Professional Documents
Culture Documents
Organisation/Organization Författare/Authors
Sammanfattning/Abstract
This report evaluate the maintenance policies that been applied within specific industrial company,
Taken into considerations all corrective and preventive maintenance costs ,in addition to optimise best
preventive maintenance schedule for minimum cost.
Dynamate Intralog AB was the surveyed company that been encountered high maintenance cost
compatible with less productivity, therefore obtaining maintenance schedule policy for minimum cost
was the best solution for their problem, then by calculating their corrective and preventive
maintenance cost the optimum time was acquired. Finally, the maintenance schedule approve that
organized maintenance based on optimum time enhance the productivity and minimize the company
maintenance cost.
Nyckelord/Keywords
2011 English 58
Internet/WWW
http://www.lnu.se
2
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Acknowledgements
First of all, we would like to take the opportunity to express our gratitude to
everybody who has helped us with this thesis.
In this context, our special thanks refer to our tutor, Matias T. Hailemariam and our
examiners, Imad Alsyouf, Lars Erikson and Anders Ingwald as they have guided and
helped us with our work.
Finally, we are grateful for our families and friends who have supported us
during this period of time, firstly to Bea Cerezo Valera for her constructive
comments, then to Idriss, Nurdan, Akif, Nurdos, Hande and Zehra Aksoy.
3
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Table of contents
1. INTRODUCTION ......................................................................................................................... 8
1.1 Background ......................................................................................................................... 8
1.2 Problem discussion ............................................................................................................. 9
1.3 Problem formulation .......................................................................................................... 9
1.4 Purpose ............................................................................................................................. 10
1.5 Relevance .......................................................................................................................... 10
1.6 Limitations ........................................................................................................................ 10
1.7 Time Frame ....................................................................................................................... 10
2. METHODOLOGY ...................................................................................................................... 12
2.1 Research strategy ............................................................................................................. 12
2.2 Research design ................................................................................................................ 12
2.3 Data collection .................................................................................................................. 13
2.3.1 Semi-structured interviews......................................................................................... 14
2.3.2 Secondary analysis ..................................................................................................... 14
2.4 Validity and reliability ...................................................................................................... 14
2.5 Generalizing ...................................................................................................................... 15
3. THEORETICAL FRAMEWORK.................................................................................................... 16
3.1 Impact of Maintenance .................................................................................................... 16
3.2 Corrective Maintenance ................................................................................................... 16
3.3 Preventive Maintenance .................................................................................................. 17
3.4 Block policy ....................................................................................................................... 18
3.5 Age policy .......................................................................................................................... 18
3.6 Weibull distribution.......................................................................................................... 19
3.7 Maintenance optimization ............................................................................................... 22
3.8 Schedule maintenance ..................................................................................................... 23
3.9 Life Cycle Cost (LCC) .......................................................................................................... 24
4. EMPIRICAL DATA ..................................................................................................................... 26
4.1 General description .......................................................................................................... 26
4.2 The logistics outsourcing .................................................................................................. 26
4.3 The empty boxes process ................................................................................................. 27
4.4 Robot performance and critical components .................................................................. 28
4.5 Maintenance strategies within Dynamate Intralog AB ................................................... 28
4
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
5
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
List of tables
Table 1. Time Frame .................................................................................................................... 11
Table 2. The value of m ............................................................................................................... 40
Table 3. The optimum time for each component to perform PM .............................................. 40
Table 4. The optimum time to perform PM ................................................................................ 41
List of figures
Figure 1. Maintenance-related time ............................................................................................. 9
Figure 2. Corrective maintenance cycle ...................................................................................... 17
Figure 3. Example of age policy ................................................................................................... 18
Figure 4. Curve shows the total cost with increasing PM actions to an optimal time ................ 22
Figure 5. TPL circulation .............................................................................................................. 27
Figure 6. No. of failures for each critical component during 5190 hours ................................... 38
Figure 7. The time at which the components have failed ........................................................... 39
Figure 8. Current PM Time and Optimum time .......................................................................... 41
List of images
Image 1. The wooden box ........................................................................................................... 27
Image 2. The photocell in palletizing robot................................................................................. 31
Image 3. The brake motor ........................................................................................................... 31
Image 4. The gearbox .................................................................................................................. 32
Image 5. The air bellows ............................................................................................................. 32
Image 6. The control list .............................................................................................................. 33
6
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
List of abbreviations
CM Corrective maintenance
PM Preventive maintenance
Cf Cost of failure
7
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
1. INTRODUCTION
This chapter will present an overview about the report, which includes: Background, problem
discussion, problem formulation, purpose, relevance, limitations and time table.
