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Industrial Engineering & Management
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Modelling of Enablers for Maintenance Management by ISM Method

Sachin Yadav and Ankur Sharma*

Department of Mechanical Engineering, HMR Institute of Technology and Management, Delhi, India

*Corresponding Author:
Ankur Sharma
Department of Mechanical Engineering
HMR Institute of Technology and Management
Delhi, India
Tel: 011-27724114
E-mail: er.ankurncce@gmail.com

Received Date: December 06, 2016; Accepted Date: Februry 17, 2017; Published Date: February 24, 2017

Citation: Yadav S, Sharma A (2017) Modelling of Enablers for Maintenance Management by ISM Method. Ind Eng Manage 6: 203. doi:10.4172/2169-0316.1000203

Copyright: © 2017 Yadav S, et al. This is an open-access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.

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Abstract

The intent of this paper is to assert the enablers for maintenance management and indicates the strong relationship inaugurate between the enablers by using the interpretive structural modeling (ISM). A good maintenance organization presents clear roles and responsibilities, an adequate span of control, facilitation of good supervision, effective reporting, and a regular improvement culture. ISM is used here to refer to the systematic application of some elementary notions of graph theory in such a way that theoretical, conceptual, and computational leverage is exploited to efficiently construct a directed graph, or network representation, of the complex pattern of a contextual relationship among a set of elements. This work has tried to identify the barriers for successful implementation of maintenance management by manufacturing sectors to improve their performance. In this framework, total 15 barriers have been identified from literature review and expert meet from different interest areas for successful implementation of maintenance management. Effective implementation of MM will improve overall performance of organization in terms of lead time, manufacturing cost, machine breakdown and quality of product with reduction in product rejection. This paper is good for achieve continued improvement by evaluating performance, taking corrective actions, and measuring progress and prepare for future changes by anticipating needs and organizing flexibly

Keywords

Maintenance management (MM); Interpretive structural modeling (ISM); Impact Matrix Cross-reference multiplication applied to a classification (MICMAC); Enablers; Total productive maintenance (TPM)

Introduction

Maintenance management (MM) is a maintenance program which involves an incipiently defined concept for maintaining plants and equipment. MM program’s goal is to very increase working well and getting a lot done, at the same time, increase in employee mood and job happiness with rise in quality and cost of production is low as possible. MM takes into preventive support as a necessary and almost important part of the business. It is no more viewed as a movement with nobenefit. Upkeep’s down time is booked as a part of the assembling day and, for some cases, as a vital part of the assembling procedure. The goal is to unscheduled maintenance to a minimum and hold emergency. The aim of productive maintenance is to maximize plant and equipment efficiency.

The objectives to be achieved and for which MM was introduced are as follows:

• Avoid wastage in a quickly changing economic environment;

• Producing goods without reducing product quality;

• Reduce cost;

• Produce a quantity with low batch at the earliest possible time.

Products send to the clients must be non-imperfect

Selection of technology and its putting into effect in a making industry will be a great physical acts offer for organization to live on in complete in competition market. During different operations major or minor barriers take place needing payment to breakdown which leads to copies of smaller size in amount produced and it forced the organization to instrument MM. It means MM cannot be successfully implemented until all departments integrate effectively. For good putting into effect of MM, top business managers need to chief place on different-different aspects to do with organization working including organization society development, employees training, united as complete thing of departments and so on. In addition to this, management needs to understand structural relationship between different variables, which will help in developing strategies for effective implementation of MM. Due to the complexity in implementation of MM following steps discuss in this paper

• For implementation of MM, the critical success factors are to be identified.

• The establishment of relationship among identified critical success factors.

Identification of critical success factors

To effectively take part in competition in complete markets, firms must be quick and able to bend in their move to meet amount produced needs. In today rapidly changing earth, in competition better chances in price need to be achieved by organizations, quality, high amount produced, make seem minimize losses, new thing and things taken round to at the same time. To meet these questions, good putting into effect of MM can play an important part. Major enablers had a discussion about as

Top management supports: Direct participation by the highest level executives in a special and seriously important point of view or programs of an organization. MM programs can be constructive if and only if the top management is fully committed and intricate. According to Ahuja et al. [1-4] it has to do with everyone in the organization, from top-level business managers of amount produced trained workmen using machines, and amount produced support groups to outside suppliers.

