Maintenance Strategies For Industrial And Manufacturing Operations

As consultant, you have attended a conference on maintenance management strategy. You will choose one of the proposed case study.  You will propose a strategy for the company and support your choice with evidence. 

 

Reasons for Equipment Failure

Maintenance is a risk management practice applied in industries, manufacturing firms and companies like the Industrial Oil Company, Lagos Nigeria to maximize production and minimize loss.  Good knowledge about the how the equipment performs and how the practices of management operate help in coming up with an appropriate maintenance that the organization adopts to ensure adequate performance of the latter.  The ability to note the reasons as to why equipment fails in the production process, how they fail and when they fail, gives the operation manager a wide range of option to choose from alternatives of maintenance strategies that might help expand equipment performance and raise cost which would otherwise direct to inspections (Bragg and Steven, 2010).

Production equipment is bound to fail in their process of production when neglected, and little attention is given to monitoring how they perform. Therefore, to offset this, relevant strategies have to be adopted to ensure that production breakdown is dealt with to ensure profit maximization.  The management has the responsibility of providing that proper strategic maintenance decision is arrived at to initiate the quality performance of equipment through repairs hence reduce the cost to the user.  It is argued that for machine operators to reputable strategies for their management strategies, they must understand when, where, how and why equipment fails (Milac?ic?, 2008). Being in a position to point out equipment’s weaknesses and strengths go a long way to inform which mode of care needs to be taken to ensure that equipment life is not threatened thus reaping the benefits of maximum service from least cost of maintenance.

To put in place suggestions escalating from maintenance strategies like Reliability Centered Maintenance, Total Productive Maintenance and Business Centered Maintenance as applied by the company, the owner of the production process ought to observe critical guidelines to ensure that the methodology is useful and relevant as per the desired outcome. Having understood the reasons and philosophy for equipment failure, the reason for it failing, when it fails and the available strategies to mitigate the identified problems. The owner of production equipment has to follow the following steps for sound maintenance and desired production outcome.

In his capacity and with the production demands bestowed to him, he is required to assemble sufficient data in line with his available production equipment, analyze their performance and find out their downtime, mean-time-in failing the response of the technician, parts spend and deliveries made on time. Considering that, one can account for the inspection liabilities that particular equipment consumes at average costs. 

Adopting Relevant Maintenance Strategies

After assembling relevant data on equipment performance, the operator can precisely estimate the average cost of one hour of downtime, an avenue which will help measure the effect of maintenance on production. And how much money is required to affect specific support that may result in improved performance?

The third step requires the operator to consider going through the through the variables of the operation process. It is critical for it informs him of the amount of money that is required in initiating a plan for significant spares, the effect that an increase in the number of the available machines will have on the general performance and how the desired work system will improve uptime equipment performance (Rezg, et al., 2014).

As one continues to analyze the available variables, he/she will start to see opportunities that may result to value addition. With investment ideas in place and the urge to cut on maintenance cost, the owner may opt to add a Computerized Maintenance Monitoring System (CMMS) which is vital as it comes with the benefit of virtual system variables maintenance, it also increases feedback for the technician, which generally reduces the time that would otherwise slow production process.

With the CMMS in place, assets of production in the line of action is displayed at the touch of a button and readily displayed on a computer screen. It informs that critical parts and spares in machines can be tracked and promptly replaced.

Preventive maintenance strategies are required to offset the problem at hand. it helps the technician plan well thus save time. Serves to reduce downtime of the production process.

At this stage, one is advised to accept the idea of predictive tools along with his already established preventive maintenance checklist...

After putting in place, predictive tools the owner should develop a strategy which takes equipment care to the next step by engaging the user. It goes a step ahead to include and provide clear and easy ways for the user in operation.

While approaching the reliability level. The Reliability Centered Maintenance (RCM) sums the steps above together. With keen interest, default equipment is no longer directed to the PMs Schedules.

Conclusion

The above steps are ideal and appropriate for they help establish proper metrics and processes within an operating system and the relevant people to look into the issues, and also, they provide platforms for engaging with customers through inquiry aimed at revamping production processes. It is always argued that such steps are a full journey, therefore, not for the faint-hearted; for you are required to learn the maintenance process and techniques. It’s an investment worth handsome pay to your organization. 

Steps to Follow for Sound Maintenance and Desired Production Outcome

Introduction

In the perspective of software and machine maintenance, total production maintenance is coiled to refer to the regular check-ups done on machines to reduce the likelihood of breaking down and failing to perform as anticipated. The strategy is designed in a way that the required resources are readily available and the timeline for maintenance is based on open time and using triggers.

Production equipment is vital for industrial and manufacturing operations lifeblood. When impaired, it results in the breakdown of the customer and organizational products. To avoid such scenario, it’s important to keep them running, not waiting until they fail. It’s crucial to note the performance of machines so that you can learn the signs which can lead to serious trouble that may impact production (Bragg, 2010).

To prevent this, the organization ought to apply planned preventive maintenance to ensure that the production process of the organization is on the go and not affected by machine breakdown and equipment’s non-performance. Such intervention allows for regular machine maintenance, and inspections thus enable the concerned person to discover things that may become issues before they become real issues.

How Planned Preventive Maintenance Works

The effectiveness of Planned Preventive maintenance works best in line with the manufacturers or industrial schedule. Similarly, motor assembly companies recommend that to keep a car running and functioning correctly, the owner needs to keep on checking and changing the oil after every 3,000 miles or after three months. (Wilson, Reginald. The Encyclopedia of Information Science and Technology, Third Edition, pp. 2686-2698).