1.1 Background
The definition of maintenance may combine the technical and administrative actions
that intended to retain an item or restore it to a state in which it can perform a
required function. Maintenance provides crucial support for heavy and capital-
intensive industry by keeping machinery and equipment in a safe operating condition.
Therefore, maintenance plays a main role in sustaining long-term profitability and
competitiveness for an organization (Aditya and Uday, 2006).
Thus, the market demands on products with higher quality, faster delivery and more
reliable characteristics led to the development of manufacturing systems combining
automation (robotic machines), integration and flexibility. Accordingly this complex
system becoming more vulnerable to various kinds of disturbances, such as
components failure and incidental faults, but maintenance strategies consistent with
high applicable performance may mitigate it. The assimilation of maintenance
management could increase the productive time (availability), reliability, and optimise
performance due to many policies that correlated with high maintainability
techniques. There are two common maintenance strategies dealing with industrial
machinery known as corrective and preventive maintenance, the examples of
corrective maintenance (CM) are configuration of mechanical part and control
equipment when the robot break down (Fix when it’s break). In other hand, preventive
maintenance (PM) can be classified into three categories: time driven, predictive, and
equipment driven. Scheduled maintenance derived from periodic, time intervals of the
system to replace the part. The concept behind it is that wear parts have a fixed
number of cycles to failure which is converted to operating time. By determining the
optimum time to maintain or replace the part with minimum total cost (Mobley,
2004).
1
Maintenance strategy: It is plans which direct the maintenance management towered a desired future
state (Levitt, 2003).
8
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
In order to establish an effective Preventive maintenance (time based), failure data are
required and it does not have to be based on Expert opinions anymore. Using
statistical methods, scheduled maintenance can be optimized, taking into
consideration the three types of maintenance: preventive maintenance, inspection
maintenance and predictive maintenance (Didson, 1994).
9
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
1.4 Purpose
The goal of this report is to identify the optimum time that a certain PM actions should
take a place by analyzing the company maintenance policy towards their robot
availability.
1.5 Relevance
In today’s business, a valuable utilization of the machinery (robots) and incorporated
maintenance policies2 are a prerequisite for keep on challenging into the market and
gain profits. Thus, all the efforts regarding to decrease idle time and minimize delivery
delays should be made.
The relevance of this report includes the importance of implementing the right
maintenance policy at the right time in order to avoid unnecessary PM action which
could affect the machine availability.
1.6 Limitations
Maintenance management is wide subject and it’s difficult to consider all the elements
within it, therefore, our focusing will be only on the company applied method. In
addition to, visits limitation to company that narrowing our observations.
In order to follow up with submission dates, a time plan was developed at the
beginning of week ten. The time frame for the accomplishment of this work is shown
in the following table.
2
Maintenance policy: An identified step used to implement the maintenance actions (Levitt, 2003).
10
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
11
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
2. METHODOLOGY
In this chapter different methods had been selected by the authors in order to reveal the
process of the research. The chapter contains the research strategy, the research design, data
collection, validity and reliability, as well as generalizing.
The deductive approach is when the researcher deduces a hypothesis based on what is
known in a specific field, and by collecting data the researcher will reach his or her
findings. Some researchers prefer the inductive approach which is the opposite from
deductive approach. In the inductive approach “theory is the outcome of research”
(Bryman and Bell, 2007, p.14).
12
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
As the purpose of this thesis is to determine the exact optimum period to perform PM
actions, the causal method will be used. The authors will confront the cause-and-effect
problems by determining which policy is the most suitable for the robot.
Moreover, Bryman & Bell (2007) assert that a research design provides a structure for
the collection and analysis of data and there are five different types: experimental
design, cross-sectional or social survey design, longitudinal design, case study design
and comparative design.
