Investigation of Maintenance strategy to words profit maximization ‘A case study in Ethiopian Shipping & Logistics Services Enterprise Kality in Land Transport Branch ESLSE Kebebe Urgie Bedasa A Thesis Submitted to the department of Mechanical Engineering School of Mechanical, Chemical and Materials Engineering Presented in Partial Fulfillment of the Requirement for the Degree of Master’s in Mechanical Engineering (Specialization in Manufacturing Engineering) Office of Graduate Studies Adama Science and Technology University December, 2022 ‘Adama, EthiopiaInvestigation of Maintenance strategy to words profit maximization A case study in Ethiopian Shipping & Logistics Services Enterprise Kality in Land Transport Branch ESLSE Kebebe Urgie Bedasa Advisor: Moera Gutu Jiru (PhD) Associate Professor A Thesis Submitted to the department of Mechanical Engineering School of Mechanical, Chemical and Materials Engineering Presented in Partial Fulfillment of the Requirement for the Degree of Master’s in Mechanical Engineering (Specialization in manufacturing Engineering) Office of Graduate Studies Adama Science and Technology University December, 2022 Adama, EthiopiaDeclaration Thereby declare that this Master Thesis entitled Investigation of Maintenance strategy to words profit maximization” is my original work. That is, it has not been submitted for the award of any academic degree, diploma or certificate in any other university. All sources of materials that are used for this thesis have been duly acknowledged through citation Kebebe Urgie Name of the student Signature DateRecommendation we, the advisor(s) of this thesis, hereby certify that I/we have read the revised version of the thesis entitled “Investigation of Maintenance strategy to words profit maximization” prepared under my/our guidance by Kebebe Urgie submitted in partial fulfillment of the requirements for the degree of Master of Science in manufacturing Engineering. Therefore, lave recommend the submission of revised version of the thesis to the department following the applicable procedures. Advisor Date‘Approval Sheet we, the advisors of the thesis entitled “Investigation of Maintenance strategy to words profit maximization” and developed by Kebebe Urgie, hereby certify that the recommendation and suggestions made by the board of examiners are appropriately incorporated into the final version of the thesis. Dr. Moera Gu ‘Advisor Signature Date We, the undersigned, members of the Board of Examiners of the thesis by -- Kebebe Urgie have read and evaluated the thesis entitled “Investigation of Maintenance strategy to words profit maximization” and examined the candidate during open defense. This is, therefore, to certify that the thesis is accepted for partial fulfillment of the requirement of the degree of Master of Science in manufacturing Engineering Chairperson Signature Date Internal Examiner Signature Date External Examiner Signature Date Finally, approval and acceptance of the thesis is contingent upon submission of its final copy to the Office of Postgraduate Studies (OPGS) through the Department Graduate Council (DGC) and School Graduate Committee (SGC). Department Head Signature Date School Dean Signature Date Office of Postgraduate Studies, Dean Signature DateACKNOWLEDGEMENT First and foremost, { would like to thank the almighty God for the good health & well-being He bestowed upon me, that were necessary to complete this thesis I would like to graciously thank my Advisor Dr, Moera Gutu for his support, supervision, feedback and constant academic and moral support. He had strong faith in my ability to achieve better results by pushing me to my limits and by making himself available at any time to accommodate me. Secondly, I would like to thank the management and staff of Ethiopian Shipping & logisties Service Enterprise Kality branch on which this research study was conducted and all those who supported me in conducting this study successfully, I am particularly thankful to Mr. Dereje Zenebe (Forman of Body Repair Group Maintenance) & for my co-worker Mr. Atilaw, Mr. Kagnew Belachew and Mr. Dejene Diriba for their Supporting and covering My work When I preparing this Thesis. My special gratitude also goes to my classmate Diriba Ejersa. 1am especially grateful and thankful to all my family members. Especially my wife Imabet Girma, and my wonderful child, Siifan for their constant perseverance in making my dream come true, You have helped me through bad and good, to ensure I had nothing but the best. Your love and guidance mean the world to me and has led me to where I am today, I love you, and God bless you allTABLE OF CONTENTS CONTENTS Declaration Recommendation Approval Sheet. ACKNOWLEDGEMENT Acronyms and Abbreviations Abstract CHAPTER -1 1. Introduction 1.1 Background of the Study 1.2. Problem Statement 1,3. Basic Research Question 1.4. Objectives 1.5. Significance of the study 1.6. Scope of the thesis work 1.7. Expected Results from the study 1.8. Organization of the Study CHAPTER -2 2. Literature Review. 2.1, Definition of terms 2.2. Maintenance concept globally 2.3. Maintenance in Africa 2.4, Basic Maintenance philosophies 2.5. Maintenance management 2.6. Maintenance and Performance 2.7. Maintenance performance measurement, 2.8. Maintenance in Transport industry 2.9, Research gaps CHAPTER 3 3. Materials and Methods 3.1, Research Method Page a Z, 3 3 3 3 5 5 5 7 10 ul 20 32 33 34 36 36 363.1. 1. Data collection method and tools 36 3.2, Sampling and sample size 37 3.3. Data Analysis 38 3.4, Research framework 39 3.5, Ethical Consideration 4. CHAPTER - 4 42 4, Data Analysis and Discussions 42 4.1, Documentation Review 47 4.3, Conceptual Framework of Maintenance Management 33 4.5, Implementation procedure 65 4.6, Validation 66 Chapter -5. 67 5. Conclusion and Recommendation 67 5.1. Conclusion. 