PART B

Introduction:
In today's competitive industrial landscape, the optimization of production processes is paramount for
ensuring operational efficiency, product quality, and customer satisfaction. Advanced maintenance
practices play a pivotal role in achieving these objectives by minimizing downtime, reducing costs, and
enhancing overall productivity. This introduction sets the stage for evaluating and implementing such
practices within the context of Polar Crush, a local beverage company facing challenges in its
production line operations.
This work aims to address the deficiencies in maintenance strategies observed at Polar Crush, focusing
on the implementation of advanced maintenance techniques to mitigate frequent breakdowns and
improve production line reliability. By critically analyzing the existing operations and maintenance
framework, this study seeks to enhance the company's understanding of its engineering operations
function and management components.
Key objectives include:
1. Assessing the current maintenance landscape and identifying areas for improvement.
2. Proposing and evaluating appropriate advanced maintenance strategies tailored to the specific needs
of Polar Crush.
3. Highlighting the potential benefits of adopting proactive maintenance approaches, such as predictive
maintenance and Total Productive Maintenance (TPM), in optimizing production processes and
minimizing disruptions.

Through this examination, the assignment endeavors to foster a deeper critical awareness of
engineering operations management principles and equip stakeholders with the knowledge and tools
necessary to enhance operational effectiveness and competitiveness in the market.
The Literature Review
- Reactive maintenance.

Reactive maintenance, also known as corrective maintenance or breakdown maintenance, is a strategy

where maintenance actions are taken after a failure has occurred. This approach is characterized by its
responsiveness to unexpected breakdowns rather than pre-emptive actions (Rukijkanpanich &
Mingmongkol, 2019). While reactive maintenance can minimize immediate costs in terms of
manpower and money, it can lead to unpredictability in maintenance schedules, fluctuating operations,
and increased overall maintenance costs when catastrophic failures happen (Solms & Meyer, 2021).
Over the centuries, maintenance strategies have evolved to include a mix of reactive, preventive, and
predictive maintenance approaches (Lundgren et al., 2021). Preventive maintenance, a proactive
strategy that involves scheduled inspections and maintenance tasks to prevent failures, has been
identified as a key component in maintaining high-rise residential buildings (Chua et al., 2018). In
contrast, reactive maintenance is often associated with increased costs and operational disruptions due
to its unplanned nature (Solms & Meyer, 2021).

Studies have shown that organisms, including humans, make trade-offs in their life history strategies
concerning growth, maintenance, and reproduction (Dishakjian et al., 2020). These trade-offs are
essential for understanding how different species allocate resources to ensure survival and reproductive
success. Reactive maintenance, as part of these strategies, reflects a balance between immediate
response to failures and the long-term maintenance of systems (Dishakjian et al., 2020).

- Planned maintenance, and Preventive maintenance.

Maintenance strategies have evolved over time to address the challenges of ensuring the longevity and
efficiency of various systems and structures. Two key maintenance strategies that have been
extensively studied are planned maintenance and preventive maintenance. Planned maintenance
involves setting long-term goals for maintaining buildings or components and making short-term
adjustments based on new information (Lind & Muyingo, 2012). On the other hand, preventive
maintenance focuses on improving the efficiency of maintenance actions to allow for less frequent
maintenance by increasing the time between actions (Dellagi & Darghouth, 2021).

Research has shown that maintenance activities are crucial, especially for older building stocks from
past decades that require renovation or demolition (Lind & Muyingo, 2012). Additionally, the
reliability-centered maintenance (RCM) strategy has been highlighted as an organized framework for
enhancing the reliability of power distribution systems and reducing maintenance costs through
cost/benefit analyses and reliability assessments (Firouz & Ghadimi, 2015).

In the context of manufacturing systems, integrated maintenance and spare parts management have
been explored to consider the impact of production rate variations on system degradation and optimal
maintenance strategies (Dellagi et al., 2020). Furthermore, the importance of establishing maintenance
strategies based on the service life of components has been emphasized for safety, cost-effectiveness,
and occupant satisfaction (Park et al., 2018).

