Rosmaini Ahmad and Shahrul Kamaruddin
The purpose of this paper is to present the development of a maintenance engineering policy in the context of a decision support model based on a production machine process…
Abstract
Purpose
The purpose of this paper is to present the development of a maintenance engineering policy in the context of a decision support model based on a production machine process perspective.
Design/methodology/approach
The structure of the policy is called the maintenance decision support (MDS) model, which consists of three steps: initial setup, deterioration monitoring, and decision making. A detailed presentation of each step of the proposed model together with a real case example from the pulp manufacturing industry proves the applicability of the model.
Findings
Validation of the proposed MDS model is as follows. In Task 1 of Step 1, the cutting, sealing, and perforating line processes are classified as critical machining processes. The analysis of Task 2 of Step 1 found that cutting knife, bearing, and motor are classified as the components that most possibly contribute to the cutting appearance quality. In Task 3 of Step 1, it was found that the cutting knife is classified as a maintenance-significant component with non-repairable and single-component type characteristics. The result of Step 2 suggested that at the 29th hour of operating time, the decision of do-something was suggested. In the following step (Step 3), for the case of the cutting knife, which has been classified as a non-repairable type component, the decision to perform preventive replacement of cutting knife is recommended to be carried out at the 29th hour of operating time.
Research limitations/implications
The uniqueness of this model is that it systematically considers different machinery component(s) characteristics, including single- and multiple-component cases, repairable and non-repairable types, and functional or/and physical failure types, to make maintenance decisions.
Practical implications
The proposed MDS model provides a systematic guideline for identifying, evaluating, and monitoring, which makes maintenance-related decisions. Three significant maintenance decisions can be determined based on the proposed MDS model, which includes an appropriate time-to-perform maintenance, correct maintenance actions to be performed, and the right component required for maintenance (for multi-component cases).
Originality/value
One of the vital elements in considering the production machine process perspective toward the development of the MDS model is the need to use product output/quality characteristics for machine deterioration-monitoring and decision-making processes.
Details
Keywords
Ernnie Illyani Basri, Izatul Hamimi Abdul Razak, Hasnida Ab-Samat and Shahrul Kamaruddin
The purpose of this paper is to provide comprehensive information on preventive maintenance (PM) planning and methods used in the industry in order to achieve an effective…
Abstract
Purpose
The purpose of this paper is to provide comprehensive information on preventive maintenance (PM) planning and methods used in the industry in order to achieve an effective maintenance system.
Design/methodology/approach
The literature review is organized in a way that provides the general overview of the researches done in the PM. This paper discusses the literatures that had been reviewed on four main topics, which are the holistic view of maintenance policies, PM planning, PM planning concept and PM planning-based in developing optimal planning in executing PM actions.
Findings
PM policy is one of the original proactive techniques that has been used since the start of researches on maintenance system. Review of the methods presented in this paper shows that most researches analyse effectiveness using artificial intelligence, simulation, mathematical formulation, matrix formation, critical analysis and multi-criteria method. While in practice, PM activities were either planned based on cost, time or failure. Research trends on planning and methods for PM show that the variation of approaches used over the year from early 1990s until today.
Practical implications
Research about PM is known to be extensively conducted and majority of companies applied the policy in their production line. However, most analysis and method suggested in published literatures were done based on mathematical computation rather than focussing on solution to real problems in the industry. This normally would lead to the problems in understanding by the practitioner. Therefore, this paper presented researches on PM planning and suggested on the methods that are practical, simple and effective for application in the real industry.
Originality/value
The originality of this paper comes from its detail analysis of PM planning in term of its research focus and also direction for application. Extensive reviews on the methods adopted in relation to PM planning based on the planning-based such as cost-based, time-based and failure-based were also provided.
Details
Keywords
Hasnida Ab-Samat and Shahrul Kamaruddin
Opportunistic maintenance (OM) policy is a prospective maintenance approach that instigates for a more effective and optimized system. The purpose of this paper is to provide the…
Abstract
Purpose
Opportunistic maintenance (OM) policy is a prospective maintenance approach that instigates for a more effective and optimized system. The purpose of this paper is to provide the steps and methods used in model development processes for the application of the OM policy.
