Justification of world‐class maintenance systems using analytic hierarchy constant sum method

Abstract

PurposeIn recent times, many organizations implementing total productive maintenance (TPM) have been failing in their attempts. Researchers attribute these failures to the shortcomings of TPM and of the implementing organizations. This paper aims to conduct a detailed study in order to understand these shortcomings and seeks to propose various solutions in the form of “best practices”, which leads to the development of world‐class maintenance systems (WMS). However, development of such alterative maintenance systems raises the following question: if an organization is planning to implement and improve their existing maintenance system then how can the manager make a decision between choosing alternative systems such as traditional maintenance systems, TPM and WMS? In the case of TPM or WMS, top management should be involved from the beginning to implement and follow up, as these decisions are complex and involve huge investment in the long term. Before starting implementation, top management should be convinced of the necessary justification, which requires analysis of various qualitative and quantitative factors apart from analyzing various tangible and intangible benefits. In such a situation, the conventional, financial justification techniques alone cannot be used.Design/methodology/approachThe paper attempts to demonstrate the use of a multi‐attribute decision‐making (MADM) model, namely, the analytic hierarchy constant sum method (AHCSM) for justification of WMS by analyzing the performance measures of an organization.FindingsThe model showed that WMS is the best among the alternatives considered for the given circumstances. From the extensive analysis of the results from the model, implementing WMS would result in overall improvement in the performance of an organization.Practical implicationsThe paper attempts to provide an understanding about the TPM shortcomings, WMS and its characteristics, apart from describing the proposed framework in detail. In addition to this, the AHCSM model has been developed for the justification of WMS and the algorithm for the same has been described in a step‐by‐step manner. It is believed that this MADM model will be useful for managers to supplement their strategic decisions.Originality/valueAccording to the authors' knowledge, there has been so far no paper in the literature which has demonstrated the application of AHCSM in the field of maintenance management.

Justification of TQM-TPM implementations in manufacturing organisations using analytical hierarchy process: a decision-making approach under uncertainty

“…Maintenance is responsible for controlling the cost of manpower, material, tools and overhead (Foster and VanTran, 1990;Pintelon and Gelders, 1992). Thus, the recognition of equipment's role in organisation's success necessitated the development of a comprehensive concept of equipment repair, service and maintenance (Kodali et al, 2009). Thus, an effective maintenance programme can make significant contributions to production efficiency, plant availability, reliability and organisational profitability and to support production, maintenance must ensure equipment availability to produce products at the required quantity and quality levels (Ahuja and Khamba, 2008a).…”

A Hybrid MCDM Approach Based on Fuzzy ANP and Fuzzy TOPSIS for Technology Selection

“…It is also proposed necessarily to evaluate total costs, systems' implementation time, and system's reliability. The determined criteria of Kodali et al (2009) for justification of maintenance systems included commonly applied criteria as cost, quality and productivity, systems reliability, also, some criteria covering a wider approach to environment, morale, and safety. Anand and Kodali (2009) developed an ANP model for selecting lean manufacturing systems.…”

ICT-Enabled Integrated Operations: Towards a Framework for the Integration of Manufacturing- and Maintenance Planning and Control

“…However, when designing the roadmap to future maintenance it is not sufficient to solely implement TPM as a traditional concept for the business [32]. This view is also supported by Kodali et al [16] where the shortcomings for TPM are elaborated. This leads then to the development of the world class maintenance (WCM) systems.…”