Journal of Quality in Maintenance Engineering

Turn-around maintenance management in a processing industry: A case study : Table of Contents

Shaligram Pokharel, Jianxin (Roger) Jiao — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose The purpose of this paper is to provide a case study for professionals who are in research and practice in maintenance engineering. Design/methodology/approach This is a case study. Therefore, on-site involvement in the development of steps for maintenance projects has been included. Findings The case study shows that, if project management practice and involvement of external experts and parties are allowed in the maintenance projects, then issues in maintenance projects can be addressed more clearly and the cost and schedule for such a maintenance project can also be optimized. The use of information technology in the whole process can be facilitated not only during the planning phase, but also during the execution and review process. Research limitations/implications Implication of this study can be seen in TAM projects where time and energy have to be spent to get the best practice. The case study will show a real life example of TAM. Practical implications The paper should help one to understand the implications of starting a turn-around maintenance project and the issues built therein. The case study highlights that collaborative planning and execution of TAM are useful. Collaboration could be in terms of internal parties, such as decision makers and managers, or of external parties, such as external experts and contractors. Originality/value There are only a few studies in the turn-around management process. As oil refining is an important economic process, learning of cases in one of the major oil-refining plants can help others to emulate the process so that overall efficiency of turn-around maintenance can be increased across the industry.

Occupational risks in industrial maintenance : Table of Contents

Salla Lind, Sanna Nenonen — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose The aim of this paper is to describe the most important occupational risks in maintenance operations. Design/methodology/approach This study analyzed all maintenance-related fatalities since 1985 together with one group of severe accidents in Finland. In connection with the study, risk assessments were carried out in companies with the aim of charting the risks on sites. Findings The results indicate that the typical risks in maintenance operations involve poor ergonomics and that the most severe risks among these can lead to direct injury. Severe or even fatal injuries are mainly caused by crushing or falling. Practical implications To manage the risks, maintenance operations should be taken more carefully into account when designing and reconstructing machinery and work environments. It should be ensured that workers have relevant safety knowledge by means of risk assessments and instruction in safe working practice. In addition, safety cooperation with the customer is essential. Originality/value The findings indicate that maintenance operations include certain occupational risks. Among such risks, subcontracting offers a specific challenge to the service provider's safety management. The findings of this study provide advice on the safety measures necessary for accident prevention and how to execute them.

Modelling preventive maintenance for auxiliary components : Table of Contents

Salman T. Al-Mishari, S.M.A. Suliman — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose The purpose of this paper is to develop a preventive maintenance (PM) model for auxiliary components whose failures may not necessarily correspond to system failure but rather to faster system degradation. Design/methodology/approach The concept of load sharing was utilized to build a suitable Markov model for the problem. Regression analysis was used to estimate the various transition rates of the model. A real field application was used to illustrate the model. Findings Models addressing the design of an optimal PM strategy for such a problem are rare in the literature. The load-sharing concept was borrowed and found very useful to model this problem. Regression analysis based on real field data was also found to be useful to estimate the model transition rates. Originality/value This paper addresses a problem that is not given enough attention in the currently available literature. Available models assume that a PM activity will restore the equipment to an as new, or at least to a better, condition. There exist situations, however, where a PM activity does not amend any damage but instead slows down further deterioration.

Strategies and success factors for overcoming challenges in TPM implementation in Indian manufacturing industry : Table of Contents

I.P.S. Ahuja, J.S. Khamba — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose The purpose of this study is to evaluate the challenges before Indian manufacturing organizations for adapting to proactive total productive maintenance (TPM) initiatives. The aim of this research is to critically examine the factors influencing the implementation of TPM practices in the Indian manufacturing industry, and to devise an overall maintenance strategy for overcoming obstacles to successful TPM implementation. Design/methodology/approach The study focuses on systematic identification of obstacles in TPM implementation and working out success factors towards improving manufacturing performance in Indian industry through strategic TPM initiatives. Findings The study highlights the strong potential of TPM implementation initiatives in affecting organizational performance improvements. The paper reveals that implementing TPM is by no means an easy task, which is heavily burdened by organizational, cultural, behavioral, technological, operational, financial, and departmental barriers. Research limitations/implications The study has been conducted in Indian manufacturing organizations to formulate the critical success factors and enablers for overcoming obstacles to successful TPM implementation with regard to its preparedness to face global challenges. Practical implications The study stresses the need for improving the synergy between the maintenance function and other organizational quality improvement initiatives in the organizations, to establish maintenance as a competitive strategy for meeting the challenges of a highly competitive environment. Originality/value The study highlights the difficulties faced by Indian manufacturing organizations in their attempt to implement TPM initiatives in order to improve organizational efficiency.

