility. The data were examined using a methodology based on statistical analysis of the historical data collected and were verified using heuristic machines profiles. Results showed AU electricity consumption varied between 10 and 26% per machine. When weekend data (non-productive periods) were excluded from calculations, AU electricity consumption reduced. Past work focuses on optimising single machine, and the quantification of wasted electricity is not always clear. This research work can be applied to one or more machines, and to single or multiple products passing through the same machine. It places particular attention to AU electricity since potential energy and cost reduction of up to 20% could be achieved. Hence, this work can aid in developing key performance indicators to measure energy usage in manufacturing operations, particularly focused towards reducing AU electricity consumption.

Purpose – The purpose of the current original research is to determine the effect that the current period of economic recession has had on maintenance practices in Ireland. Design/methodology/approach – A survey, which was aimed exclusively at senior maintenance management level, was designed to assess the impact that this period of recession and subsequent austerity has had across three chosen indicators-technical, personal and economical-from a maintenance perspective. Findings – It was determined that maintenance practices in Ireland, irrespective of the origin of the organisation, were not immune from budget reductions and reductions in the levels of maintenance personnel. The survey suggests that retrenchment was the option of choice for organisations with 19 per cent increasing maintenance intervals and 11 per cent reporting a decrease in machine availability as a result. An analysis was also undertaken to accept or reject the hypothesis that the maintenance practices of indigenous Irish organisations have been more adversely affected than those of their non-indigenous Irish-based counterparts. The hypothesis was accepted. Research limitations/implications – Although the analysis is based upon simple descriptive statistics-it provides invaluable information to maintenance policy decision makers. Originality/value – The work is entirely original. Any work from other authors is duly referenced.

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As a management paradigm, it is accepted that maintenance management is less well developed than other management activities. One of the reasons for this underdevelopment can be traced to the way maintenance personnel are trained during their vocational, undergraduate and initial professional development phases. Historical records for all vocational training and all current undergraduate courses in Ireland that include a maintenance training element were reviewed. This course of research aims to discover the reasons why such training is poorly resourced, especially in an era where access to statistical modelling and predictive maintenance tools is commonplace. Ireland provides an interesting locus for the research as Ireland has a rich manufacturing topography. The research has shown that despite a well-funded third level and further education sector, Ireland still suffers from poor levels of maintenance personnel training. This research will be of interest to senior managers concerned with enterprise optimisation.