67 5.2. Recommendation 68 5.3. FUTURE WORK 69 References 70 Appendix A Questionary i Appendix Al Operational Downtimes v Appendix A2 Maintenance Downtimes Appendix B Annual Vehicle Performance Report& OEE Table Appendix C Codes for CMMS. viii viLIST OF TABLES TABLE Table 1.1: Produetion(trip) Truck performance ‘Table 2.1: Emerging trends in maintenance .....0-nnnnnnnnnnnnnn oe 8 Table 2.2: Prepared paper on Maintenance Area in AfFiCA ne Table 2.3: classification of maintenance type based on maintenance tiggers....ecesnene 12 Table 2.4: CSFs for managerial process in MM..n.nnsnnnnnnnnnnnnnnnnnnnn so IT Table 3.1: Participants for data collection with their respective position 38 Table 4.1: General information .....0nnnennennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnes A Table 4.4: Common Failure of Spare Parts 35 Table 4.5: Proposed KPI 63 vilList of Figures Figure PAGE Figure 2.1, Maintenance strategies... Figure 2.2. Elements of Preventive Maintenance. ....o:ssnsnisnnnininnnnntnnnnsnaie Figure 2.3, Work flow of reliability analysis (Ismail et al., 2020) .. Figure 2.4, Risk based maintenance framework. Authors (Alaswad & Xiang, 2017) Figure 2.5. Foundation and pillars of TPM (Labiyi, 2019). ...00.e0eenrnnnnnnnnenenne VT Figure 2.6. The maintenance workflow (Keat, and Ya’akob 2021) won Figure 2.7: framework 1 (Vanneste & Van Wassenhove, 19958)... Figure 2.8. schematic overview of the proposed framework . soe 2d Figure 2.9. Maintenance management framework (Marquez et al., 2009) 25 Figure 2.10. CIBOCOF framework (Waeyenbergh, 2020) Figure 2.11, Maintenance management framework (Wireman, 2005)... Figure 2.12. maintenance management framework (Hesham, 2015) Figure 2.13. maintenance reengineering framework (Sharma, 2013)... Figure 2.14. The maintenance management framework (Keat and Ya’akob 2021)... Figure 2.15. Key Maintenance Performance Indicators. Figure 3.1: Research framework ....nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnenees 40 Figure 4.3. Total Truck Downtime (2011) E. Figure 4.4, Total Truck Downtime Specific Area (2011) E.C Figure 4.6. Total Truck Downtime Specific Area (2012) E.C sescnnnnnnnnnneeneenee 49 Figure 4.7. Total Truck Downtime (2013) E.C .. Figure 4.8, Total Downtime Specific Area (2013) E.C... Figure 4.9, OEE of 215 Trucks 2013 E.C Figure 4.10. proposed workflow. Figure 4.11. Truck Information Menu: developed by authors (Researcher)... 60 Figure 4.12. labor information Menu: developed by authors (Researcher)... 60 Figure 4.13. Store information Menu: developed by authors (Researcher) .....snsnnnnn 61 Figure 4.14. Cost information Menu: developed by authors (Researchet) -..nnuenennnnee 61 Figure 4.15 Analysis Menu: developed by authors (Researcher). 2 Figure 4.16: Report Menu: developed by authors (Researcher). Figure 4.17: Proposed Conceptual framework of maintenance management... villBSC BM MMS FMEA FTA GCMMS HSE KPI MMIS MMT MPM OEEE, PdM QED RCA RCM RPN ‘TPM TQM VDM VDM wo Acronyms and Abbreviations Balance score card Computerized mi ntenance management System Failure Modes and Effects Analysis Fault Tree Analysis Garage Computerized Maintenance Management System Health, Safety and environment Key Performance Indicator Maintenance Model Integration System Maintenance management tool Maintenance Performance Measurement Overall Environmental Equipment Effectiveness Predictive maintenance ity-centered maintenance Risk Priority Number Total Productive Maintenance Total quality management Value-driven maintenance Value-driven maintenance Work OrderAbstract Maintenance is the combination of all technical, administrative and timely actions the life cycle of the object intended to maintain, today many industries in our country are facing a crisis of asset processing that leads to lower production, Ethiopian Shipping & Logistics Services Enterprise Kality in Land Transport Branch was one of the industries that facing crisis. The ‘main purpose of this thesis was investigation of maintenance strategy to words profit ‘maximization by addressing the root causes of fragmentation and developing the CMMS software with developing maintenance management framework in the case company, both the quantitative and qualitative data required for the survey were collected from the company. the data obtained from the respondents were to a ystematic questionnaire distributed by a sample of 67 respondents taken from the Department of Maintenance management staff and the downtime truck data were obtained from the company's annual report. The data collected was analyzed by analytics tools, namely Microsoft Excel and SPSS analysis and the proposed solution was provided to improve company productivity. This analysis identified the key area facing the downtime in company, maintenance under road call repair and maintenance under body was a critical area of downtime resulted in loss of production for truck drivers. The CMMS concept and maintenance management framework was developed for the trial company in this study, the new concept framework discusses both the theoretical and practical areas identified in this study and developed software (KalityGCMMS) which was used to collect data for all work in the company workshop. Verification was done by presenting research to technical staff and managers to obtain their expert opinion and find it appropriate, The Research can also be used as part of new research in this area. Keywords: Computerized maintenance management systems, CMMS, maintenance ‘management Framework, maintenance, maintenance management.CHAPTER -1 1. Introduction 1.1 Background of the Study Er-ratby and Mabrouki 2018, manufacturing industry has experienced an unprecedented degree of change in the last three decades, involving drastic changes in management approaches, product and process technologies, customer expectations, supplier attitudes as well as competitive behavior, in today's rapidly changing marketplace, slow and steady improvements in manufacturing operations do not guarantee sustained profitability or organizational survival. thus, the organizations need to improve at a faster rate than their competitors if they are to become or remain leaders in the industry(Ismail and Kamal 2020). Bakr et al., 2020 shows that in recent years, industry managers have been gradually moving (o the idea that maintenance can be a profit generating function rather than merely a cost center. when it comes to issues such as reliability, availability, safety, quality and cost-effectiveness of equipment and facilities, there is no doubt that maintenance costs can be high and often representing a significant portion of recurrent budgets(Fraser and Tseng 2015). 1.2. Problem Statement On literature an increasingly number of companies replace the current reactive, “fire-fighting” maintenance strategy with proactive strategies(Gackowiee, 2019), (Franciosi et al., 2018), (Nijhof and Andre HJ Jeurissen, 2017). This is also the current maintenance practice in ESLSE Kallity branch which hinders the company from not achieving its targets. Table 1.1: Production(trip) Truck performance Trip Total Total Total Plantobe | Actual Performa | Maintenane | Operational | Days Year | produced{ | produced neein | ¢ Down Downtime tripped) | tripped) | |% Time Days | in Day 2011 |3s4 [27 76.2 9145 776 88695 2012 | 3.2 26 812 8154 865 75190 2013 | 2.75 24 87.2 7231 668 68620 ‘The company data indicates that the average track production performance of the past three years is around 81.5 %, The main reasons that hinder the company not to achieve the target are Maintenance down time and valid other stoppages.