Emerald | Journal of Quality in Maintenance Engineering | Table of Contents

Maintenance reengineering framework: a case study

literatinetwork@emeraldinsight.com (Somesh Kumar Sharma) — Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – The purpose of this paper is to radically redesign the methodology of plant maintenance and develop a three phase framework. A framework for effective and continuous maintenance improvement is presented. Design/methodology/approach – The first phase determines the key performance area, the second phase makes decision about the appropriate policy selection and third phase aims to generate capability in an organization to compete at world level. A case is presented here, of the implementation of a “maintenance reengineering framework”, developed with the aid of certain maintenance components. Findings – The maintenance reengineering framework, when implemented, proved successful with a more than 90 per cent rise in production rate. Research limitations/implications – The paper contributes some guidelines which can be helpful in making decision about the selection of maintenance policy and for the achievement of world-class effectiveness. Practical implications – Maintenance reengineering (MR) framework includes the core concepts of preventive maintenance practices, total maintenance management and system perspectives of maintenance. Its implementation goes through three phases from identification of key performance area, via suitable maintenance policy selection to generating the capability for world-class effectiveness. The experience of this pilot implementation in a cement company in India suggested the feasibility of this framework in elevating the performance of maintenance management. Originality/value – This article offers a framework that addresses research on maintenance reengineering. It attempts to establish a relationship among the components of maintenance, which can bring potential benefits to the corporations of similar operations and nature.

A computerised model to enhance the cost-effectiveness of production and maintenance dynamic decisions: A case study at Fiat

literatinetwork@emeraldinsight.com (Basim Al-Najjar, Martin Jacobsson) — Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – To develop and test a model and software-based support system for better understanding of the interactions between man-machine-maintenance-economy (MMME), and enable cost-effective decisions. Design/methodology/approach – The study is based on published knowledge and experience within maintenance, maintenance organization and production, and a case study. Findings – Development of a model describing interactions between man-machine-maintenance-economy interactions and MMME software module. MMME test shows its ability to identify, quantify, assess and follow up losses in production time which is necessary when planning effective maintenance actions. Research limitations/implications – In the paper the focus is to quantify production time losses in order to identify the root causes of the problem. The case study is performed at a manufacturing plant for truck engines. Practical implications – A systematic approach of how to quantify and evaluate losses in production time in order to identify problems and problem areas within the production. This approach is discussed and motivated with the aim of achieving more cost-effective decisions in maintenance. Originality/value – The model and software application developed enables a structured way of analyzing production time losses in order to find cost-effective solutions to the problems. The model is very flexible enabling it to be customized for a wide spectrum of branches.

Maintenance of subsea petroleum production systems: a case study

Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – The purpose of this paper is to identify and discuss maintenance challenges and maintenance practices for subsea petroleum production systems. Design/methodology/approach – Maintenance challenges, current practices and factors that influence the maintenance and support practices were identified by a literature review and by using a case study conducted in the Norwegian oil and gas industry. The case study was based on semi-structured face-to-face interviews with a number of experts working in the subsea systems’ design, installation and support services in the Norwegian oil and gas industry. Findings – The paper identifies and discusses subsea petroleum production system failures, maintenance, inspection, modification and support practices. Findings from literature are validated, and new challenges are identified and discussed. Research limitations/implications – The research is based on a case study in the Norwegian petroleum industry, but may be applicable in other countries as well. The subsea production systems are critical production systems, and failures may result in long downtime and costly maintenance, inspection and support services. Hence, inspection, maintenance and modification intervention support services requires careful project planning, implementation and execution, taking into account all influencing factors. Originality/value – The identified challenges can be used by decision makers in offshore maintenance projects.

Certification of maintenance providers: a competitive advantage

Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – The purpose of this paper is to synthesize some relevant norms, namely European norms (EN), to the maintenance field. Design/methodology/approach – The methodology is based on the conjunction of the most relevant norms to the maintenance field that represent a coherent set of tools to aid maintenance activity and maintenance companies to achieve a new level of competitiveness. Findings – Until now, the companies have not given relevance to specific certifications, such as PAS 55 or NP4492. But, with the increase of competitiveness and the market more and more exigent, it is necessary to introduce this new paradigm to raise the maintenance activity at an upper level. Practical implications – The approach presented in the paper constitutes a base for an upper level of competitiveness among companies, based on common standards that make the maintenance activity more exigent and transparent. Originality/value – The paper presents a conjunction among standards, including the newest ones, that constitutes a new vision for maintenance providers, representing a definitive contribution for a new positioning of the maintenance market.