Design/methodology/approach
Dubbed as opportunistic principle toward optimal maintenance system (OPTOMS) for OM policy toward optimal maintenance system, the model is devised as a decision support system model and contains five phases. The motivation and focus of the model resolve around the need for a practical framework or model of maintenance policy for the application in an industry. In this paper, the OPTOMS model was verified and validated to ensure that the model is applicable in the industry and robust as a support system in decision making for the optimal maintenance system.
Findings
From the verification steps conducted in a case study company, it was found that the developed model incorporated simple but practical tools like check sheet, failure mode and effect analysis (FMEA), control chart that has been commonly used in the industry.
Practical implications
This paper provides the general explanations of the developed model and tools used for each phase in implementing OM to achieve an optimal maintenance system. Based on a case study conducted in a semiconductor company, the OPTOMS model can align and prepare the company in increasing machine reliability by reducing machine downtime.
Originality/value
The novelty of this paper is based on the in-depth discussion of all phases and steps in the model that emphasize on how the model will become practical theories in conducting an OM policy in a company. The proposed methods and tools for data collection and analysis are practical and commonly used in the industry. The framework is designed for practical application in the industry. The users would be from the Maintenance and Production Department.
Details
Keywords
Izatul Hamimi Abdul Razak, Shahrul Kamaruddin, Ishak Abdul Azid and Indra Putra Almanar
The purpose of this paper is to provide an understanding on implementation and operation of ISO 13485:2003 – “Medical Devices – Quality Management System – Requirements for…
Abstract
Purpose
The purpose of this paper is to provide an understanding on implementation and operation of ISO 13485:2003 – “Medical Devices – Quality Management System – Requirements for Regulatory Purposes” – in the perspective of medical device industries in Malaysia. The study is focused on the Malaysian Small and Medium Enterprises (SMEs) which currently have accredited to ISO 9001:2000 quality management systems.
Design/methodology/approach
Literature research and comparative analysis between ISO 13485:2003 and ISO 9001:2000 standard and requirements. A reference model is developed to assist the Malaysian SMEs towards ISO 13485:2003 accreditation.
Findings
Unlike ISO 9001:2000, ISO 13485:2003 stresses the safety and efficacy of medical devices that are being produced. For this reason risk management is an essential process that needs to be adopted into the ISO 13485:2003 quality management system. Moreover, to demonstrate the effectiveness of the ISO 13485:2003 implementation, this standard has placed great emphasis on documentation requirements which are more prescriptive in insisting on the use of formal procedures.
Originality/value
The paper provides guidelines to ISO 13485:2003 implementations as well as risk management approaches for small and medium‐sized businesses of Malaysian medical device manufacturers, which at the same time maintains its ISO 9001:2000 certification.
Details
Keywords
Shahrul Kamaruddin, Zahid A. Khan, Arshad Noor Siddiquee and Yee-Sheng Wong
As the manufacturing activities in today's industries are getting more and more complex, it is required for the manufacturing firm to have a good shop floor production scheduling…
Abstract
Purpose
As the manufacturing activities in today's industries are getting more and more complex, it is required for the manufacturing firm to have a good shop floor production scheduling to plan and schedule their production orders. An accurate scheduling is essential to any manufacturing firm in order to be competitive in global market. The paper aims to discuss these issues.
Design/methodology/approach
Two types of shop floors, job shop and cellular layout, were developed by using WITNESS simulation package. Consequently, the performance of forward scheduling and backward scheduling in both job shop and cellular layout was compared using simulation method, and the results were analyzed by using analysis of variance (ANOVA). Through analysis, the best scheduling approach and layout to be used by manufacturing firm in order to achieve the make-to-order (MTO) production and inventory strategy were reported.
Findings
The results from simulation show that backward scheduling in job shop layout has the lowest average throughput time, lowest lateness, and highest labour productivity than forward scheduling. While in cellular layout, forward scheduling has the lowest average throughput time, lowest lateness, and highest labour productivity than backward scheduling in all conditions. It shows that the performance of scheduling approach is different in each production layout.