> Valid other stoppages are downtimes due to lack of quality spare parts, political instability, unplanned insurance operation, and other factors that cannot be avoided or beyond by management. > Operational downtime can be caused by Truck breakdowns or operational problems. This alss includes human resource related issues such as operating trucks at maximum speed by drivers so as to get incentives, under staffed maintenance team, commitment of maintenance staff to perform routine and non-routine inspections periodically and high turnover of truck drivers. This indicates that there is a maintenance problem in the company, in addition to normal wear and deterioration, other failures may occur especially when the equipment are pushed beyond their design limits or due to operational errors. Therefore, this study addresses the maintenance problem by investigate maintenance strategy of the company in order t 1. erease profit maximization of the company. Basic Research Question The research work consists four main questions as a guiding question in order to meet the objectives and develop maintenance system to the company. The questions include: 1, What is the present maintenance system in ESLSE? 2. What are the major problems in the current maintenance system on ESLSE? 3. What are the causes of poor maintenance in the ESLSE? 4, How to improve the existing maintenance problems of ESLSE? 1.4. Objectives 1.4.1. General objective The main objective of this thesis is to Investigate Maintenance strategy to words profit maximization by addressing the root causes of breakdowns and developing maintenance management framework with CMMS software in Ethiopian Shipping & Logistics Services Enterprise Kality in Land Transport Branch. 1.4.2. specific objectives ‘The specific objectives of this research are: 1. To evaluate company maintenance performance, maintenance culture and challeng2. Developing maintenance management system (maintenance management framework) based on the existing models. 3. To transfer all manual controlling maintenance management activities to computerized maintenance management system or (CMMS) software that centralizes maintenance information and fac tates the processes of maintenance operations. 1.5. Significance of the study ‘The main aim of Truck maintenance is to maintain the funct mnality of the Trucks and to minimize its breakdowns. for mechanical equipment, the maintenance management will involve repair, replacement, and serving of tools. It also ensures the proper working and to intercept fluctuations that occur in the duration of the production process. ‘The fact remains that, any kind of change even a minor downtime could reduce the overall efficiency of Trucks which would lead to major production losses. Therefore, it is important for organizations today to get and implement a good maintenance management strategy with the best Framework including computerized maintenance management system. Without or in the absence of equipment management, it might be possible to face some consequences in revert of careless decisions. 1.6. Scope of the thesis work Research focuses on case company maintenance management system and any maintenance related issues. 1.7. Expected Results from the study. The main expected result from thi > Identified existing maintenance management gaps. paper is: - > A newly developed maintenance management system software and maintenance management Framework for Ethiopian Shipping and Logi ies Service Enterpri Organization of the Study The thesis has four chapters, The first chapter is about the introduction of the study and Contains background of the study, statement of the problem, significance of the study and scope of the study. The second chapter is an intensive literature review from various sources on theconcept of maintenance at the global and African level, maintenance triggers, strategies, performance indicators, maintenance management frameworks. The third chapter is the research methodology. In th s chapter Data collection and presentation methods, data analysis tools, sampling, sampling techniques and methodological framework presented in detail, primary data collected from various sources through observation, interviews and questionnaires properly integrated and presented in a descriptive manner according to the objective of the study. The fourth chapter deals with results and discus jons, data analyzed using overall device efficieney analysis, cause and effect diagram, and various statistical tools. Within this chapter, the maintenance management system for the case company and its implementation procedure will be developed. conclusion, recommendations and references are described correctly, Attachments that contain the necessary information related to the work are attached at the end of this post.CHAPTER -2 2. Literature Review 2.1. Definition of terms Maintenance is a function that must be perform under normally adverse circumstances and stress, and its main objective is to rapidly restore the equipment to its operational readiness state using available resources(Falorca, 2019). Maintenance is combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it can perf and Rota 2019). 'm the required function(Choudhary, 2016)(Talamo According to John Dixon, without understanding the maintenance management process and establishing a sound maintenance strategy, no improvement effort will have an impact on ess sectors-and profitability of the industry. “Maintenance management is important to all bu: critical to those that are capital intensive.” - John Dixon(Consulting and Paper, 2018). Corporate maintenance systems should reflect the level of cooperation with partners in the supply chains. If the enterprise deepens cooperation with supplicrs and customers, it will probably affect the method to manage the production equipment maintenance (Bransk, and Pat me cases determines 2016). maintenance is an important factor in quality assurance and in s the long-term success of a company, Poorly maintained resources can cause instability and partially or completely pause the production(Pukite and Geipele, 2017). Malfunctioning machines or complete breakdowns can become a costly process for most companies. When breakdowns occur the labor cost per unit rises as time passes until the machines again run as normal(Bakri et al., 2020). Any unplanned downtime of machinery equipment or devices would degrade or interrupt a company’s core business