Development of a framework for industrial service innovation management and coordination : Table of Contents

Sukhvir Singh Panesar, Tore Markeset — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose The purpose of this study is to identify different service innovation drivers, innovation process activities and to understand industrial services innovation management and coordination, as well as to develop a framework for industrial service innovation management and coordination. Design/methodology/approach The study involved collection of information and data from the literature and the Norwegian oil and gas (O&G) industry. A survey was conducted to get an overview of existing practices and guided interviews were conducted to confirm the findings of the survey. Findings The study indicates that the market needs are considered the most important innovation process driver, feedback from the customers is the most important activity to encourage service innovations, whilst return on investments is the most important decision-making factor in evaluating innovation feasibility. Employees are the most important source of innovation ideas. Furthermore, interactions between different companies, as well as involvement of customer, employees and suppliers in the innovation process are becoming increasingly important. Practical implications The study shows that service providers and receivers often collaborate in the innovation processes, and that many of the activities are performed simultaneously. This results in the collaborative parties needing to put resources on managing and coordinating the innovation process in a structured, effective and efficient way. The proposed framework for service innovation management and coordination provides practitioners with a structured approach to manage industrial service innovations. Research limitations/implications The findings are based on the data collected from a number of companies from the O&G industry in Norway. Originality/value The paper identifies different innovation process drivers and activities and proposes a modified framework for industrial services innovation management and coordination based on the study analysis, interaction with the practitioners and using available literature on innovation management.

Simultaneous determination of production lot size and preventive maintenance schedule for unreliable production system : Table of Contents

Anis Chelbi, Nidhal Rezg, Mehdi Radhoui — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose The purpose of this study is to propose and model an integrated production-maintenance strategy for unreliable production systems producing conforming and non-conforming items. Design/methodology/approach The proposed integrated policy is defined and modeled mathematically. Findings The paper focuses on finding simultaneously the optimal values of the lot size Q and the age T at which preventive maintenance must be performed. These values minimize the total average cost per time unit over an infinite horizon. Practical implications The paper attempts to integrate in a single model the three main aspects of any manufacturing system: production, maintenance, and quality. It deals with the lot-sizing problem for a production system which may randomly shift to an out-of-control state and produce non-conforming units. The system is submitted to an age-based preventive maintenance policy. The effect of performing preventive maintenance on quality- and inventory-related costs is shown through a numerical example. Originality/value The paper proposes an integrated model that links EMQ, quality and an age-based preventive maintenance policy. It is shown that performing preventive maintenance yields reduction in inventory- and quality-related costs.

Safety risk assessment in industrial maintenance : Table of Contents

Salla Lind, Sanna Nenonen, Jouni Kivistö-Rahnasto — Sun Jun 01 14:15:05 BST 2008

Abstract:
Purpose This paper aims to answer the following questions: What conditions must be taken into account in order to manage maintenance-related risks? and how can the service-providing company assess and manage maintenance-related risks? Design/methodology/approach The study was based on analyses concerning: maintenance-related risks in companies; literature review; and real accident data. The development process was carried out in cooperation with companies providing maintenance services. Findings Based on the findings, the method takes into account various risks relating to maintenance operations. The method includes specific parts for safety planning and hazard identification for managing maintenance safety. In addition, it provides a safety check-list for the worker. Research limitations/implications The usability and feasibility of the method should be reassessed and developed. The method could be especially useful in an electronic form. Practical implications The method can be utilized for assessing maintenance-related occupational risks in different working environments. The results from the assessments create the basis for risk management in industrial maintenance. Originality/value Owing to certain specific safety challenges, maintenance operations require a specific risk assessment method. However, such a method has not been previously available. The findings and feedback indicate that this kind of a risk assessment tool can be useful in companies.