The literature also discusses the significance of selecting suitable maintenance strategies, such as
proactive and aggressive approaches, using fuzzy logic modeling and historical data to improve
maintenance decision-making (Sharma et al., 2005). Moreover, studies have addressed the optimization
of maintenance strategies considering imperfect preventive maintenance and the hybrid hazard rate
model to enhance maintenance effectiveness (Li et al., 2021).

- Total Productive Maintenance (TPM).

Total Productive Maintenance (TPM) is a comprehensive culture and philosophy that revolutionizes the
approach towards maintenance (Ahuja & Khamba, 2008). The implementation of TPM involves key
constructs such as disciplined maintenance, information tracking, housekeeping, and operator
involvement, which are crucial for enhancing operational performance (Modgil & Sharma, 2016).
Reliable manufacturing equipment is essential for the performance and profitability of manufacturing
systems, emphasizing the importance of TPM in ensuring operational efficiency (Jain et al., 2015).

Furthermore, integrating TPM with methodologies like Total Quality Management (TQM) has been
explored to enhance manufacturing performance. While Just-In-Time (JIT), TQM, and Employee
Involvement (EI) are recognized for their contributions to manufacturing performance, synergistically
implementing TPM alongside these strategies can further elevate operational excellence (McKone et
al., 2000). Additionally, combining TPM with methodologies like Quality Function Deployment (QFD)
offers a novel approach to improving quality in maintenance engineering, demonstrating the versatility
and adaptability of TPM in various contexts (Pramod et al., 2006).
However, the successful implementation of TPM faces challenges such as organizational barriers
including political, financial, departmental, and inter-occupational hurdles, which can impede effective
adoption of TPM practices (Cooke, 2000). Overcoming these obstacles requires a concerted effort
towards managing commitment and organizational change, highlighting the need for a strategic and
holistic approach to TPM implementation (Hansson et al., 2003).

- Reliability Centred Maintenance (RCM).

Maintenance strategies have evolved over time, with various approaches developed to optimize the
upkeep of different assets. One prominent strategy is Reliability Centered Maintenance (RCM), which
focuses on identifying the most efficient maintenance tasks to ensure equipment reliability (Jiang,
2024). However, the application of maintenance strategies like RCM may have limitations, such as the
challenge of ranking maintenance alternatives to select the optimal solution (Emovon et al., 2015).

Studies have explored different paradigms and solution approaches for maintenance strategy selection,
emphasizing the need for comprehensive reviews to address research gaps and enhance decision-
making processes (Patil et al., 2021). Additionally, the use of hybrid models, such as those
incorporating the PROMETHEE method, has been proposed to optimize maintenance policies in
specific sectors like hydroelectric power plants (Özcan et al., 2021).

Furthermore, research has investigated the impact of maintenance interventions on heritage buildings
over centuries, underscoring the importance of understanding the effectiveness of maintenance,
rehabilitation, and other interventions on the functionality of historical structures (Prieto et al., 2019).
In the context of modern infrastructure, fuzzy logic models have been developed to benchmark
maintenance strategies for concrete structures, aiming to identify the best combination of maintenance
approaches (Peiris & Silva, 2019).

The selection of maintenance strategies involves complex decision-making processes, often utilizing
methods like decision-making grids and Jack-Knife diagrams to compare different approaches
(Seecharan et al., 2018). Moreover, the integration of maintenance data sets using manual and
computer-based tools has been observed in various industries, highlighting the importance of
standardization and knowledge management in optimizing maintenance practices (Wakiru et al., 2021).
- Condition monitoring applications in the advances of Industry 4.0
Maintenance strategies have evolved over time, with various paradigms and solution approaches being
developed to address challenges in different industries. The selection of maintenance strategies
involves a comprehensive review of current practices and methodologies (Patil et al., 2021). These
strategies encompass a range of approaches, including condition monitoring, which has advanced
significantly with the emergence of Industry 4.0 technologies.