Organization culture: The values and behaviors that contribute to the unique social and psychological environment of an organization. The culture of organization includes an organization’s degrees in which event is probable, experiences, philosophies, and values which place in ship for goods them together, and that are expressed in their self-picture, the outside earth effects on one another, inner workings, and degrees in which event is probable for future. Poor to do with organization necessary qualities in managing the support purpose, use effectively can hardly, cruelly, seriously act on competition-friendliness by getting amount putting through reduced, list of things getting increased, and that leads to poor due-date doing a play by Patterson et al. [5,6] and Ashayeri [7].

Development of maintenance strategy: Maintenance managers and support engineers are asked to undergo growth a support secret design for their plant and necessary things. A document needs to be undergone growth by them. In the document you give an account of how the least plant and necessary things support money used and efforts are used by you to make certain the necessary doing a play of amount produced from your producing plant and necessary things. Even least good, in a measures-taking of making organizations guided by Cholasuke et al. [8] only one-third part of the organizations, form of good business managers practices related to support tended to get money for the full benefits of their support business managers first moves. Some of the important causes producing an effect, which need to be thought out as in the road toward working well operation support business managers, as taken to be from the literature by Refs. [9-11].

Employee training and empowerment: Training in the skills is necessary in order to do the added responsibilities. Way in to information is necessary on which decisions can be made. Expert knowledge to take first move and secret is necessary on the part of the worker to take on greater responsibility. Companies practicing TPM at all times get done surprising outcomes, including making feeble, poor necessary things breakdowns, making seem unimportant doing nothing and minor stops (necessary in unmanned plants), making become less goes from one’s country and claims in quality making stronger amount produced, making less giving birth and costs, list of things reduction, copies of smaller size in chance events, and making stronger worker sense of mixed into (as made clear by the thing put forward of getting better suggestions by Suzuki [12]. Moreover, good TPM putting into effect leads to important untouchable benefits such as unbroken stretch getting better of workforce skills and knowledge, fostering worker guiding reason through enough act of giving power, be made clear of roles and responsibilities for workers, a system for as an unbroken stretch supporting and controlling necessary things, gave greater value to quality of living of work, made lower, less tendency not to be present and gave greater value to news in the workplace by Carannante [13]. TPM is person one is going be married to take both group events (amount produced and support) together by a mix of good working experiences, group working, and unbroken stretch getting better by Cooke [14,15].

Investment on maintenance system: According to Teresko [16] monies put into business in support is the basic purposes, uses of a firm and comes back got better quality, safety, dependability, and able to make ready adjustments and lead times. Support, being an important support purpose, use in undertakings with important money put into business in plants and machinery, plays an important part in meeting this tall order. In addition, the overall view money put into business in to do with man resources can outcome in better hardware 4 use of, higher product quality and made lower, less giving birth costs [17,18].

Developing the coordination between departments: Productivity enhancement in organizations provides a great push for gave greater value to worker into line to do with organization ends, purposes, inter-departmental relations, worker motivation-contributions, and making ready a society development of Kaizens and unbroken stretch improvements in the organizations, thereby getting (making) better the to do with organization powers [19]. It has to do with everyone in the organization, from top-level business managers to producing trained workmen using machines, and producing support groups to outside suppliers [3]. It goes round all departments including support, operations, buildings, design engineering, project engineering, making engineering, list of things and stores, getting something for money, accounting and controlling of money, and plant and place business managers [20].

Benchmarking of processes: Benchmarking is the process of making a comparison one’s business processes and doing a play metrics to industry bests or best practices from other industries measures representatively measured are quality, time and price. Benchmarking is simply the comparison of one organization’s practices and doing a play against those of others. It seeks to make out quality examples, or “most good experiences,” to send in name for in measuring and getting (making) better doing a play. Benchmarking is full of danger toward doing world-class support operation levels by Refs. [21-23]. It is to be noted that although benchmarking is one of the key elements for the unbroken stretch getting better process [24] only 17 of the got broken up (into simpler parts) papers (11 part of a hundred), presented, or even said something about to benchmarking techniques in associations 1 with support operation measurement. The questions of stiff competition and the private road for profits are forcing the organizations to instrument different amount produced getting better efforts to meet the questions took a position by ever-changing market demands [25].