Originality/value
Suitable scheduling approach is needed in manufacturing industry as to maximize production rate and optimize machine and process capability. This paper presents an empirical study about the assembly process of radio cassette player of one manufacturing industry in order to investigate the impact of variety of orders and different number of two workers on the performance of production scheduling approach. Forward scheduling and backward scheduling are used to schedule the production orders.
Details
Keywords
Siew-Hong Ding, Shahrul Kamaruddin and Ishak Abdul Azid
An optimal maintenance policy is key to the improvement of the availability and reliability of a system at an acceptable level without a significant increase in investment…
Abstract
Purpose
An optimal maintenance policy is key to the improvement of the availability and reliability of a system at an acceptable level without a significant increase in investment. However, the selection process is a complicated task because it requires in-depth knowledge on maintenance policies and on the technical requirements of maintenance. The difficulties and complexity of the selection process arise from the combination of conflicting maintenance constraints such as available spares, size of workforce, and maintenance skills. The paper aims to discuss these issues.
Design/methodology/approach
The proposed maintenance policy selection (MPS) model is separated into three major phases. The first phase identifies the critical system (CS) based on failure frequency. The failure mechanism in the CS is then analyzed by using a failure mode and effect analysis in the second phase. In the third phase, a multi-criteria decision making method, called the technique for order of preference by similarity to ideal solution, is adopted to identify an optimal maintenance policy that can minimize the failures.
Findings
Through a case study, preventive maintenance was selected as the optimal maintenance policy for the reduction of system failures. The results obtained from the case study not only provide evidence of the feasibility and practicability of the developed model, but also test the acceptability and rationale of the developed model from the industry perspective. Valuable knowledge and experience from employees were extracted and utilized through the proposed model to rank the optimal maintenance policy based on the capability to reduce failure.
Originality/value
The practicality of the MPS model is justified through an implementation in the palm oil industry. The application of the MPS model can also be extended to other manufacturing industries.
Details
Keywords
Rosmaini Ahmad, Shahrul Kamaruddin, Zahid A. Khan, Mohzani Mokthar and Indra Putra Almanar
To introduce a research carried out in a real world for implementing a dust control system (DCS) for controlling the indoor air quality (IAP) on the production floor of one of the…
Abstract
Purpose
To introduce a research carried out in a real world for implementing a dust control system (DCS) for controlling the indoor air quality (IAP) on the production floor of one of the major electronics company in Malaysia.
Design/methodology/approach
The paper is arranged as follows, a brief description of the significant of DCS in electronic industry and brief introduction to the electronic company as a case study company for introducing the DCS. The discussion on the characteristics management and planning tools (MPTs) that have been adopted as the analysing tools for assisting in the decision‐making process in identifying the problems and improvement strategies. It follows by the detail analysis phase regarding the implementation process that it as backbone for introducing the DCS. Finally a discussion about the result obtained from the MPT analysis on the techniques for identifying the root causes of the dust pollution problem as well as the best improvement strategies that can be adopted by the case study company.
Findings
Three analysis techniques from MPT have been used; there are relation diagram, tree diagram and prioritization matrices analyses. These techniques are very powerful for analysing the specific problem using verbal data. The outputs (results) from these techniques have been used as the solutions to the dust pollution problem. As a result, the implementations of DCS successfully reduce the dust level and stabilise the dust distribution on the production floor.
Practical implications
This paper offer a systematic way in identifying and controlling the IAP in industry.
Originality/value
This paper introduces very useful methods in decision making for identifying the solutions for environmental problem and implementation of DCS in a real world environment.
Details
Keywords
Shye-Nee Low, Shahrul Kamaruddin and Ishak Abdul Azid
The purpose of this paper is to investigate multiple criteria decision-making (MCDM) processes within a flow-line production-improvement activity. Investigation can lead to…
Abstract
Purpose
The purpose of this paper is to investigate multiple criteria decision-making (MCDM) processes within a flow-line production-improvement activity. Investigation can lead to understanding of how a process improvement framework influences the decision and fulfillment of the potential to successfully change the operation process.
