Structured maintenance engineering policy development based on a production machine process perspective

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.