Development of practical opportunistic maintenance (om) policy based model for manufacturing system
Loading...
Date
2015-10-01
Authors
Hasnida Ab Samat
Journal Title
Journal ISSN
Volume Title
Publisher
Abstract
Maintenance is conducted to ensure that all equipment in a company are repaired, replaced, adjusted and modified according to production requirements. Effective and optimized maintenance system are highly acquired in today’s manufacturing system. With the advancement of technologies and complexity of systems, there is a new maintenance approach called prospective maintenance where the policy is ‘opportunistic maintenance’ (OM). OM can be defined as maintenance activities that are conducted to repair a component and at the same time opportunistically repair/replace other components in the system with the aim to avoid future failures and reduce the number of machine downtime. It is the combination of corrective maintenance (CM) which is applied when any failure occurred, with preventive maintenance (PM) -a planned and scheduled maintenance approach to prevent failure to happen. Any machine stoppage due to failure is the ‘opportunity’ to conduct PM. However, the challenge to achieve optimal maintenance system using OM policy is to find a balanced trade-off between maintenance cost and component or machine age and reliability features. Throughout the years, literatures that had been published lingers around conceptual theory and numerical analysis of the policy yet in the realistic and practical model for the application is lacking. The focus of this research is directed towards the issues of OM application in achieving optimal maintenance system. Based on conceptual identification of principle, concept and characteristics of OM policy, a decision making model was developed. With the acronyms of OPTOMS for Opportunistic Policy towards Optimal Maintenance System, the model was developed in five phases with the usage of Check Sheet and
Stacked-Bar Chart for machine selection phase, Failure Mode and Effect Analysis (FMEA) for failure analysis and Control Chart for performance measurement phase. In this model, OM principle are studied and developed into a set of rules with some limitations and assumptions to suit the policy into practical environment. Detail discussions were provided to make OM as a practical policy in achieving optimal maintenance system. The model is validated and verified in a semiconductor company. The outcomes of this case study confirmed the application and practicality of the OPTOMS model as a decision support system in applying OM policy. The developed model helps the company to plan and to schedule maintenance activities in reducing cost and machine downtime as well as increasing up to 20% of its machine availability and reliability.