Case study design “is concerned with the complexity and particular nature of the case
in question”. A case study can be: a single organization, a single location, a person, or a
single event (Bryman & Bell, 2007, p.62).
In this thesis a case study design will be applied because the data will be collected from
an industrial company located in Sweden. For this reason this design is the most
suitable for the thesis in order to obtain appropriate data and develops analytic and
problem solving skills. Furthermore, this kind of research requires a tangible approach
whilst connected to failures and statistical distributions, although it allows for
exploration of solutions for complex issues and applying new knowledge. The case
study here enables us to observe the current situation and monitoring all the factors
surrounded by it.
This thesis is a result of both qualitative and quantitative research, as the authors
investigate and evaluate maintenance policy in the industrial sector using data which is
verbally coded as well as statistics in order to provide cost effective solutions to the
case study. Therefore both methods are suitable in order to create a deeper
understanding about our topic.
For this paper, data was collected through interviews with different employees at the
company and by analyzing statistics and documents that have been collected by the
case study. The methods that will be applied in this thesis in order to get the most
significant data are detailed below.
13
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
The authors of this paper will interview several workers in the company with the
purpose of obtaining expert information about maintenance actions. The interviews
will consist of ten questions of different types such as open and closed questions. See
appendix (1). Thus, we will reduce the duration of the interview as well as making it
easier for interviewees to answer. The questions will be accurate in order to reach our
purpose. These questions mostly been formulated based on recent observations and
meeting with production and logistics manager, in addition to recent data collected
from last year of robot effectiveness such as availability, productivity and reliability
(failure data).
14
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
This thesis will provide the validity of the data by collecting accurate and relevant
information from various articles and books in order to find the most appropriate
theories for our thesis. Furthermore, the questions for the interview will be formulated
in a careful way to get the best relevant answers. Therefore the ways that been
performed for designing the questions taken into considerations the internal, external
and content validity. To provide reliability, the authors will interview different
operators and group leaders in order to know how the maintenance affects the robot.
The questions are related to every part of the process with the aim of achieving a
wider perspective.
2.5 Generalizing
Generalization of results involves that the researcher create a representative sample in
order to generalize the results to other groups or cases beyond than the one of the
research (Bryman and Bell, 2007). The qualitative method as well as quantitative can
be generalized, some of the reasons may be the situation of the case study or the type
of the research (Saunders et al., 2007).
Consequently, may this method encountered an internal and external blocks through
implementation stage such as human errors or learning curve minimization, especially
this way based on high corrective cost over preventive cost, and in such companies a
certain corrective action still benefiting more than life based maintenance.
15
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
3. THEORETICAL FRAMEWORK
This chapter contains theories about maintenance management in order to provide a clear
picture of the theories which will be used in the research.
Nowadays organizations are not only satisfied with keep machines in good conditions
further, maintenance actions could be planned and totally efficient. Maintenance
sometimes could be critical aspect in an organization it could turn unnecessary cost
into profits. In united state over than $600 billion has been spent on critical plant
systems although it has been increased to $800 billion by 10 years (Mobley, 2004).
16
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Mean time to failure (MTTF) or the bathtub curve shows that there is a high probability
of occurrence of failure in the first phase which is the installation phase. After a period
of time the machine goes into the Normal phase where it supposes to work as it
designed. Then the cost of maintain the machine goes higher and higher with time
because of wear out. In preventive maintenance machine repaired according to
schedules based on MTTF statistically (Mobley, 2004).
17
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
A fixed time intervals is identified for PM actions to take a place, these actions are
scheduled and is being implemented periodically. This policy wins normally when the
cost of preventive maintenance is lower comparing with other PM cost polices.
Moving towered from fixed intervals that are scheduled to a dynamic scheduling for
those intervals based on operating hours, defined as age policy (Sherwin, 2010).
18
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Figure above shows two operating cycle for a component, first cycle component has
been operating till tp and scheduled PM took a place. Next cycle component has been
fail prior tp, that case PM actions has been rescheduled for the next cycle. The
objective of this model is that tp is being optimum and PM actions (replacement, break
down maintenance) are performed with minimum cost per unit time (Duffuaa et al.,
1998).