Recent research has focused on the application of condition monitoring within the context of Industry
4.0. The integration of technologies such as predictive maintenance, IoT sensors, and data analytics has
transformed maintenance practices, enabling real-time monitoring and predictive maintenance
interventions (Cauchi et al., 2018). This shift towards data-driven decision-making has enhanced the
efficiency and effectiveness of maintenance strategies, particularly in smart buildings and industrial
settings.

Studies have highlighted the importance of energy efficiency in maintenance strategies, emphasizing
the relationship between maintenance practices and energy consumption (Firdaus et al., 2023).
Sustainable maintenance approaches are crucial for optimizing energy usage while ensuring equipment
reliability, leading to cost savings and environmental sustainability goals.

The selection of maintenance strategies involves complex decision-making processes. Various

methodologies such as Analytic Hierarchy Process (AHP), Genetic Algorithms, and Multiple-Criteria
Decision Analysis (MCDM) have been utilized to optimize maintenance strategy selection (Kurian et
al., 2019; Arjomandi et al., 2021; Emovon et al., 2015). These decision support tools assist in
evaluating criteria like cost, resources, failures, and safety to determine the most suitable maintenance
approach for specific industrial contexts (Jawwad & AbuNaffa, 2021).

CALCULATIONS
Hypothetical Data
ITEM DATA

Shift Length 9 hours = 540min

Short Breaks 2 @ 30 min = 60 min.

Meal Break 1 @ 30 min = 30 min.

Down Time 30 mins

Ideal Run Rate 57 pieces per minute

Total Pieces 21,045

Reject Pieces 305

Planned Production Time = [Shift length – Breaks] = [540 – 90] = 450mins

Operating Time = PPT – Down Time = 450 – 30 = 420mins
Good piece = Total piece – Rejected = 21045 – 305 = 20740 pieces

420
Availability = Operating Time / PPT = = 0.9333 * 100 = 93.3%
450
21045
Performance = (Total Pieces / Operating Time) / Ideal Run Rate = = 0.879 = 87.9%
420 x 57
20740
Quality = Good Pieces / Total Pieces = = 0.985 x 100 = 98.5%
21045
OEE = Availability x Performance x Quality = 0.933 x 0.879 x 0.985 = 0.807 = 80.7%

What should the company expect

The calculated Overall Equipment Effectiveness (OEE) of 80.7% for Polar Crush indicates that the
equipment is operating at 80.7% of its maximum potential efficiency. While the availability of 93.3%
suggests some room for improvement in minimizing downtime through preventive maintenance
schedules, improving equipment reliability, and promptly addressing root causes of failures, the
performance of 87.9% highlights potential inefficiencies in production processes. Streamlining
workflows, optimizing equipment settings, and eliminating bottlenecks can enhance performance.
Additionally, the high-quality percentage of 98.5% underscores the need for further reduction of
rejected pieces through rigorous quality control measures, employee training, and ongoing process
improvements.
SUGGESTED MAINTENANCE APPLICATIONS
To optimize maintenance strategies and maximize efficiency and effectiveness at Polar Crush, the following actions can be considered:
S/N Maintenance Internal Pillars Expected Impact Justification and Literature
Strategies and Reference
Their Internal
Pillars:

1 Predictive • Condition Monitoring: Implement • Reduced Downtime: By • According to a study by Li et al.

Maintenance sensors and monitoring systems at each detecting issues before they (2017), predictive maintenance
(PdM): production station to continuously escalate into failures, has been shown to reduce
collect data on equipment health and predictive maintenance helps maintenance costs by up to 30%
performance indicators such as minimize unplanned and increase equipment uptime
temperature, vibration, and pressure. downtime and production by 20% through proactive
This data is then analyzed using disruptions, thereby identification of equipment
predictive analytics to anticipate improving overall equipment failures.
potential failures before they occur. effectiveness (OEE). • Similarly, research by Jardine et
• Data Analytics: Utilize advanced • Cost Savings: By scheduling al. (2006) highlights the
analytics techniques to analyze the maintenance activities based effectiveness of predictive
collected data and identify patterns or on actual equipment maintenance in enhancing
anomalies indicative of impending condition rather than equipment reliability and
equipment failures. Machine learning arbitrary time intervals, minimizing downtime by
algorithms can be employed to improve organizations can optimize identifying potential failure
the accuracy of failure predictions over resource allocation and modes and taking preventive
time. reduce unnecessary actions accordingly.
 • Asset Health Management: Develop a maintenance costs.
centralized asset health management • Enhanced Equipment
system that integrates data from various Reliability: Predictive
sources to provide real-time insights maintenance enables early
into equipment condition. This allows detection and resolution of
for proactive maintenance interventions equipment issues, leading to
based on the prioritization of critical improved reliability and
assets. longevity of production
assets.

