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Strategic Maintenance Development focusing on use of Condition Based Maintenance in Manufacturing Industry
Publication Type:
Licentiate Thesis
Abstract
The growth of global competition has created remarkable changes in the way
manufacturing companies operate. These changes have affected maintenance and
made its role even more crucial for business success. To remain competitive,
manufacturing companies need to continuously increase the effectiveness and
efficiency of their production processes. Further, the introduction of lean
manufacturing has increased concerns regarding equipment availability and,
therefore, the demand for effective maintenance. Despite the increasing demand
for reliable production equipment, few manufacturing companies pursue the
development of strategic maintenance. Moreover, conventional maintenance
strategies, such as corrective maintenance, are no longer sufficient to satisfy
industrial needs, such as reducing failures and degradations of manufacturing
systems to the greatest possible extent. The concept of maintenance has evolved
over the last few decades from a corrective attitude (maintenance intervention
after a failure) to a predictive attitude (maintenance intervention to prevent the
fault). Strategies and concepts such as condition-based maintenance (CBM) have
thus evolved to support this ideal outcome. CBM is a set of maintenance actions
based on the real-time or near-real-time assessment of equipment conditions,
which is obtained from embedded sensors and/or external tests and
measurements taken by portable equipment and/or subjective condition
monitoring. CBM is increasingly recognized as the most efficient strategy for
performing maintenance in a wide variety of industries. However, the practical
implementation of advanced maintenance technologies, such as CBM, in the
manufacturing industry is relatively limited.
Therefore, the objective of this research is to study how to develop and
implement a CBM strategy in the manufacturing industry. This thesis will begin
with an overall analysis of maintenance management to illustrate how to
formulate a maintenance strategy and will continue with a focus on CBM, the
cost effectiveness of implementing CBM, an introductory review of applied
CBM practices and a discussion of CBM implementation processes in the
manufacturing industry. The data were collected through case studies, mainly at
one major manufacturing site. The bulk of the data were collected during a pilot
CBM implementation project. Following the findings from these efforts, a
formulated maintenance strategy is developed and presented, and factors to
evaluate CBM cost effectiveness are assessed. These factors indicate the benefits
of CBM, mostly with regard to reducing the probability of experiencing maximal
damage to production equipment and reducing production losses, particularly at
high production volumes. Further, a process of CBM implementation is
presented. Some of the main elements in the process are the selection of the
components to be monitored, the techniques and technologies for doing so and
their installation, and finally, the analysis of the results of condition monitoring.
Bibtex
@misc{Rastegari4084,
author = {Ali Rastegari},
title = {Strategic Maintenance Development focusing on use of Condition Based Maintenance in Manufacturing Industry},
month = {September},
year = {2015},
url = {http://www.ipr.mdu.se/publications/4084-}
}