potentially resulting in significant penalties and unmeasurable reputation loss(Ran et al., 2019). as Maletic, Al-najjar and Gomiscek, Effective maintenance aims to enhance company’s profitability and competitiveness through continuous cost-effective improvement of production process efficiency, effectiveness and productivity, which can be achieved via maintaining and improving the quality of all the elements contribute in the production process continuously and cost-effectively (Maletic, 2014)(Al-najjar and Gomiscek, 2014).All management activities that determine maintenance objectives, strategies and responsibilities to carry them out through, such as maintenance planning, planning and control methods in the organization. including economic (Choudhary, 2016), according to (Oluwatoyin and Olotuah, 2015), All the activities of the management that determine the maintenance objectives or priorities (defined as targets assigned and accepted by the management and maintenance department), strategies defined as a management method in order to achieve maintenance objectives and responsibilities to implement them by means such as maintenance planning, maintenance control, supervision and several improving methods with including ‘economical aspects in the organization. Maintenance was forgotten during years in detriment of more visible organizational functions such as production or logistics, since for many companies it is considered a function without value (Lopes et al., 2016). Therefore, performance of the maintenance process is critical for the long-term value creation and economic viability of many industries, itis important that the performance of the maintenance process be measured, so that it can be controlled and monitored for taking appropriate and corrective actions to minimize and mitigate risks in the area of safety, meet societal responsibilities and enhance the effectiveness and efficiency of the asset maintained (Shihundla and Adenuga 2019) according to Nijhof, Andre HJ Jeurissen Knowledge is a central component to predictive maintenance which is often referred to as a condition-based imminent maintenance. AC this level, diagnostic equipment is used to measure the physical condition of equipment such as temperature, vibration, noise, lubrication, and corrosion(Nijhof Jeurissen 2017). ‘The main idea behind condition-based maintenance (CBM) is to use degradation information detected from on-line physical equipment sensing techniques and measures to minimize system downtime by balancing the risk of failure and achievable profits. (Femandez del Amo et al., 2018) and Mkalaf says the majority of organizations that apply TPM or RCM gain the benefit ofa reduction in machinery failure. This is because technical infrastructure is maintained in a proper condition which promotes production continuity. There is also a sizeable reduction in machine maintenance costs(Mkalaf, 2016). Maintenance management requires the adoption of a basic systems approach, i.e., the implementation of company goals to management goals as well as-known maintenance management philosophies (TPM, RCM, RBI) applied to improve processes often remain only on the basis of service implementation without the need fullintegration into existing management systems.(Pacaiova and Glatz, 2015).Computerized Maintenance Management System (CMMS) to plan, schedule and execute these activities. A standardized process to Identify, Plan, Schedule, Execute and Close (IPSEC) will help streamline the transition process (Palakodeti, 2019). Maintenance performance measurement is defined as the multidisciplinary process of measuring and justifying the value created by maintenance investment, and taking care of the organization’s stockholders’ requirements 2018). viewed strategically from the overall business perspective(Er-ratby and Mabroul A common occurrence when reviewing literature is the fact that authors use an array of terms and words to describe the same or similar concept. The study of maintenance management is no different with terms such as: maintenance models; maintenance methods; maintenance techniques; maintenanee systems; maintenance types; maintenance philosophies; and maintenance strategies regularly used Maintenance management models throughout the literature to describe the same notion on maintenance( Hvolb and Tseng 2015). 2.2. Maintenance concept globally Falorca 2019, Due to the increasing technical advancements, the stimulus of productivity and quality is moving from man to machine. Productivity and quality may be increased only by implementing well developed and organized maintenance system Maintenance is normally perceived to have a poorer rate of return than any other major budget item. Yet, most companies can reduce maintenance costs by at least one-third, and improve the level of productivity, by giving maintenance the management priority it requires. That priority must span all levels of an organization’s management structure to develop an understanding at each level of the significance maintenance can have upon the success or failure of organization objective (Oluwatobi et al., 2019)(Ismai_ and Kamal 2020) but according to Trojan, in Europe, Traditionally, maintenance is sorted and performed by time-based fixed intervals, and it is called preventive maintenance, or by corrective maintenance after breakdown (Trojan, 2018). In 21 century new thinking and new strategies will be required to realize potential benefits and turn them into profitability. All in all, profitable operations will be the ones that have employed modern thinking to evolve an equipment management strategy that takes effective advantage ‘of new information, technology, and methods(Er-ratby and Mabrouki, 2018).The economic downturn and the dynamic business environment drive companies to seek more efficient and effective maintenance. Thus, the increasing competition in the market creates a need to search new ways in which companies can differentiate themselves and gain more profit and better competitive position(Alsyouf, 2017), Hwang and Samat 2019, Maintenance has two parts, an engineering and management part, the engineering part of maintenance is all about to improve maintenance operations, reduce the amount and frequency of maintenance, reduce the effect of complexity, reduce the required ‘maintenance skills, reduce the amount of supply support, determine the optimal frequency and extent of preventive maintenance to be performed, improve and ensure maximum utilization of maintenance equipment, and improve maintenance organization. On the other hand, the management part talks about all management