2 Total • Autonomous Maintenance: Empower • Increased Equipment • Research by Nakajima

Productive operators to perform routine Availability: TPM focuses on (1988) highlights the
Maintenance maintenance tasks such as cleaning, maximizing equipment effectiveness of TPM in
(TPM) lubrication, and basic inspections to uptime by involving improving equipment
prevent equipment deterioration and operators in proactive reliability, reducing
identify abnormalities at an early stage. maintenance activities, downtime, and enhancing
• Planned Maintenance: Develop a leading to improved asset overall equipment
structured maintenance schedule based availability and production effectiveness by involving
on equipment usage patterns, output. operators in maintenance
production schedules, and historical • Empowered Workforce: By activities and fostering a
failure data. This involves conducting involving operators in culture of continuous
preventive maintenance activities such maintenance activities, TPM improvement.
as component replacement and fosters a sense of ownership • Similarly, a study by Gijo
calibration at predetermined intervals. and accountability among and Antony (2014)
 • Continuous Improvement (Kaizen): employees, leading to underscores the positive
Foster a culture of continuous increased engagement and impact of TPM on reducing
improvement among employees to morale. defects, improving
identify and address root causes of • Reduced Defects and Waste: productivity, and enhancing
equipment failures, inefficiencies, and Continuous improvement employee morale through
waste through systematic problem- initiatives under TPM help empowerment and
solving methodologies. identify and eliminate involvement in maintenance
sources of defects and waste activities.
in the production process,
resulting in higher product
quality and reduced rework.

3 Reliability- • Asset Criticality Analysis: Conduct a • Enhanced Equipment • A study by Mobley (2002)
Centered comprehensive assessment of Reliability: RCM focuses on emphasizes the importance
Maintenance production assets to identify critical proactively addressing of RCM in optimizing
(RCM) equipment that has a significant impact potential failure modes of maintenance strategies and
on production output, quality, or safety. critical equipment, resulting maximizing equipment
This helps prioritize maintenance in improved reliability, reliability by focusing on
efforts and allocate resources availability, and proactive maintenance tasks
effectively. performance. tailored to the specific needs
• Failure Mode and Effects Analysis • Optimal Resource of each asset.
(FMEA): Analyze potential failure Allocation: By prioritizing • Similarly, research by
modes of critical equipment and their maintenance activities based Nowlan and Heap (1978)
consequences on production operations. on asset criticality and failure demonstrates the
 Develop proactive maintenance consequences, RCM helps effectiveness of RCM in
strategies to mitigate or prevent these allocate resources more reducing maintenance costs
failure modes through appropriate effectively, ensuring that and improving equipment
maintenance tasks. maintenance efforts are performance by prioritizing
• Maintenance Optimization: Optimize focused on areas with the maintenance activities based
maintenance strategies based on the greatest impact on production on asset criticality and
identified failure modes, taking into operations. failure consequences.
account factors such as equipment • Cost Savings: RCM helps
reliability, cost of failure, and minimize unnecessary
consequences of downtime. This maintenance activities and
involves selecting the most cost- reduce the risk of
effective maintenance approach for catastrophic failures, leading
each asset. to cost savings associated
with maintenance labor,
spare parts, and production
downtime.
Conclusion
In conclusion, implementing advanced maintenance strategies such as Predictive Maintenance, Total
Productive Maintenance, and Reliability-Centered Maintenance at Polar Crush can enhance equipment
reliability, minimize downtime, and optimize resource allocation. Continuous monitoring, employee
development, and data-driven decision-making are crucial for sustaining and improving these strategies
effectively.

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