Prioritization of Effective Lean Tools for Reliability Analysis & Maintenance Strategy

Abstract

Asset or equipment reliability and availability have occupied extensive attention because of an emerging competitive environment and the overall operating and production cost. The main focus of this manuscript is to prioritize the lean tool and select an appropriate maintenance strategy for the repairable assets in the maintenance shop of the SIMGA1 shipyard. Five (5) assets of that maintenance shop such as an air compressor machine, 500-ton press machine, overhead crane machine, VDF lathe machine, and Roller machine were under breakdown maintenance. Due to the continuous degradation of those assets, attempts should be taken to enhance the reliability parameters by predicting upcoming failure events for each equipment or asset. QFD-AHP is a rapid tool in which quality function deployment is integrated with AHP to make an optimal selection. Firstly, the integrated QFD-AHP method is employed to prioritize the lean tools for that maintenance shop. 5S and KPI are the best fit for that shop among ten lean tools. Non Homogenous Poisson Process (NHPP) is a model which represents the no. of failure experienced up to time (t). NHPP and Weibull analysis are utilized to predict future failure events and analyzed the nature of the failure accordingly. From the results of the Weibull analysis and NHPP analysis, it is shown that the slope (β) of the failure rate is greater than 1 for all assets. Overhead crane m/c and 500-ton press m/c are the most critical m/c according to equipment criticality analysis. Finally, a decision diagram is utilized to extract the most congruent maintenance strategies based on the reliability parameter of five (5) assets. The approach employed in this study helps maintenance practitioners to achieve lean maintenance.