Effective maintenance system: Today’s maintenance organization, like different departments, is under continuous pressure so as to reduce price, show results, and which in turn supports the mission and goal of the organization. After all, it is a degree in which event is probable from the business point of view which is reasoning.

In such an able to work general condition, maintenance manager’s part is full of danger. As such, maintenance managers are being called on to get mixed together and straight to the maintenance efforts so in connection with meet overall view goals of organization well and effectively [26,27]. In making organizations, maintenance related costs are put a value on to be 25% of the overall operating price [28,29]. The working well maintenance purpose, use united as complete thing with engineering and other purposes, uses related to making in the organization can help to but for very great amounts of time, money and other useful resources in trading with always-working and also trading with able to use, maintainability and doing a play issue [30]. Total productive maintenance (TPM) is one of the best tools for making our industries competitive and effective in the field of maintenance [31,32].

Quality management system: A quality management system (QMS) is a collection of business processes focused on consistently meeting customer requirements and enhancing their satisfaction. It is expressed as the organizational structure, policies, procedures, processes and resources needed to implement quality management. Its function is to develop standards globally in an effort to improve the exchange of goods and services internationally. MM is considered to be an effective strategic improvement that includes initiative to improving quality in maintenance engineering activities [33,34]. TPM is a partnership between maintenance and productivity functions in the organization to improve product quality, reduce waste, reduce manufacturing cost, increase equipment availability, and improve the company’s state of maintenance [35]. The quality and maintenance functions are vital factors for achieving sustainability in a manufacturing organization [36].

Reduction in M/C breakdown: Companies practicing MM invariably achieve startling results, including reducing equipment breakdowns, minimizing idling and minor stops (indispensable in unmanned plants), lessening defects and claims in quality, boosting productivity, trimming labor and costs, inventory shrinkage, reducing accidents, and boosting employee involvement (as shown by the submission of improvement suggestions) by Suzuki [12].

Improve safety and health management: According to Steinbacher and Steinbacher [37], TPM is all of the strategies needed to sustain a healthy maintenance log. As an employer, it is your responsibility to maintain a safe and healthy workplace. A safety and health management system, or safety program, can help you focus your efforts at improving your work environment. In a safe and healthy workplace, employees have a stake in the success of the program-safety and health is everyone’s responsibility.

A safety and health management system means the part of the organization’s management system which covers:

• The health and safety work organization and policy in a company;

• The planning process for accident and ill health prevention;

• The line management responsibilities and

• The practices, procedures and resources for developing and implementing, reviewing and maintaining the occupational safety and health policy.

Reduction in manufacturing lead time: Companies practicing TPM invariably achieve startling results including reducing equipment breakdowns, minimizing idling and minor stops (indispensable in unmanned plants), lessening defects and claim sin quality, boosting productivity, trimming labor and costs, inventory shrinkage, reducing accidents, and boosting employee involvement (as shown by the submission of improvement suggestions) [12].

Reduction in product rejection rate: According to Soviet law, output (articles, semi finished products, parts, and so forth) that does not correspond in quality to standards, technical specifications, and other technical norms. A distinction is drawn between reparable and irreparable production rejects. It is technically possible and economically advisable to repair the defects in reparable rejects at the enterprise. Irreparable rejects are articles whose defects are technically impossible or economically disadvantageous to eliminate. Such articles may be used as waste.

Rejects may be the result of incorrect adjustment of a machine tool, malfunctioning of equipment and tools, errors in technical specifications (plans and drafts, for example), disruption of production discipline, or the workers’ low level of skill. The discovery of defective products is the responsibility of the workers, the foremen, and the employees of the technical control department. Production rejects are reduced by organizational and technical measures, including the mechanization and automation of production processes, proper maintenance of equipment and fittings, and the introduction of advanced forms and methods of technical control. Many factors are of great significance in preventing production rejects: zero-defect manufacturing, strict observance of production discipline in the work area, correct organization of labor, improved worker skills, the development of socialist emulation for high product quality, and material and moral incentives for the workers to manufacture highquality products.

