Integration of the Decisions Associated with Maintenance Management and Process Control for a Series Production System

By Rasay, Hassan; Fallahnezhad, Mohammad Saber et al. | Iranian Journal of Management Studies, Spring 2018 | Go to article overview

Integration of the Decisions Associated with Maintenance Management and Process Control for a Series Production System


Rasay, Hassan, Fallahnezhad, Mohammad Saber, Zaremehrjerdi, Yahia, Iranian Journal of Management Studies


(ProQuest: ... denotes formulae omitted.)

Introduction

Maintenance Management (MM) and Statistical Process Control (SPC) play a key role in managing production systems. As discussed by many practitioners and researchers, there are many interdependencies between MM and SPC verifying the study of the integrated models (Liu, Jiang, & Zhang, 2017). This section is organized into three subsections. In the first, second and third subsections, the basic concepts of maintenance management, statistical process control, and series system are introduced, respectively.

Maintenance Management (MM)

MM includes activities that are implemented with the aim of restoring or maintaining a production system in a state that the required functions of the system can be economically performed (Ahmad & Kamaruddin, 2012). Four main objectives are mentioned for MM including 1- ensuring system function (availability, efficiency and product quality), 2- ensuring system life (asset management), 3-ensuring safety, 4- ensuring human well-being (Dekker, 1996). Ding and Kamaruddin (Ding & Kamaruddin, 2015) classified the MM policies into five groups including corrective maintenance, preventive maintenance, CBM or predictive maintenance, autonomous maintenance, and design-out maintenance.

Corrective maintenance is the oldest type of maintenance policy and its actions taken to restore a failure system into operational states (Ahmad & Kamaruddin, 2012). Thus, this policy includes the simple actions that are usually performed after the system completely fails or its function reduces to an unacceptable level. Preventive maintenance policy is a more advanced policy for maintenance planning. In the simplest state, this policy prescribes the maintenance actions at the equal distant intervals irrespective of the system operational state. The aim of a preventive maintenance is to retain a system in the operational state and avoid its complete failure (Ahuja & Khamba, 2008). CBM or predictive maintenance is a modern maintenance policy that its aim is to optimize the performance of preventive maintenance (Alaswad & Xiang, 2017). This policy was introduced in 1975 with the aim of optimizing the performance of preventive maintenance. The basic of the CBM policy is condition monitoring. In condition monitoring, the information about the system operational state is collected, then this information is analyzed and based on these analyses, an appropriate decision about the maintenance actions are taken. In autonomous maintenance, the maintenance and production department cooperate to perform maintenance jobs. Design-out maintenance is a policy that its aim is to improve rather than just conducting maintenance actions (Ding & Kamaruddin, 2015).

Statistical Process Control (SPC)

SPC consists of some problem-solving tools that are effective in reducing process variation and improving process capability and stability. Thus, reducing process variation can be stated as the primary goal of SPC (Montgomery, 2009). SPC includes seven major tools: 1-Histogram or steam-and-leaf plot, 2- check sheet, 3- Pareto chart, 4-cause-and-effect diagram, 5- defect concentration diagram, 6- scatter diagram, and 7- control chart. Elimination of the process variation is the eventual goal of SPC (Montgomery, 2009).

In each production process, two types of variation exist including chance cause of variation and assignable cause of variation. Chance cause of variation is a natural or inherent part of a production process. It is usually cumulative of many small effects, essentially unavoidable. On the other hand, assignable causes of variation are generally larger than chance causes of variation. Three main sources exist for the assignable causes which include operator errors, defective raw material and improperly adjusted machine. A process is in-control if only chance causes affect it. On the other hand, a process is out-of-control if an assignable cause affects the process. …

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