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Strategic Maintenance Development focusing on use of Condition Based Maintenance in Manufacturing Industry
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation. (Innofacture)
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The growth of global competition caused remarkable changes in the way manufacturing companies operate. These changes have affected maintenance and made its role even more crucial in business success. In order to stay competitive, manufacturing companies need to continuously increase the effectiveness and efficiency of their production processes. Further, by introducing lean manufacturing the concern about equipment availability is increased and so, the demand for effective maintenance. Despite the increasing demand on reliable production equipment, few manufacturing companies work with strategic maintenance development. Moreover, conventional maintenance strategies such as corrective maintenance are not sufficient today to fulfill the industrial needs on maximum reduction of failures and degradations of manufacturing systems. The concept of maintenance has evolved over the last few decades from a corrective attitude (maintenance intervention after a failure), to a predictive attitude (maintenance intervention fixed to prevent the fault). Strategies and concepts such as Condition Based Maintenance (CBM) have thus evolved to support this ideal situation. CBM is a set of maintenance actions based on real-time or near real-time assessment of equipment condition, which is obtained from embedded sensors and/or external tests and measurements taken by portable equipment and/or subjective condition monitoring. CBM is becoming recognized as the most efficient strategy for carrying out maintenance in a wide variety of industries. However, the practical implementation of advanced maintenance technologies, such as CBM, in manufacturing industry is more scarce.

Therefore, the objective with this research is to study on how to implement and develop an effective and efficient CBM strategy in manufacturing industry. This thesis will start with an analysis of the overall maintenance management to illustrate how to formulate a maintenance strategy, following with the focus on CBM; cost effectiveness of implementing CBM; an introductory review of applied CBM practices and CBM implementation process, all in manufacturing industry. The data was collected through case studies mainly at one major manufacturing site. The main part of the data was collected during a pilot project to implement CBM. As the result, a formulated maintenance strategy has been developed and presented. Factors to evaluate CBM cost effectiveness have been assessed. These factors indicate the benefits of CBM mostly in reducing probability of having maximal damage in production equipment and reducing production losses particularly in high production volumes. Further, a process of CBM implementation has been presented. Some of the main elements in the process are selection of the components to be monitored, techniques and technologies as well as installation of the technologies and finally how to analyze the results from the condition monitoring.

Place, publisher, year, edition, pages
Västerås: Mälardalen University , 2015.
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 213
National Category
Reliability and Maintenance
Research subject
Innovation and Design
Identifiers
URN: urn:nbn:se:mdh:diva-28486ISBN: 978-91-7485-220-2 (print)OAI: oai:DiVA.org:mdh-28486DiVA: diva2:826111
Presentation
2015-09-24, Filen, Smedjegatan 37, Eskilstuna, 10:00 (English)
Opponent
Supervisors
Available from: 2015-06-25 Created: 2015-06-24 Last updated: 2015-09-04Bibliographically approved
List of papers
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4. Implementation of Condition Based Maintenance in Manufacturing Industry – A Pilot Case Study
Open this publication in new window or tab >>Implementation of Condition Based Maintenance in Manufacturing Industry – A Pilot Case Study
2014 (English)In: 2014 IEEE Conference on Prognostics and Health Management (PHM), IEEE conference proceedings, 2014, Article number 7036377- p.Conference paper, Published paper (Refereed)
Abstract [en]

This paper presents a guide for implementation of Condition Based Maintenance (CBM) in a manufacturing industry, considering the technical constituents and organizational aspects when implementing CBM. The empirical base for the study is a case study from a major manufacturing site in Sweden. The data was collected during a pilot project to implement CBM at the case company. The purpose of the pilot study at the company was to implement online condition monitoring on some of the critical components in the hardening process. Hereby, two of the main online condition monitoring techniques namely vibration analysis and Shock Pulse Method (SPM) have been implemented and tested on electric motors to monitor bearing conditions. The paper presents the process of implementation and the elements included in this process. Some of the main elements in the implementation process are selection of the components to be monitored, techniques and technologies as well as installation of the technologies and finally how to analyze the results from the condition monitoring. The data from online condition monitoring on the electric motors, driving the furnace fans, are recorded and presented in the paper including breakdown data on two objects. This information is leading to useful and reliable knowledge for maintenance work to be cost effective and be able to increase the overall equipment availability (OEA). In addition to this, the result indicates to what extent advanced CBM practices are applicable in the hardening environment in the manufacturing company and it provides guidance for further research and development in this area. The paper concludes with a discussion on possible future trends and research areas, needed to increase the effective and efficient use of CBM.

Place, publisher, year, edition, pages
IEEE conference proceedings, 2014
Keyword
Condition based maintenance, Condition monitoring, Implementation
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:mdh:diva-28480 (URN)10.1109/ICPHM.2014.7036377 (DOI)2-s2.0-84929587482 (Scopus ID)9781479949427 (ISBN)
External cooperation:
Conference
2014 IEEE Conference on Prognostics and Health Management (PHM), 22-25 June, Cheney, USA
Funder
XPRES - Initiative for excellence in production research
Available from: 2015-06-24 Created: 2015-06-24 Last updated: 2016-08-25Bibliographically approved

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