The cost of PM actions and break down maintenance are associated with the Total
expected cost per cycle which is:
Where R(tp) is the probability that the component will survives till t p (Duffuaa el at.,
1998).
f(t) = β/ηβ(t-ɣ)β-1exp[-(t-ɣ/η)β]
And
R(t) = exp[-(t-ɣ/η)β]
Where: γ = Location parameter
β = Shape parameter
η = Scale parameter
19
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
The Weibull distribution model gives an insight of how the distribution will look like. By
using the three parameters mentioned above as an input. Obtaining a graph from
those inputs could be possible which will show the probability that a certain
component will fail at a certain point in time. The two parameters are obtained by
setting γ=0 which give:
f(t) = β/ηβ(t)β-1exp-(t/η)β
The first parameter that is used is called the Location parameter denoted by γ
(Gamma). This determines where the graph will start and in most cases it always
assumed to be zero showing that it is the minimum time to failure. When gamma
parameter is set to be zero, this is called the two-parameter Weibull distribution.
The shape parameter is the second parameter usually denoted by β. This parameter
determines the shape of the graph and known as the Weibull slope. The β parameter is
the function of the hazard rates (Murthy et al., 2004).
With some values of (β), the equation will reduce to other distribution model. For
example if β=1, the p.d.f of the three-parameter, Weibull will reduce to the two-
parameter exponential distribution with the probability density function f(t) given as:
The different slope will approach the value of η at different F(t) depending on time.
The last parameter in Weibull distribution is called the scale parameter denoted by η.
The scale parameter is the point at which 63.2% of the products have failed. The
higher the number of η value, the more the graph is stretched over period of time
(Murthy et al., 2004).
20
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
According to Dodson (1994), there are four most commonly used methods to estimate
Weibull parameters:
MLE refers to Maximum Likelihood Estimation, one of the most widely statistics
method to estimate Weibulls’ parameters. Based on maximize the value that maximize
the probability of a data. Let X1,X2,…..Xn be independent random variables which are
the representations for the probability density function f(x,Ɵ).
- Moment estimation
This method is used in estimation parameters by matching the moment of the sample
to the moment defined by distribution. In case of Weibull two parameters, first and
second moment for a sample data would be variance and mean which equal to:
And
Both of them are a graphical method used in order to estimate the Weibull
parameters. The cumulative distributions are being linearized by a logarithmic
transformation. Median rank is being used in probability approach. Furthermore if it
would be a manual approach it would require special papers. But due to high
technique in computers, linearization can easily be done.
21
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Figure 4. Curve shows the total cost with increasing PM actions to an optimal time
Source: Levitt , 2003, pp.12
Figure above shows the minimum overall cost with increasing PM costs to an optimum
time. Notice that cost becomes stabilized with time since PM actions going no more
effective.
Implementing a maintenance policy does not mean avoiding extra cost all the time.
Defining the right time interval in order to PM actions take a place is exactly what all
organizations looking for. With time PM costs increased and become ineffective then,
it would preferable to have breakdown instead of running ineffective PM actions. This
caused by age of the system wearing out (Levitt, 2003).
The area denoted by X is all organizations interest in which the total cost during this
time interval would be the minimum. As mentioned before, determining this time
interval is the biggest challenge. Dodson (1994) asserts that minimizing the total cost
per unit time in order to find the optimum time according to the following equation:
22
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Instead of minimizing the previous equation every time by usual numerical routine,
Dodson (1994) has developed a table that can easily used and applicable by following
assumptions:
The optimum time between preventive maintenance actions can be easily calculated
by the following formula:
Procedure is that the right actions are being carefully taken at the right time. Discipline
is that all actions are planned and under control. Discipline is the check aspect for PM
actions; hence it could not be overlooked. Failing of implementing a scheduled
maintenance for some organization mainly comes from discipline aspect, which is
being ignored. Scheduled maintenance is one step forward of improving PM actions to
be in accurate need of it (Mobley, 2004).
According to Mobley (2004), there are six main elements for accurate procedure:
Listing of components plus the intervals that they should received a preventive
maintenance.