Risk based integrity modeling of offshore process components suffering stochastic degradation

Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – The purpose of this paper is to develop a risk-based integrity model for the optimal replacement of offshore process components, based on the likelihood and consequence of failure arising from time-dependent degradation mechanisms. Design/methodology/approach – Risk is a combination of the probability of failure and its likely consequences. Offshore process component degradation mechanisms are modeled using Bayesian prior-posterior analysis. The failure consequences are developed in terms of the cost incurred as a result of failure, inspection and maintenance. By combining the cumulative posterior probability of failure and the equivalent cost of degradations, the operational life-risk curve is produced. The optimal replacement strategy is obtained as the global minimum of the operational risk curve. Findings – The offshore process component degradation mechanisms are random processes. The proposed risk-based integrity model can be used to model these processes effectively to obtain an optimal replacement strategy. Bayesian analysis can be used to model the uncertainty in the degradation data. The Bayesian posterior estimation using an M-H algorithm converged to satisfactory results using 10,000 simulations. The computed operational risk curve is observed to be a convex function of the service life. Furthermore, it is observed that the application of this model will reduce the risk of operation close to an ALARP level and consequently will promote the safety of operation. Research limitations/implications – The developed model is applicable to offshore process components which suffer time-dependent stochastic degradation mechanisms. Furthermore, this model is developed based on an assumption that the component degradation processes are independent. In reality, the degradation processes may not be independent. Practical implications – The developed methodology and models will assist asset integrity engineers/managers in estimating optimal replacement intervals for offshore process components. This can reduce operating costs and resources required for inspection and maintenance (IM) tasks. Originality/value – The frequent replacement of offshore process components involves higher cost and risk. Similarly, the late replacement of components may result in failure and costly breakdown maintenance. The developed model estimates an optimal replacement strategy for offshore process components suffering stochastic degradation. Implementation of the developed model improves component integrity, increases safety, reduces potential shutdown and reduces operational cost.

Vibration- and acoustic-emissions based novelty detection of fretted bearings

literatinetwork@emeraldinsight.com (Jordan McBain, Greg Lakanen, Markus Timusk) — Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – The purpose of this paper is to examine the use of a new feature reduction technique with novelty detection on vibration and acoustic-emission sensors monitoring bearings mounted in the test benches of automotive manufacturers. Design/methodology/approach – Signals from standard accelerometers and acoustic-emission sensors were gathered from bearings operating under steady conditions on an accessory-drive test bench. The bearings under test were subject to a variety of faults including fretting. These signals were processed and reduced to standard feature vectors, the dimensionality of which was reduced using a new principal-component-like technique optimized for novelty detection. The reduced data were analyzed with a novelty detection technique called the Support Vector Data Descriptor. Findings – The classification results from these sensors, after being reduced with the proposed feature reduction technique, are substantially improved over those achievable with only standard novelty detection; nearly zero-percent classification error was achieved. Research limitations/implications – The feature reduction technique depends, in part, on the availability of the fault type in question – potentially violating the normal novelty detection assumption of limited abnormal data. This may require the manufacturer to gather real or simulated fault data prior to running tests. Practical implications – Incipient faults may be detectable at a much earlier stage in a manufacturer's component failure analysis. Test engineers may use this technique to reliably automate the fault detection process and enable improved root-cause analysis through the earlier identification of faults. Originality/value – The application of the feature reduction technique will provide manufacturers and researchers with a new means of improving fault detection in machinery components.

Fault tree analysis considering sequence dependence and repairable input events

literatinetwork@emeraldinsight.com (Tetsushi Yuge, Shinya Ozeki, Shigeru Yanagi) — Fri, 24 May 2013 00:00:00 +0100

Abstract

Purpose – This paper aims to present two methods for calculating the steady state probability of a repairable fault tree with priority AND gates and repeated basic events when the minimal cut sets are given. Design/methodology/approach – The authors consider a situation that the occurrence of an operational demand and its disappearance occur alternately. We assume that both the occurrence and the restoration of the basic event are statistically independent and exponentially distributed. Here, restoration means the disappearance of the occurring event as a result of a restoration action. First, we obtain the steady state probability of an output event of a single-priority AND gate by Markov analysis. Then, we propose two methods of obtaining the top event probability based on an Inclusion-Exclusion method and by considering the sum of disjoint probabilities. Findings – The closed form expression of steady state probability of a priority AND gate is derived. The proposed methods for obtaining the top event probability are compared numerically with conventional Markov analysis and Monte Carlo simulation to verify the effectiveness. The result shows the effectiveness of the authors’ methods. Originality/value – The methodology presented shows a new solution for calculating the top event probability of repairable dynamic fault trees.