activities that determine maintenance goals or priorities (defined as goals assigned and accepted by the management and maintenance department), strategy defined as a management method to achieve maintenance goals and responsibilities and carry them out by means such as maintenance planning, maintenance control and supervision, and several improving methods including economical aspects in the organization the function of providing policy guidance for ‘maintenance activities, in addition to exercising technical and management control of ‘maintenance programs(Er-ratby and Mabrouki, 2018). Literatures show that maintenance management is very important for the performance of the company (Fonseca et al. 2017). Table 2.1: Emerging trends in maintenance ‘Attribute Earlier Emerging Mechanization-Automation Manpower Simple Globalizations (crossing boundaries) “Attitude towards Technical matter—profit Necessary evil | contributor- ‘maintenance ° partnership Maintenance (CM-PM-RCM- eth or ss strategy TPM ECM, SMM, ete Maintenance Mathematical Application oriented, integration optimization ah with models(quantitativey | Wi#h limited qualitative approaches applicationsMaintenance Not existed Part of vertical contracting outsourcing Maintenance Models in. Integration with MMIS scheduling isolation Reference numbers, Performance surveys, Maintenance management indicators indicators, tool (MMT)model models -Hibi and Luck Value based Performance approach, Balance score card systems audit (BSC)approach, ‘measurement approach, Quality function deployment approaches proach, y ploy data envelopment | (QFD) analysis (DEA) PMS integration within Poor Developing formation system Data collection in measurement of OEE Not sufficiently | Designing of data collection treated system Evolution in middle ware software (e.g., communication between corporate and plant floor), workgroup ‘computing, integrated system Main frame applications and Evolution of MMIS_ | mostly administration oriented technology, inter enterprise technology Graphical user interface (GUI)— Spare parts Inventory maintenance management ‘management administration | information systems (MMIS) Maintenance strategy in MRP system, New maintenance | Techniques in Sint itaplementation of TOM, policies isolation itr Maintenance management frameworks and related tools and techniques are reviewed for this paper and the details are found on maintenance management section.2.3. Maintenance in Africa Only few literatures can be discovered in Africa level this shows that more emphasis needs to be given on maintenance area, Revealed literatures are more on evaluation of maintenance ‘management system, improving quality and productivity through maintenance management system. A total of four thesis and four articles reviewed. Table 2.2: Prepared paper on Maintenance Area in Africa No| Title of paper Type of paper Year Area Integrating Lean and Green Paradigms in 1 | Maintenance Management (South Africa) Journal 2017 Maintenance ‘management Total Productive Maintenance A Case 2. | Study in Manufacturing Industry (Ethiopia) Journal 2012 Maintenance management Medical devices in Sub-Saharan Africa: optimal assistance via 3 | acomputerized maintenance ‘management system (CMMs) Journal 2019 Maintenance management Prospects of Maintenance Management Functions in Sugar Industries: A Case Study on Ethiopian Metchara Sugar Factory Thesis 2015 Maintenance management 102. Basic Maintenance philosophies 2.4.1. Maintenance triggers When maintenance triggers occur, it indicates that maintenance must be performed at an operational level. Maintenance triggers are used to alert a technician that maintenance is required. When maintenance tr ers are received the operational requirements for the maintenance can be planned, acted upon, and recorded using a CMMS or manual datasheet There are five main maintenance triggers: breakdown, time-based, event-based, usage-based, and condition-based(Nuratirah and Salmiah, 2018) and (Bakri et al., 2020) > Breakdown trigger: Breakdown maintenance triggers are initiated when a piece of equipment breaks down into an unusable state, for these maintenance triggers maintenance is required to return the device to service and the failure trigger is the only maintenance trigger used when the maintenance strategy has not been designed at the tactical or strategic level. If the equipment maintenance plan has been specified as a run-to-failure strategy, then the failure trigger is only trigger used for maintenance of that machine. In this case, maintenance, even if unscheduled, remains scheduled maintenance. When a facility has a preventive maintenance strategy, failure trigger initiates maintenance that is both unscheduled and unscheduled > Usage Trigger: A common example of a usage trigger for maintenance is the schedule suggested by car manufacturers. For example, a car manufacturer may suggest maintenance every 10,000 km. This type of maintenance is triggered through recorded meter data, Other examples include usage based on hours of use and number of production cycles. > Condition Trigger: A condition-based trigger for maintenance occurs after the condition of the equipment has been assessed and consequently determined to be unsatisfactor for continued use without maintenance being planned. Various techniques can be used to assess the condition of a machine, ranging from inexpensive methods such as visual inspection through to more technically demanding techniques such as vibration monitoring and thermographic analysis. Condition is the most complex trigger for maintenance. This is because data about condition must be obtained and interpreted. Often the equipment required to perform condition monitoring requires specialized training and experience to operate effectively. After the data is analyzed, it may indicate that maintenance is required > Time Trigger: Time is used frequently as a trigger for maintenance activities. With a time, trigger, maintenance is triggered whenever the calendar rolls over to a pre-specified date. uBecause the calendar is so easily predicted, time is the least complex trigger to schedule planned maintenance. Time can be used as a trigger in many ways. It can be used to trigger ‘maintenance on regular intervals, say every 6 weeks. It can also be used to trigger maintenance based on the seasons, such as “change air conditioner filters before summer”. > Event Trigger: When maintenance is needed due to an external event, an event trigger can be used. For example, a building may need to trigger a series of maintenance tasks if the basement floods, these tasks may include electrical