Updating the records for the actions that had done, and when next action due
to.
23
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Some PM actions could take a place every interval weather it is necessary or not,
hence, unnecessary stoppage may occurs. Since scheduled maintenance aim to reduce
unplanned stoppages, scheduled maintenance should be based on real actual need of
PM actions.
According to Negrea et al. (2007, p.217), the LCC includes the following steps:
Furthermore, Liu et al. (2010) state that the value of LCC can be obtained by
calculating the equation below.
CLCC = CI + CO + CM + CF + CD
CLCC = CI + CO + CM + CF + CD + Cexter
24
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
LCC can be discounted using the present value method at a certain interest rate (i)
after n years, in the present time. The following equation shows the present value of
LCC:
Where F C LCC is the future value of LCC and is equal to CLCC calculated above, and PC LCC is
the present value of LCC discounted.
25
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
4. EMPIRICAL DATA
In this chapter, a description of case company, the production process is presented. Moreover,
data gathered from the interviews and observations are included through this part.
After supplier delivered containers to Dynamate Intralog AB, the unloaded process
start taken place by workers in which they sort the boxes according to their marked
labels and then shifted to warehouse area by forklifts for later supply. On other hand,
Scania send their empty boxes by trucks to Dynamate in order to store them after
robots processing them, and these procedures related to limited and overloaded
materials in Scania’s facility. The figure below shows TPL circulation between supplier,
Scania and Dynamate.
26
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Supplier
Dynamate
Intralog Scania
AB
Figure 5. TPL circulation
Proceeding from the figure, Dynamate highlighted a core value through TPL circulation,
for that reason Dynamate was our interest of study and we are going to present the
empty boxes process in details after it arrives to company and then to robots.
Collar
Pallet
27
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Photocell, gearbox, brake motor, guide rails, chain, turntable, and robot arm; the
system performance proportionally affected by these components availability. Those
elements are going to be clarified in details in later parts.
28
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Second component is brake motor incurred mechanical failure such friction between
brake cylinder and vanes caused by unstable screws that being running for long term,
plus the erosion appeared on the surface of brake metal. Accordingly, this kind of
failure evaluated as real problem because of time needed to repair the fault and in
case of replacement by new one. In both cases it goes along 3 days to reactivate the
production engine back because of outsourcing demand for brake motor elements as
well as importing maintenance engineers who has capabilities dealing with complex
repair. Nevertheless, detecting the failure takes around 1 hour to be located. Dataset
been gathered and generated based on times to failure and number of failures. See
appendix (4).
Third component is gearbox, its very fundamental components and hard to allocate
the failure immediately might took 2 hours to detect, and in some cases the oil leakage
from the gearbox gives a deterministic sign to stop the robot and recurred the minor
failure before entering the major stoppage that long 2-4 days until the robot reactivate
again. This long period due to gearbox parts outsourcing or buying a new one, that
29
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
type of failure affect other components indeed. Dataset about this component can be
found in appendix (5).
Fourth component known as air bellows, the failure here surrounded by rusty
conditions because of corrosion basis, and that can be known through air leakages.
This is the hardest failure to detect because the system still processing and long farther
in same state down to suddenly breakdown. That’s taking almost 5 hours to detect the
failure and need 4-6 hours to restore the functional circumstances. Data set about this
component shown in appendix (6).
Finally, control list component has over-flooded fat problem suit a sliding collars and
that’s actually a serious problem been observed tangibly through our visit, also the
wear-out and corrosion appeared clearly. When this problem occurred the robot arm
stop working however attempted to reinstall again, and required the worker to stop
machine then try to remove the collar manually and put it in collar area then restart
the machine. This mission takes 5-10 minute to reuse the robot arm, but main problem
was control list and here the maintenance technician has to come and repair or
replace the control list. The time needed split into two branches either item is
available in storages and this operation to repair required 2-3 hours or they have to
wait at least 2 days to receive such a component. Data set of this component shown in
appendix (7).
