Cost effectiveness of condition based maintenance in manufacturing

Rastegari, Ali; Bengtsson, Marcus

doi:10.1109/rams.2015.7105079

Cited by 14 publications

(7 citation statements)

References 2 publications

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“…In industrial, commercial and residential settings, maintenance entails functioning checks, servicing, repairing or replacing necessary devices, equipment, machinery, building infrastructure and supporting utilities (Agency, 2016; Aigboje et al ., 2019). This has evolved over time to include a variety of terms that indicate various cost-effective procedures for keeping equipment operating; these operations might occur before or after a breakdown (Peltier, 2011; Rastegari, 2015).…”

Section: Related Literature Review and Conceptual Frameworkmentioning

confidence: 99%

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Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries

Gelaw,

Azene,

Berhan

2023

JQME

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PurposeThis research aims to investigate critical success factors, barriers and initiatives of total productive maintenance (TPM) implementation in selected manufacturing industries in Addis Ababa, Ethiopia.Design/methodology/approachThis study built and looked into a conceptual research framework. The potential barriers and success factors to TPM implementation have been highlighted. The primary study techniques used to collect relevant data were a closed-ended questionnaire and semi-structured interview questions. With the use of SPSS version 23 and SmartPLS 3.0 software, the data were examined using descriptive statistics and the inferential Partial Least Square Structural Equation Modeling (PLS-SEM) techniques.FindingsAccording to the results of descriptive statistics and multivariate analysis using PLS-SEM, the case manufacturing industries' TPM implementation initiative is in its infancy; break down maintenance is the most widely used maintenance policy; top managers are not dedicated to the implementation of TPM; and there are TPM pillars that have been weakly and strongly addressed by the case manufacturing companies.Research limitations/implicationsThe small sample size is a limitation to this study. It is therefore challenging to extrapolate the research findings to other industries. The only manufacturing KPI utilized in this study is overall equipment effectiveness (OEE). It is possible to add more parameters to the manufacturing performance measurement KPI. The relationships between TPM and other lean production methods may differ from those observed in this cross-sectional study. Longitudinal experimental studies and in-depth analyses of TPM implementations may shed further light on this.Practical implicationsDefining crucial success factors and barriers to TPM adoption, as well as identifying the weak and strong TPM pillars, will help companies in allocating their scarce resources exclusively to the most important areas. TPM is not a quick solution. It necessitates a change in both the company's and employees' attitude and their values, which takes time to bring about. Hence, it entails a long-term planning. The commitment of top managers is very important in the initiatives of TPM implementation.Originality/valueThis study is unique in that, it uses a new conceptual research model and the PLS-SEM technique to analyze relationships between TPM pillars and OEE in depth.

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Section: Related Literature Review and Conceptual Frameworkmentioning

confidence: 99%

“…After allowing an item to fail, a run-to-failure or CM plan restores its function. It is based on the notion that the failure is tolerable and that avoiding failure is either too expensive or impossible (Rastegari, 2015).…”

Section: Related Literature Review and Conceptual Frameworkmentioning

confidence: 99%

Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries

Gelaw,

Azene,

Berhan

2023

JQME

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“…al. [4] and Rastegari and Bengtsson [5] present case studies to analyze cost effectiveness of CBM in comparison with traditional maintenance policies.…”

Section: Dedicationmentioning

confidence: 99%

Condition-Based Maintenance for Queues With Degrading Servers

Ejaz

Alvarado

Gautam

et al. 2019

IEEE Trans. Automat. Sci. Eng.

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The integration of condition monitoring with queueing systems to support decision making is not well explored. This work addresses the impact of condition monitoring of the server on the system level performance experienced by entities in a queueing system. The system consists of a queue with a single server subject to Markovian degradation. The model assumes a Poisson arrival process with service times and repair times according to general distributions. We develop stability conditions and perform steady state analysis to obtain performance measures (average queue length, average degradation, etc.). We propose minimizing an objective function involving four types of costs: repair, catastrophic failure, quality and holding. The queue performance measures derived from steady state analysis are bench-marked and compared to those from a discrete event simulation model. After verifying the queuing model, a sensitivity analysis is performed to determine the relationships between system performance and model parameters. Further, we explore the impact of stochastic service times on degradation and cost coefficients on optimal repair policy.Results indicate that the total cost function is convex and thus subject to an optimal repair policy.The model is sensitive to service time, quality costs, and failure costs for late-stage policy repairs decisions and sensitive to expected repair times and repair costs for early-stage policy repair decisions. The stochastic nature of service times drastically increases the likelihood of catastrophic failure of the server, and substantially increases holding costs. However, quality degrades more for constant service times while repair costs are minimally impacted.

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“…O&G plants are still tied down by frequent breakdowns and equipment failures, production losses and cost overruns from poor maintenance systems, which can frequently be traced to lack of use or ineffective implementation of CBM (Telford et al. , 2011; Rastegari and Bengtsson, 2015a,b; van de Kerkhof et al. , 2016; Tiddens, 2018).…”

Section: Introductionmentioning

confidence: 99%

“…Other possible reasons could range from the complexities of the production systems and equipment, competence and skills of employees, organisational culture, unavailability of spares, ageing equipment and supply chain management issues (Uche and Ogbonnaya, 2013; Jain et al ., 2014; Ingemarsdotter et al ., 2021). Therefore, a successful CBM implementation demands an organisation's leadership commitment and appropriate structure, parameters, techniques and technologies (Rastegari and Bengtsson, 2015a, b; Shin and Jun, 2015).…”

Section: Introductionmentioning

confidence: 99%

Integration of Industry 4.0 to the CBM practices of the O&G upstream sector in Nigeria

Onyeme,

Liyanage

2024

IJQRM

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Purpose This study investigates the integration of Industry 4.0 (I4.0) technologies with condition-based maintenance (CBM) in upstream oil and gas (O&G) operations, focussing on developing countries like Nigeria. The research identifies barriers to this integration and suggests solutions, intending to provide practical insights for improving operational efficiency in the O&G sector.Design/methodology/approach The study commenced with an exhaustive review of extant literature to identify existing barriers to I4.0 implementation and contextualise the study. Subsequent to this foundational step, primary data are gathered through the administration of carefully constructed questionnaires targeted at professionals specialised in maintenance within the upstream O&G sector. A semi-structured interview was also conducted to elicit more nuanced, contextual insights from these professionals. Analytically, the collected data were subjected to descriptive statistical methods for summarisation and interpretation with a measurement model to define the relationships between observed variables and latent construct. Moreover, the Relative Importance Index was utilised to systematically prioritise and rank the key barriers to I4.0 integration to CBM within the upstream O&G upstream sector.FindingsThe most ranked obstacles in integrating I4.0 technologies to the CBM strategy in the O&G industry are lack of budget and finance, limited engineering and technological resources, lack of support from executives and leaders of the organisations and lack of competence. Even though the journey of digitalisation has commenced in the O&G industry, there are limited studies in this area.Originality/valueThe study serves as both an academic cornerstone and a practical guide for the operational integration of I4.0 technologies within Nigeria's O&G upstream sector. Specifically, it provides an exhaustive analysis of the obstacles impeding effective incorporation into CBM practices. Additionally, the study contributes actionable insights for industry stakeholders to enhance overall performance and achieve key performance indices (KPIs).

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Cost effectiveness of condition based maintenance in manufacturing

Cited by 14 publications

References 2 publications

Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries

Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries

Condition-Based Maintenance for Queues With Degrading Servers

Integration of Industry 4.0 to the CBM practices of the O&G upstream sector in Nigeria

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