checks, cleaning and boiler check: Table 2.3: classification of maintenance type based on maintenance triggers(Alsyout, 2017) Maintenance S.No. Maintenance type trigger Run to failure, corrective and 1 Breakdown preventive Preventive, Condition based 2 Usage and Predictive Condition based and 3. Condition Predictive Preventive, Condition based 4 Time and Predictive Preventive Condition based 5 Event and Predictive 2.4.2. Maintenance strategies According to (Eindhoven and Version, 2021) it is convenient to think of equipment as a collection of interrelated parts & Maintenance operations consist largely (but not solely) in replacing parts of equipment, There are many different approaches that can mix and match, depending on the type of assets, industry, and the size and experience of the maintenance team. 2Maintenance strates Breakdown corrective maintenance sage based maintenance Condition based nlntenaiice Biock replacement ] [Condition or over ‘and/or overhaul |] monitoring Period inspections Preventive mainten: Figure 2.1. Maintenance strategies ance Management system of an organization that is responsible for building maintenance gives guidelines for technicians and electricians what to do, when to do and most importantly how to do maintenance works(Munyensanga et al., 2018). On preventive maintenance strategy equipment’s needs to be inspected periodically, lubricate, cleaned, calibrated, tested all electrical and mechanical parts are fully functional and replaced any damaged parts so as to run the equipment in a good condition. inspection mServicng mCalbraion Testing mlignment mAdlustment mnstallation Elements of Preventive Maintenance Installation Inspection Alignment Calerstion “Testing Figure 2.2.Elements of Preventive Maintenance. (Carpitella et al., 2020)(Mohamed and Khodeir 2019) 13Reactive maintenance (breakdown maintenance) Reactive maintenance is pretty simple: fix things when they break. Since repairs are not planned, it’s a good method to employ for equipment that is not essential for operations or has a low cost think anything that’s rarely used or duplicates the function of other equipment (Fonseca et al., 2017). Predictive maintenance (PAM) Predictive maintenance (PUM) aims to prediet failures before they happen so maintenance can ‘occur at just the right time, PdM uses data from machine sensors and smart technology to alert the maintenance team when a piece of equipment is at risk of failing. For example, a sensor may use vibration analysis to alert the maintenance team that a piece of equipment is at risk of failing, at which point it will be taken offline, inspected, and repaired accordingly (Olesen and Shaker, 2020). Reliability-centered maintenance (RCM) Reliability-centered maintenance (RCM) addresses the fact that failure is not always linear. RCM is a highly. piece of equipment and customize a maintenance plan for each individual machine. The folved process that seeks to analyze all the possible failure modes for each ultimate goal of RCM is to increase equipment availability or reliability(Singgih et al., 2019). Investigate and review the ‘Tdentify the main components system information and base data snd subsystems Analyse and validate the Calculate reliability factors and reliability importance indices perfom analysis Figure 2.3. Work flow of reliability analysis (Ismail et al., 2020) 14Risk-based maintenance Risk-based maintenance (RBM) prioritizes maintenance resources toward assets that carry the most risk iff they were to fail. It is a methodology for determining the most economical use of maintenance resources. This is done so that the maintenance effort across a facility is optimized to minimize any risk of a failure(Carpitella et al., 2020). Aris -based maintenance strategy is based on two main phases: 1. Risk assessment. 2, Maintenance planning based on the risk ‘The maintenance type and frequency are prioritized based on the risk of failure. Assets that have a greater risk and consequence of failure are maintained and monitored more frequently. Assets that cay a lower risk are subjected to less stringent maintenance programs. Implementing a risk-based maintenance process means that the total risk of failure is minimized across the facility in the most economical way. The monitoring and maintenance programs for high-risk assets are typically condition-based maintenance programs. Risk-based maintenance is a suitable strategy for any maintenance plan. As a methodology, it provides a systematic approach to determine the most appropriate asset ‘maintenance plans, Upon implementation of these maintenance plans, the risk of asset failure will below. Figure 2.4, Risk based maintenance framework. Authors (Alaswad & Xiang, 2017) 15,Total productive maintenance As Oakley and Ed 2021, discussion been held on direct process improvements using lean methods valuable in reducing waste that is a direct result of manufacturing practices. Total Productive Maintenance (TPM), however, focuses on continuous improvements based on reducing wastes related to machines and tooling used in manufacturing processes through a highly effective and efficient maintenance program Total Productive Maintenance (TPM) is an approach to maintenance developed in Japan that brings the tools of total quality management (TQM) to maintenance. The only change is that instead of companies focusing on their products, their focus shifts to their assets. All of the tools and techniques used to implement, sustain, and improve the total quality effort can be utilized in TPM (Fonseca et al., 2017)The aim of TPM is to reduce six categories of equipment losses to improve overall equipment effeetiveness (OEE). The six major causes of equipment losses, according to (Kumar et al., 2018)are: 1. Failure; 4, Reduced speed. 2. Set-up and adjustments; 5. Process defects; and 3. Idling and minor stoppage. 