30
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Photocell
Brake motor has to check every Thursday by measuring the distance between the vane
and brake cylinder, the measurement has to shown 0, 2 mm through using feeler
gauge otherwise the screws around the vane must adjust the difference between
them. This operation longs from 15 minutes – 1 hour but the whole machine being
stopped. The replacement screws take place every 2 weeks and the whole robot being
stopped for almost 1 hour, and the screws cost 100 SEK.
Vane
31
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Air bellows checked monthly by monitoring the air outlet paths if there is no air
leakage through those channels besides checking the cracks that would happen
throughout chemical reactions, for instance corrosion and erosion. The inspection
longs 30-50 minutes by stopping the machine.
Outlet path
Control list criticality considered because of its role importance, the control list has to
be checked from surface cracked or lubricant troubles, for that reason the machine has
to be stopped form 30 minutes- 1 hour and dried from over-flood fat, then pour new
viscosity oil.
32
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Control list
According to appendix (3) the photocell shows 43 number of failures through 5190
hours, the labour cost as mentioned before was 450 SEK and replacement cost is 1500
SEK.
Then, Brake motor appendix (4) shows 3 number of failures during 5109 hours, the
labour cost approximately 500 SEK and parts cost about 2000-6000 SEK for instance
vane or cylinder damage, but in case of replace it with new item cost 8000 SEK. After
that, the gearbox repair may cost approximately 6000 SEK and can be less when its
minor fix such as small parts within the gearbox, labour cost at least 500 SEK, the
number of failures doesn’t occurs so often which is only 2 times see appendix (5). On
other hand, the air bellows take place quite much in failure number it reach 6 times,
and the labour cost 500 SEK beside the repair and replacement costs that ranging from
1000 SEK- 5000 SEK. At last, control list required more attention because of its
importance related to robot arm, the labour cost is 450 SEK and the replacement or
repair cost ranging from 1000 SEK- 4000 SEK.
The preventive cost classified into time spent in preventive maintenance in terms of
money and the stoppage time cost that are going to be considered in analysis part as
well.
Preventive maintenance cost for photocell within 1 week is 75 SEK and no need for
machine stoppage by cleaning the dirt upon photocell. In paradox with brake motor
33
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
that need to stop the whole robot to make preventive maintenance and it costs up to
500 SEK. The gearbox required only vision inspection to be surely about functioning
conditions, and does not required any spending cost in this activity, because it might
be included through daily work instructions. The air bellows require 225 SEK even as
considered monthly and it’s very sensitive to be checked correctly. Finally the
preventive maintenance cost for control list component may range around 500 SEK
divided into labour and lubricant cost.
34
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
5. ANALYSIS
This chapter comprising the data that have been collected about maintenance practices and
their correlations to costs, the assumptions been conducted in this part to obtain systematic
calculations.
The total maintenance cost contains of two main factors which are corrective and
preventive maintenance cost, so the calculations will take each component one by
one, starting with photocell, the formulas consists of the following combinations:
(1) Photocell
Corrective cost: Labour cost /h + Stoppage time cost + Replacement item cost
Stoppage time = 2.5×43 = 107, 5 hours and in terms of money, as the assumption
induce the time variable by each box cost 1 SEK, then Stoppage time cost = 89×1×107,5
= 9,567.5 SEK
Preventive cost: Labour cost + Stoppage time cost+ Replacement item cost
35
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Corrective cost: Labour cost /h + Stoppage time cost + Replacement item cost
Stoppage time = 30×3= 90 hours, then Stoppage time cost = 89×1×90= 8,010 SEK
Preventive cost: Labour cost + Stoppage time cost+ Replacement item cost
(3) Gearbox
Corrective cost: Labour cost /h + Stoppage time cost + Replacement item cost
Stoppage time = 30×2= 60 hours, then Stoppage time cost = 89×1×60= 4,800 SEK
36
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Preventive cost: Labour cost + Stoppage time cost+ Replacement item cost
Stoppage time = 28.6 hours, then Stoppage time cost = 89×1×28.6= 2,551.3 SEK
Corrective cost: Labour cost /h + Stoppage time cost + Replacement item cost
Stoppage time = 11×6= 66 hours, then Stoppage time cost = 89×1×66= 5,874 SEK
Preventive cost: Labour cost + Stoppage time cost+ Replacement item cost
Stoppage time = 72 hours, then Stoppage time cost = 89×1×72= 6,408 SEK
Corrective cost: Labour cost /h + Stoppage time cost + Replacement item cost
Stoppage time = 33×7= 231 hours, then Stoppage time cost = 89×1×231= 20,559 SEK
Preventive cost: Labour cost + Stoppage time cost+ Replacement item cost
Stoppage time = 21.625 hours, then Stoppage time cost = 89×1×21.625= 1,924.6 SEK
Figure 6. No. of failures for each critical component during 5190 hours
A graph above gives a holistic view about the failures that occurred during 5190
operating hours. While X axis represent the components and Y axis represents the
numbers of failure. From the graph it is so obvious that photo cell has the most
frequent failure comparing with the rest of the components.
