Integrated maintenance policies for performance improvement of a multi-unit repairable, one product manufacturing system

James M. Wakiru*, Liliane Pintelon, Peter Muchiri, Peter Chemweno

*Corresponding author for this work

Research output: Contribution to journalArticleAcademicpeer-review

2 Citations (Scopus)

Abstract

Planned and unplanned downtime emanating from maintenance, production, and operational function adversely affects the performance of manufacturing plants. This paper develops joint maintenance, production and process/operations control policies integrating Opportunistic Maintenance (OM), which takes advantage of external (operational-related downtimes) and internal maintenance opportunities. The study quantifies the effects of maintenance strategies on the plant’s performance, here, the overall equipment effectiveness (OEE), which importantly presents insights on maintenance decision support for production facilities facing significant operational-related stoppages. The study integrates both economic and structural dependence and models the influence of alternative maintenance actions of different maintenance policies, on product quality. The developed model is validated by applying to a multi-unit repairable, imperfectly maintained raw meal grinding system of a cement plant. From the simulation modelling results, integration of the opportunistic maintenance approach, complementary to corrective, preventive and condition-based maintenance strategies, show more enhanced equipment performance, as measured through the OEE.

Original languageEnglish
Pages (from-to)347-367
Number of pages21
JournalProduction Planning and Control
Volume32
Issue number5
Early online date12 Mar 2020
DOIs
Publication statusPublished - 2021

Keywords

  • corrective maintenance
  • manufacturing system
  • OEE
  • opportunistic maintenance
  • Preventive maintenance
  • product quality

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