6. Reduced yield. TPM empowers operators and uses multi-skilled crafts to minimize response time and perform producti ce maintenance, The implementation is expected to assist in improving maintenance effectiveness and control (Lundgren et al., 2018) according to (Bakri et al., 2020)TPM is an innovative approach, which holds the potential for enhancing the efficiency and effectiveness of production equipment by taking advantages of abilities and skills of all individuals in the organization, TPM focuses on maximizing the Overall Equipment Efficiency (OEE) with involvement of each and everyone in the organization. It will not only establish a complete maintenance system, but also ai 5 to improve the maintenance skills and knowledge among the shop floor operators(Alaswad & Xiang, 2017), TPM and its implications received prestigious worldwide recognition in achieving the ultimate Zero Defects and Zero Breakdown targets. Fewer breakdowns, safer workplace and better overall performance are few advantages of TPM. 16Under the TPM philosophy, everyone from top-level management to equipment operators should participate in maintenance, > Top management & reliability > Maintenance managers and engineers technicians > Operators Table 2.4: CSFs for managerial process in MM (Bakri et al., 2020) CSS Elements ‘Authors ‘Mahzan etal, 2018; Pakrudin et al. 2017; Policy on mM | Clear company policy on MM; recognition of | Hooi and Leong, 2017; Mehralian, tal, y ‘MM as vital constituent in management. | 2016; Bakri, 2015; Kumar and Kumar, 2014; Zangun and Al-Ashaab, 2014. Financial and Allocation of sufficient resources; offering mee eniet eae. Kumar and Kumar, 2014 Education and | Knowledge and competencies; development | Malzan etal, 2018; Pakrudin etal, raining ‘on employee competency 2017:Mehralian, etal, 2016: Bakri, 2015: Equipment and ‘Continual improvement of equipment and z facility ‘eligy Wacol te Katine aare Pakrudin et al, 2017; Bakr, 2015 —— Ope exchange of Mahan etal, 2018, Pakradin al communication and exchange wan eval, 2018; Pakridin etal, ‘Communication | information: feedback system: motivation. — | 2017; Bakr, 2015: ‘Scheduled monitoring and follow-up; Performance _| measurement of performance based on OEE; | Pakrudin tal, 2017:Mehratian, eta, measurement | assessment on employee competency, 2016; Singh etal, 2014, enforcement by management TPM is built on a SS foundation, with eight supporting pillars. The beginning of a TPM program will focus on establishing the SS foundation and developing an autonomous maintenance plan. This will free up the maintenance staff to begin larger projects and perform ‘more and more planned maintenance. Cree Tata) com, "eens eka Figure 2.5. Foundation and pillars of TPM (Labiyi, 2019). 7Starting the Kaizen activities through implementing the basic three pillars which include the five steps of housekeeping (5S"s), standardization and muda elimination. According to (Labiyi, 2019), the five steps of housekeeping are: Sorting: itis a process that involves selecting what you need to complete the job and removing everything else from your work area, Set in Order: Straightening specifically customizes your workstation and surrounding area to meet your work area needs. Arrange remaining items so they are easy to select, use, and return to their proper locat n. Shine: Its Emphasis is on the removal of dust, dirt, and grime, It focuses on cleaning up the place now that all the disorder and trash has been removed. Standardize: Standardizing creates a work area free of checklists; if appropriate standards are put in place, it will be easier to maintain and continue improving, by implementing this we make sure that the first three steps are maintained. Sustain: Sustaining is the end result of how well we have performed the previous four $’s, the idea Sustain implementing the 5S will demand from workers the compact self-discipline ‘connected with implementing and obeying the rules of regularity in cleaning and sor Value Driven Maintenance (Lundgren et al., 2018), original cited by Senstrom et al., (2013), Value-driven maintenance (VDM) is not @ maintenance type, but rather a philosophy developed by the founders of Mainnovation, Mark Haarman and Guy Delahay, for optimizing the value derived from maintenance at any particular point in time VDM is a maintenance management model with the aim of adding value and profit to the company. ‘The value drivers in maintenance are described as utilization, resource allocation, cost control, ‘and safety, health, and environment (HSE). Net present value is used in VDM as a measurement of profit calculated by the difference in cash inflows and outflows from the different value drivers. It gives an indication of how much value an investment or project will add to a company, and is used to analyze the profitability of investment suggestions is calculated as below formula of authors(Lundgren and Bokrantz 2018) PVPM=3(FSHE, t) + [CFCC, t) + (CFRA,t) + (CFSHE, t)|/(1+r) +t Qa) 18Where: PVPM: present value potential of maintenance FSHE,t: She factor in a year t (% compliance with SHE regulations CFAU,t: future cash flow in year from asset utilization CFCC, future cash flow in year t from the cost control CFRA,t: future cash flow in year t from resource allocation FSHE,t: future cash flow in year t from She r: discount rate ‘Total Quality Maintenance (TQMain) Mahajan 2018,studied the concept which enables the user to continuously maintain and improve the technical and economical effectiveness of manufacturing process elements and its role may be defined as “a means for monitoring and controlling deviations in a process condition and product quality, and for detecting failure causes and potential failures in order to interfere, when possible, to arrest or reduce deterioration rate before the product characteristies are intolerably affected and to perform the required actions to restore the machine process or a particular part of it to as good as new. All these should be performed at a continuously reducing cost per unit of good quality product” (Alsyouf, 2017). Features, Applicability and Benefits of TQMain ‘The features characterizing TQMain and distinguishing it from other maintenance techniques, such as preventive (PM), condition-based (CBM), reliability-centered (RCM) and total productive maintenance (TPM) can be summarized in the following based on (Lundgren et al., 2018) (Alsyouf, 2017)(Al-Najjar, 2008). It is based on a new CBM concept. It is planned and performed based on the needs arise due to the deviations in the quality of the elements involved in the production process. > It advocates the use of a common database that should be updated by real-time measurements of the essential information parameters, for real-time monitoring and assessment of the machine condition and production process technical and economic is effectiveness, product quality and working environment. Thus, within TQMain, it possible fo select and improve the most informative CM system and the most cost- effective maintenance policy effectively. 19> It is based on making intensive use of the real-time data acquisition and analysis to detect at an early stage the causes behind quality and cost factors deviations and machinery malfunctions, and following damageldefect development to prolong the component mean effective life and to improve company’s profitability and competitiveness. v It provides tools and methods for proactive-predictive maintenance, to detect and eliminate the cause behind damage initiation. If it is not possible due to the technological limitation, detect the deviation at an early stage and predict its development to reduce (or eliminate) the risk of failure. 