38
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
A graph above shows failure time for critical components. X axis represents the
number of failures while Y axis represents the time at which the component has been
failed. Failures have been registered over a 5190 operating hours. It is obviously shown
that Guide ways for example has registered three failures during these operating
hours. Those failures registered in different hours.
Due to large Number of failures for the ‘photo cell’ component it has been taken out of
the graph in order to clarify the other components.
T= (m.η) + γ
Gamma is zero here for all components, thus value of m can be easily found from the
table appendix (8).
39
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Finding the value of m, substitute it with equation 1 we have the optimum time to
replace, maintain the component. Table 4 bellow shows the optimum time for each
component. For the value of B see appendixes (9, 10, 11, and 12).
Cc/Cp β η m γ Opti T
40
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
It is obvious that there are some unnecessary PM actions which mean extra
unnecessary cost. PM could be rescheduled and implemented in groups for multiple
components.
41
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
6. RESULTS
In this chapter the final result of the thesis analysis presented. With respect to the data
collected from the company.
As results, critical components have been determined based on an interview with the
production manager. Those components are photocells and reflexes, Break motor,
Gear box, Air bellows, and Control list. Failure data for these components have been
followed a Weibull distribution. In addition estimating the value of beta and eata for
each component are essential to calculate the optimum time.
The optimum time for the critical components have been determined to let PM actions
take a place. Optimum hours are 98, 9313, 2679, 3020 and 2381 hours for photocells
and reflexes, Break motor, Gear box, Air bellows, and Control list respectively.
Based on the calculation, schedule for those critical components has been made,
aiming to reduce the total number of PM actions. A group of actions has been
scheduled together as table 4.
The number of PM actions could be reduced by knowing the exact time, therefore
unnecessary cost could be avoided. In the previous table, a PM could be performed
after 2200 operating hours for Control list and Gear Box. Instead of apply PM every
900 hours. It is obvious that two round of PM unnecessary. There for those costs could
be avoided, the total cost for PM actions for the whole components would be
Cost of PM After scheduling 87570.7 sek which is definitely less than the current one
since the total no. of planned stoppages has been reduced.
42
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
7. CONCLUSION
In this chapter the conclusion of our thesis which answer the problem formulation, criticism to
our thesis and suggestions
Company experience is one method to identify the critical components. Using FMECA
for example could make the analysis more accurate. Recording the failures of the
machine is one step forward to enhance the availability of it. Analyse a historical data
is the second step to improve the maintenance policy.
In order to avoid extra unnecessary cost Optimum time has been scheduled; PM
actions should be implemented at the right time that could effective. By determining
the optimum time a group of PM actions could be implemented at once.
The main aim for scheduling the PM actions is to identify the right time interval that
should the PM actions performed. Based on analysis and knowing the behaviour of the
system or component. Readability and availability of the data play big role in the result
part and sometimes could affect a critical decision that the organization should make.
Subsequently, the reasons behind the failure types are the core of analyzing the data
by Weibull, and the way that trends through dealt with certain reasons of faults and
not the all causes. Thus, FMEA is an integrated reliability analysis tool in order to cover
all the critical failures and their consequences in the system. For instance the external
factors may enhance the failure occurrence and the environment indeed, therefore, to
manage better solutions these factors have to be considered.
Recommendations
The company needs to enhance their workers to have enough knowledge about those
components and have best maintenance practices manual to monitor all the machine
elements in case of stoppage and breakdowns.
