Rajesh Prasad Mishra

Justification of world‐class maintenance systems using analytic hierarchy constant sum method

Purpose – In recent times, many organizations implementing total productive maintenance (TPM) have been failing in their attempts. Researchers attribute these failures to the shortcomings of TPM and of the implementing organizations. This paper aims to conduct a detailed study in order to understand these shortcomings and seeks to propose various solutions in the form of “best practices”, which leads to the development of world‐class maintenance systems (WMS). However, development of such alterative maintenance systems raises the following question: if an organization is planning to implement and improve their existing maintenance system then how can the manager make a decision between choosing alternative systems such as traditional maintenance systems, TPM and WMS? In the case of TPM or WMS, top management should be involved from the beginning to implement and follow up, as these decisions are complex and involve huge investment in the long term. Before starting implementation, top management should be ...

A SWOT analysis of total productive maintenance frameworks

In the literature of Total Productive Maintenance (TPM), a large number of frameworks have been proposed by different authors and consultants. If an organisation or a maintenance manager has to make a strategic decision of implementing TPM, it may not be easy for them to identify a suitable framework from a plethora of frameworks that are available in literature. Hence, in this paper, an attempt has been made to perform a comparative study of these frameworks using a Strengths, Weaknesses, Opportunities and Threats (SWOT) analysis. In addition to this, the SWOT analysis helped us consolidate a list of critical success factors for TPM apart from identifying the potential weaknesses and threats. Further, it can be concluded that implementation of TPM is by no means an easy task, as it is heavily burdened by weaknesses and threats. However, if an organisation implementing TPM gives due considerations to these weaknesses and threats, it can utilise the significant strengths and opportunities offered by TPM to achieve a competitive advantage.

An AHP model for quantification of benefits of World-class Maintenance Systems

In recent times, organisations are failing in their attempt to adapt and implement Total Productive Maintenance (TPM). Researchers are attributing these failures to the shortcomings of TPM, which resulted in the development of World-class Maintenance Systems (WMS). Different frameworks have been proposed to define and operate world-class maintenance in the literature. A comparative analysis of frameworks in our earlier study revealed various best practices based on which a new framework for WMS has been proposed. Contemporary organisations willing to adapt WMS find it difficult to initiate such a change, as it requires proper justification to convince top management. Further, to initiate the adaptation of WMS as a policy decision, it is necessary to quantify the benefits of WMS. Hence in this paper, an attempt has been made to demonstrate the application of Analytic Hierarchy Process (AHP) for the quantification of benefits of WMS. This model showed that implementing WMS would result in overall improvement in the performance of an organisation.

Structural modelling and analysis of world-class maintenance system: a graph theoretic approach

This aim of this paper is to develop an integrated system model for the structural modelling and analysis of world-class maintenance system (WCMS) in terms of its systems and interactions between the systems and the subsystems and performance measurement as a possible means of achieving increased organisational change. Using graph theory and matrix algebra, world-class maintenance system is first modelled with the help of a graph theory, then by a variable adjacency matrix and then by a multinomial known as a permanent function. Different structural attributes of the WCMS are identified to develop a graph theoretic model, a matrix model, and a multinomial permanent model of the maintenance. The study suggests that the tool can be used to quantify the gap between existing maintenance systems priorities and their perceptions of organisations performance. The present paper introduces the graph theoretic approach to the maintenance management. The design graph is the first mathematical model to consider all the structure aspects in an integrated and concurrent way in the proposed methodology.

A SWOT analysis of reliability centered maintenance framework

Purpose – The purpose of this paper is to use well-established methodology strengths, weaknesses, opportunities and threats (SWOT) analysis – in order to identify the important factors for reliability centered maintenance (RCM) implementation. Design/methodology/approach – The paper demonstrates a SWOT analysis for different 19 frameworks of RCM to make a strategic decision for implementing RCM in different organizations. The various 19 frameworks are grouped together into three clusters, namely Group A, Group B and Group C based on their qualitative or theoretical, quantitative and practical approach, respectively. Findings – The strengths and weaknesses are identified by internal factors while the opportunities and threats are identified by external factors of an organization for each group of frameworks. Also, it was observed that each group of frameworks has a unique set of strengths and weaknesses. Research limitations/implications – In this paper, the SWOT analysis for RCM implementation is limited ...