2.5. Maintenance management ‘As a author Lu et al. 2020, A good maintenance management system makes equipment and facilities available, Availability means the production team can demand and receive any item such as light, power, air, gas, heating, cooling, or machine tools when it is needed. If the required equipment or service is down, or if the machine stops short of completing a job, time and money are wasted. A good maintenance management system helps to accomplish minimal downtime. Figure 2.6. The maintenance workflow (Keat, and Ya’akob 2021) 20Basie steps of management stated by Fusko et al., 2018 are request, approval, plan, schedule, performing work, recording data accounting for costs, developing management information, updating equipment history and providing management control reports. Elements of effective maintenance management includes i, Maintenance Policy: vi. Job Planning and ii, Material Control Scheduling iii, Work Order System vii, Backlog Control and iv. Equipment Records Priority System v. Preventive and Corrective viii, Performance Measurement Maintenance 2.5.1. Maintenance management framework In this section former developed frameworks are reviewed. Maintenance must be considered holistically so as to develop an appropriate maintenance concept. Maintenance Framework 1 Vanneste & Van Wassenhove, 1995a, present a brief review of developments in maintenance theory and practice, and in information technology and decision support models, The model is an integrated approach that combines elements from these domains into a powerful tool for dealing with maintenance problems. They also show how this framework can be used to set up ‘a continuous improvement program for maintenance management and apply the concepts to an industrial case. This approach has eight stages by improving the Deming cycle. Phase | Obtain a clear picture of the current factory performance: at this stage list of questions developed in order to have a clear picture of the organization. Phase 2. Analyze quality and downtime problems: At this phase location of the majority quality and downtime problems, relative importance, frequency of occurrences, causes and ‘consequences identified by using histogram, pareto analysis, quality control charts, cause and effect diagrams, FMEA methods. Phase 3. Analyze the effectiveness of alternative solutions for major problems. Different solutions generated and their hidden and tangible costs identified. They mentioned that both costs as well as benefits of a solution, especially in the hidden part are uncertain and difficult to estimate an exact value. 21Therefore, itis necessary to include scenario analysis by comparing one solution cost benefit analysis with another solution, it became easy to prioritizes the proposed solutions. This phase has 4 steps are: 1, Obtain a list of alternative solutions to each problem. 2. Estimate the cost and benefits of major solution. 3, Make a prioritized list. 4, Select one or more solution Phase 4. Analyze the efficiency of maintenance procedures, to identify how much preventive maintenance be to performed, how many spare parts to be kept in stock decision models used. ‘The input for the models such as cost, lifetime distribution is obtained from effectiveness analysis, additional data analysis and experts opinion, At this phase 3 models selected, maintenance and replacement model (it is a maintenance field), spare part provisioning model (it is under Inventory management) and scheduling model (it is under production scheduling). Three models under maintenance and replacement model selected, these are Deterministic age replacement model, Probabilistic age replacement model and group replacement model. a ‘common factor among these models is that the unit deteriorates as it ages. Phase 5. Plan action. Planning of actions and information process takes place to keep the track of the result, After defining performance measures and organizing the data gathering process target will be set Phase 6, Implement actions and gather data, Planned actions on phase five will be implemented and data’s’ will be collected. Phase 7. Monitor actions and process data. And the last phase will be adapting actions ot information procedures in case of undesired evaluation. Performance Indicators (P.L.'s) provide ‘a tool to measure certain quantities and check whether and to what extent objectives are being met. In the integrated approach, the effectiveness analysis precedes the effectiveness analysis. 22‘Adapt plans! Picture of procedures performance ee | eae c Quality/ DT Monitor actions |/ Implement actions | | Effectiveness of /| solutions Plan actions VY Efficiency of A\ | procedures Figure 2.7: framework 1 (Vanneste & Van Wassenhove, 199Sa) Efficiency ssauaanoay Framework 2 This framework offers guidance for developing a tailored maintenance concept, The paper ‘emphasized that Maintenance concept should be unique for each company due to two reasons. ‘One is the relevant factors are different from company to company and the other reason is high speed technological innovations. Due to this a flexible maintenance concept that allows feedback and improvement needs to developed. nowadays great emphasis is put on the availability, reliability and safety of production, Computerized information used for information source in addition to that workers’ experience and know-how (knowledge) considered. The framework was developed for a large process industry with the goal of developing total company maintenance for all different plants and all different installations. The proposed framework has six steps. Step 1. Identification of objectives and resources: the first objective of maintenance is to secure reliability and availability, to reduce cost, protect their commercial margins, to meet the severe laws of safety and environment and to enhance produ ity. Step 2. Identification of most important system: Depending on the objectives and the situation, weight factors can be used to underline the relative importance of each objective conceming bottlenecks, loss of production, Step 3. Criticality analysis: here the most critical component with in the selected most important system identified. A simplified FMECA used in table form, economic and technical aspects and knowledge in human's head considered. The reason for 23