Furthermore, the inspection is very fundamental for avoiding system idle and
malfunctions components later on, hence may condition based maintenance be
suitable to be investigate in future.
43
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
References
Aditya, P. and Uday, K., 2006. Maintenance performance measurement (MPM): issues
and challenges. Journal of Quality in Maintenance Engineering, 12(3), pp.239-251
Bryman, A. and Bell E., 2007. Business Research methods. United States: Oxford
University Press, Inc.
Chitra,T., 2003. Life Based Maintenance Policy for Minimum Cost, CASSA, [online]
Available at: <ftp://ftp.estec.esa.nl/pub3/tos-
qq/qq/RAMS2003ConferenceProceedings/DATA/13BP4.PDF> [Accessed 19 April 2011].
Creswell, J., 2009. Research design: Qualitative, Quantitative, and mixed methods
approaches. 3rd ed. United States: Sage Publications, Inc.
Dodson, B. and Kirkland, J., 1994. The Reliability & Maintenance Analyst.
Duffuaa, S. Campbell, J. and Raouf, A., 1998. Planning and control of maintenance
systems: modelling and analysis. New York: John Wiley.
Ghauri, P. and Grønhaug, K., 2005. Research Methods in Business Studies: A Practical
Guide. 3rd ed. Europe: Prentice Hall.
Langford, J., 2007. Logistics: Principles and Applications. 2nd ed. United States: The
McGraw-Hill Companies, Inc.
Levitt, J., 2003. Complete guide to preventive and predictive maintenance. 1st ed. New
York: Industrial Press
Liu, L. et al., 2010. Life Cycle Cost Estimate of Power System Planning. In: POWERCON,
International Conference on Power System Technology. Hangzhou, China, 24-28
October 2010. United States: IEEE
Murthy, D.N. Prabhakar, Xie, Min & Jiang, Renyan, 2004. Weibull models. Hoboken,
N.J.: Wiley-Interscience
44
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Sarma, K.C. and Adeli, H., 2002. Life-cycle cost optimization of steel structures.
International Journal for numerical methods in engineering, 55(12), pp.1451-1462
Saunders, M. Lewis, P. and Thornhill, A., 2007. Research Methods for Business
Students. 4th ed. England: Prentice Hall.
Shavit, T.H., 1993. Age Renewal and Block Renewal. Extracts from a compendium by
D.J. Sherwin, 30(1).
Sheu, C. and Krajewski, L.J, 1994. A decision model for corrective maintenance
management. International Journal of Production Research, 32(6), pp.1365-1382
45
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 1
QUESTIONNAIRE
1- What is the logistic connection between Dynamate and Scania along the supply
chain?
7- What are the maintenance strategies and policies towards these components,
and if there any analysis tools dealing with?
8- Is there any human factors and untrained worker may affect negatively the
palletizing robotic system?
9- How much money and time were spending in corrective maintenance respect
to failure components?
10- How much money and time were spending in preventive maintenance and if it
been scheduled?
46
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 2
This table present the boxes number that been produced in week 6
47
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 3
Component No. of failures during 5190 hours
Photo cell 43
48
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
32 3745
33 3885
34 3990
35 4085
36 4196
37 4303
38 4420
39 4519
40 4640
41 4734
42 4847
43 4976
49
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 4
Component No. of failures during 5190 hours
Brake Motor 3
Failure No. at T
1 2407
2 3641
3 4753
Table of failures for Brake motor during 5190
50
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 5
Component No. of failures during 5190 hours
Gear Box 2
Failure No. at T
1 3588
2 4799
Table shows the failure time for Gear box
51
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 6
Component No. of failures during 5190 hours
Gear Box 2
Failure No. at T
1 3588
2 4799
Table shows the failure time for Gear box
52
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 7
Component No. of failures during 5190 hours
Control List 7
Failure No. at T
1 2700
2 2923
3 3444
4
4133
5 4456
6 4878
7 5045
53
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 8
54
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 9
Break Motor
55
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 10
Gear Box
56
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 11
Air bellows
57
Scheduled maintenance policy for minimum cost – A case study
Linnaeus University – Spring 2011
Appendix 12
Control List
58