Design/methodology/approach
The improvement process selection (IPS) framework is built systematically by incorporating all related decision criteria with suitable tools required to select improvement alternatives. The process consists of three phases: identification, prediction, and selection. The IPS framework is validated through a case study of a company that was carrying out a flow-line production-improvement project.
Findings
The developed framework is used to prioritize the problem scope and select the solutions from various options. The case study illustrates the process through which the developed framework provided a systematic approach in identifying the solutions and achieving the desired performance improvement. Prediction result analysis shows the framework achieved sustainable process improvement changes and prevents management levels from higher risks in failure improvement. The feedback of the case study has verified the robustness of the framework.
Practical implications
Quantitative improvement tools, such as MCDM employed in the IPS framework are vital for better understanding of the improvement impact of changes. Thus, the improvement solution alternatives can be analyzed in more comprehensive ways by considering numerous performance metrics in order to select the best improvement alternatives.
Originality/value
The IPS framework can assist the company in determining optimal decisions in relation to selection of improvement alternatives. As a result, production performance can be affected positively.
Details
Keywords
Izatul Hamimi Abdul Razak, Shahrul Kamaruddin and Ishak Abdul Azid
The paper aims to introduce a model for measuring individual performance named Workforce Competency Model (WFCM). Notable aspects of the model including its…
Abstract
Purpose
The paper aims to introduce a model for measuring individual performance named Workforce Competency Model (WFCM). Notable aspects of the model including its validation/verification are explored and presented by means of a case study.
Design/methodology/approach
The model is developed by referring to the previously developed models in literature, which are concerned with the measurement of human or individual performance. Taking into account the organization's needs for each of the workers to be evaluated on identified indicators, performances of individual maintenance workers are quantified according to factors that contribute to those indicators.
Findings
Previous studies show the significance of human involvement in maintenance has been highlighted in many industries; the human element is one of the primary aspects that influence maintenance effectiveness. A model for quantifying individual workers' performance is introduced. A case study carried out in an electronic packaging company for verification and validation purpose demonstrates the developed model is efficient, accurate, flexible and feasible.
Originality/value
This paper presents a unique approach to developing a model that can be used as a tool to effectively evaluate maintenance workforce performance. This study involves a thorough review of the past literature to design the concept to be used, the development process of the model, and validation of the developed model through a case study. The great challenge to the success of this project is to develop the model so that a robust and feasible measurement tool can be built.
Details
Keywords
Hasnida Ab-Samat and Shahrul Kamaruddin
This paper reviews the literature on opportunistic maintenance (OM) as new advance maintenance approach and policy. The purpose of this paper is to conceptually identify common…
Abstract
Purpose
This paper reviews the literature on opportunistic maintenance (OM) as new advance maintenance approach and policy. The purpose of this paper is to conceptually identify common principle and thereby provide absolute definition, concept and characteristics of this policy.
Design/methodology/approach
A conceptual analysis was conducted on various literatures to clarify a number of principle and concepts as a method for understanding information on OM. The analysis involves the process of separating the compound terms used in the literatures into a few parts, analyse them and then recombining them to have more clear understanding of the policy.
Findings
The paper discussed the maintenance approach, genealogy, principle, concept and applications of OM both in numerical analysis and real industry. OM policy is developed based on combination of age replacement policy and block replacement policy and in practical; OM is applied as the combination of corrective maintenance which is applied when any failure occurred, with preventive maintenance (PM) – a planned and scheduled maintenance approach to prevent failure to happen. Any machine shutdown or stoppages due to failure is the “opportunity” to conduct PM even though it is not as planned. The characterization of OM was provided in order to present its theoretical novelty for researchers and practical significance for industries.
Practical implications
To date, there is no publication that reviews the OM in-depth and provides clear understanding on the topic. Therefore, this paper aims to show lineage of OM and the current trend in researches. This discussion will pave the way of new research areas on this optimal maintenance policy. Clear definition and principle of OM provided in this paper will trigger interest in its practicality as well as aid industries to understand and conduct OM in operation plant.
Originality/value
This paper discussed the available literature about OM in various perspectives and scopes for further understanding of the topic by maintenance management professionals and researchers. Therefore, OM can be widely studied and applied in real industry as it is an effective and optimal maintenance policy.