Strengths, weaknesses, opportunities and threats analysis of lean implementation frameworks

The aim of this paper is to use the SWOT analysis that can be used as a decision-making aid to choose an appropriate framework according to the industry needs. Various databases were searched for research on lean implementation and the obstacles to successful lean implementation. Following this, analysis was carried out to identify the major success factors and an ideal lean implementation framework. Based on SWOT analysis it has found that every framework has its own sets of strengths and weaknesses. Decision makers can know the suitability of different framework. But most important is what model which suit to most of the situations. This paper developed a lean implementation model which is more generic, has overcome the most of the issues related to implementation compared to other frameworks. The lean implementation frameworks identified are not industry centric but more generic in nature.

Identification of Positive Deviance—Methodology Development

Corporate efforts to improve the bottom line traditionally focus on shortcoming and issues. A comprehensive set of analytical tools and methodologies (e.g., Lean Management, Six Sigma) have been developed and are deployed in attempts to fix identified problems. However, little guidance is available on how to actually come up with improved organizational and process designs. Organizations tend to rely on approaches such as brainstorming that do not lead to consistent and reliable outcomes. It is proposed to benefit from conducting a dedicated study on internal sources for business improvement. This so-called positive deviance approach utilizes internal best practices and converts successful, but hidden best practices into widely deployed, corporate practices. The paper develops a methodology to identifying exceptional performers and map their behaviors and activities which made them successful. The objective was to identify practical quick wins which can be implemented through existing account auditing activities.

A multi-attribute decision model for justification of World-Class Maintenance Systems

In recent times, many organisations are failing in their attempt to achieve a world-class status through Total Productive Maintenance (TPM) due to various shortcomings. Hence, in our earlier study, a new framework for World-Class Maintenance Systems (WMS) was proposed to overcome some of these shortcomings. Organisations that are planning to adapt World-Class Manufacturing (WCM) practices such as TPM, WMS etc. require proper justification to convince the top management. Hence, in this paper, an application of a Multi-Attribute Decision-Making (MADM) model – namely, the Analytic Hierarchy Binary Model (AHBM) is demonstrated for the justification of WMS. From the extensive analysis of the results, it is found that the WMS is the best among the alternative maintenance systems available.

A Failure Mode Effect and Criticality Analysis of Conventional Milling Machine Using Fuzzy Logic: Case Study of RCM

The purpose of this paper is to select the appropriate maintenance strategies for each failure mode of functionally significant item of conventional milling machine. In order to describe the criticality analysis of conventional milling machine, this paper presents a study on reliability-centered maintenance with fuzzy logic and its comparison with conventional method. On the basis of fuzzy logic, failure mode and effect analysis is introduced integrating with fuzzy linguistic scale method. After that, weighted Euclidean distance formula and centroid defuzzification is used for calculating risk priority number. The results indicate that based on risk priority number, value criticality ranking was decided, and appropriate maintenance strategies were suggested for each failure mode. It also reflects that a more accurate ranking can be performed by the application of fuzzy logic using linguistic rule to failure mode and effect analysis. Copyright

An Application of Reliability Centered Maintenance Using RPN Mean and Range on Conventional Lathe Machine

RCM provides a structured and practical approach for arriving at an acceptable maintenance strategy for each component of a given system. In this paper, a study on reliability centered maintenance (RCM) has been conducted to reduce the total number of failures and its effects on the conventional lathe machine. The risk priority number (RPN) is, one of the key factors in determining the critical ranking of a failure mode of the mechanical equipment but there is a drawback in determining the critical ranking from RPN. There might be more than one failure modes which can share the same RPN number and therefore critical ranking cannot be assigned to those failure modes. Initially, the Severity, Occurrence and Detection rating integrating with failure mode and effect analysis (FMEA) is taken from several experts and then RPN is calculated for each of those experts. Then the criticality of the failure mode of the functionally significant items of conventional lathe machine is judged on the basis of mean RPN value as well as using the range. Overall the risk or criticality level of each failure mode is identified. After that, RCM logic is used for selection of a proper maintenance strategy for each failure mode.