The inspection idea is applied to all machinery used for production in any given organization. For example, the conveyor system belt should be checked on a monthly basis, the gears on a weekly and the whole system after every six months (Mobley, 2009). The procedure applies to both offices and industrial equipment. Such office equipment’s include computers and copiers; and the inspections include software updates, network tests and toner changes and other inspections that will result in proper equipment performance. 

Benefits of Production Maintenance Strategy

Appropriate for setting up orders for replacement parts well in advance of when you need them.

Helps the management schedule inspections for down times and lessen the impact on production time.

If the organization has several pieces of the same equipment’s, you can get a voluminous discount for ordering equipment parts in bulk or sometimes reduces shipping costs.

What to consider when choosing a maintenance management software program

Different Maintenance Strategies for Industrial and Manufacturing Operations

Pick a program that can handle both planned and unplanned machine breakdown; this allows easier and efficient management of maintenance done on equipment. (Pinjala, Srinivas et al., 2007)

Be keen to note maintenance due to warnings or alerts. It is facilitated with the use of soft-wares that inspects machines stability and performance rate.

Impacts of maintenance strategies

Maintenance strategies enable the management to assign different but specific activities to its employees for achievement of a common goal in the organization and implementation of layout procedures. Maintenance strategies offer a good common ground for the organization as costs are hugely cut off as decision making is fast and readily applicable. Building proper and predictable patterns through strategic management helps reduce different experiences for clients whenever they do business with your company (Noyes, Daniel, and Pérès, 2008). 

According to Bianca, Audra (2018), maintenance strategies assist in achieving a goal that has been set out by the organization. Any strategic management starts with laying out a plan that focuses on long-term achievements.  It also acts as a measuring factor on whether those goals and objectives are achieved after a particular period.  The management team also is supposed to know the significance of implementing a goal in the organization.  Employees must see sense in accomplishing their goals which in return helps the organization in doing better thus raising its entire revenues. 

As the sole owner of the organization, the way you put in place your maintenance strategies dramatically impact the general performance. The motivation for employees is a crucial factor in achieving the organizational goals. Setting high expectations for your employees enables them to perform well and try their best in attaining the company’s goals. (Oseghale, 2009).

According to Czarniawska-Joerges & Ho?pfl 2009, maintenance strategies also aid in the way you will report your organization next goals and the achievement of each set objective. The evaluation also becomes easy because you are running the company for a specific purpose. Respect for employees and the management is also enhanced because the administration is honest what they have achieved as a whole and what they have not.

Reliability is a major factor to consider in your maintenance strategy. According. Mann., Saxena and Knapp 2009, planned maintenance is usually introduced to an organization to cut down the expenses which might be incurred while correcting any necessary repairs or inspection of equipment.  Bushell 2010, suggests that planned preventive maintenance is worth it particularly for the wear and tear machines because it generally minimizes the cost.

Maintenance strategies determine the opportunities and threats that may be subjected to your organization thus the management can plan accordingly to take advantage of the opportunities to benefit the organization or combat the threats which might affect the organization as a whole.  Dunn 2007, carried out a critical analysis of condition-based maintenance whereby the key results were outlining the business opportunities and the driving changes in the industry. 

References

Bianca, Audra. (2018) "The Impact of Strategic Management on Organizational Performance." Small Business - Chron.com.  New York publishers.

Bragg, S. M. (2010) Cost Reduction Analysis: Tools and Strategies. Hoboken: John Wiley & Sons.

Bushell, R.J., (2010) Preventing the Problem: A New Look at Building Planned Preventive Maintenance. Institute of Building.

Czarniawska-Joerges, B., & Ho?pfl, H. (2009) Casting the other: The production and maintenance of inequalities in work organizations. London: Routledge.

Mann, L., Saxena, A., and Knapp, G.M., (2009) Statistical-based or condition-based preventive maintenance. Journal of Quality in Maintenance Engineering, 1(1), pp.46-59.

Milac?ic?, V. R., McWaters, J. F., & Univerzitet u Beogradu. (2008) IFIP TC 5/WG 5.3 Working Conference on Diagnostic and Preventive Maintenance Strategies in Manufacturing Systems: Proceedings of the IFIP TC 5/WG 5.3

Mobley, R. K. (2009) An Introduction to Predictive Maintenance. (Referex Mechanical Engineering and Materials.) San Diego: Butterworth-Heinemann [Imprint.

Oseghale, G.E., (2009) Impact of Maintenance Strategies on the Performance of Industrial Facilities in Selected Industrial Estates in Lagos State, Nigeria. Print

Bragg, Steven M (2010) Cost Reduction Analysis: Tools and Strategies. John Wiley & Sons.

Czarniawska-Joerges, Barbara, and Heather H (2010) Casting the Other: The Production and Maintenance of Inequalities in Work Organizations. Routledge.

Noyes, Daniel, and François P (2010) "Maintenance Strategies Integrated into Production Management : Towards Performance Optimization." IFAC Proceedings Volumes, vol. 31, no. 15, pp. 969-974.

Pinjala, Srinivas K., et al. (2007) "An empirical investigation on the relationship between business and maintenance strategies." International Journal of Production Economics, vol. 104, no. 1, pp. 214-229.

Wilson, (Reginald 2015) "Outage Analysis and Maintenance Strategies in Hydroelectric Production." Encyclopedia of Information Science and Technology, Third Edition, pp. 2686-2698