Manufacturing cost reduction: Intense competition has been witnessed in terms of less costs, quality improvement and diversity in products with superior performance by Chandra and Sastry [38]. TPM implementation is the reduction in occurrence of unlikely and unexpected machine breakdowns that disrupt production and this may result in losses, which can exceed millions of dollars annually by Gosavi [39].

TPM initiatives in production help in streamlining the manufacturing and other business functions, and garnering sustained profits [2].

TPM contributes effectively to improving the competitiveness and effectiveness of industries in the field of maintenance [40,41].

Improvement in performance: Performance improvement is measuring the output of a particular business process or procedure, then modifying the process or procedure to increase the output, increase efficiency, or increase the effectiveness of the process or procedure. Modern manufacturing requires that organizations that wish to be successful and to achieve world-class manufacturing must possess both effective and efficient maintenance. The intense competitive pressure on the organizations is triggering the top management of these enterprises to look at the performance of each and every business function, including manufacturing or maintenance for achieving competitive advantage [42,43]. It provides a systematic method for establishing production targets, and incorporates practical management tools and techniques in order to achieve a balanced view of process availability, performance efficiency and rate of quality [44]. The objective of TPM is to create a sense of joint responsibility between supervision, operators and maintenance workers, not only to keep machines running smoothly, but also to optimize their overall performance [45,46]. We obtain the overall equipment effectiveness OEE for the production line. The indicator OEE gives us the measurement of equipment performance; taking into account all factors that reduce the capacity utilization. Mathematical formula used for finding the overall performance efficiency is used as below:

Performance efficiency (P)=(Processed amount × 100)/(Operating time/Theoretical cycle time)

Indian manufacturing industries can implement TPM as a strategy and culture for improving the manufacturing performance (Table 1).

S.No. Critical success factor Author
1 Top management support Ben-Daya and Duffuaa,[47]
Pintelonet al.[42]
Cooke [14],
2 Organization culture Parida and Kumar [11]
3 Development of maintenance strategy Bateman [48]
Kans and Ingwald[49]
Parida and Kumar[11]
4 Employee training and empowerment Cooke[14]
Guimaraeset al.[50]
Tsang and Chan [10]
Ahmed et al.[51]
Ireland and Dale [52]
Sharma et al.[40]
Tsarouhas[53]
5 Investment on maintenance system/technologies Teresko[16]
Heizer and Render [54]
6 Developing the coordination between departments Cuaet al.[55]
McKoneet al.[56,57]
Bakerjan[58]
7 Bench marking of processes Ireland and Dale [52]
Cooke and Ng et al. [14]
Raouf and Ben-Daya[22]
Madu[23]
Ahren and Parida[24]
8 Effective maintenance system Bamberet al.[59]
Willmott[61]
Chan et al.[18]
Choi and Eboch[62]
Hendricks and Singhal[63]
Sun [64]
9 Quality management system Heizer and Render[54]
10 Reduction in m/c breakdown Nakaiima, 1988;
Babicz[65]
Chan et al.[18]
Van der Wal and Lynn[66]
Willmott[67]
Noon et al.[68]
Lofsten[69]
11 Improved safety and health management Al-Najjar and Alsyouf[27]
Cooke[15]
Rankin et al.[70]
Patankar and Taylor[71]
Bamber[60]
Ireland and Dale[72]
Shamsuddinet al.[73]
Parida and Kumar [11]
12 Reduction in manufacturing lead time Teresko[16]
Schonberger[73]
Al-Najjar and Alsyouf[27]
13 Reduction in product rejection rate Turner et al.[74]
Willmott[75]
Noon et al.[68]
Nakaiima, 1988;
Babicz[65]
Chan et al.[18]
Van der Wal and Lynn[66]
14 Manufacturing cost reduction Concettiet al.[76]
Rhyne[35]
Gotoh[77]
Hipkin and Cock[78]
Sharma et al.[40]
Cuaet al.[55]
McKoneet al.[56,57]
Seth and Tripathi[79,80];Tripathi[81]
15 Improvement in performance Pintelonet al.[43]
Bulentet al.[44]
Tajiri and Gotoh[45]
Hutchins[46]

Table 1: Critical success factors for implementation of maintenance management.

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