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Evolution of Technical Systems Maintenance Approaches – Review and a Case Study

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The importance of technical objects maintenance issues takes on particular significance in the area of increasing competition an increasingly higher demands in the area of quality, reliability and productivity of performed system’s functions and tasks. The main objectives of maintenance have evolved for the last fifty years. Thus, the article is aimed at the investigation of maintenance approaches evolution. The authors focus on the presentation of basic literature review covering the main maintenance approaches, from Maintenance 1.0 to Maintenance 4.0. First, the authors provide the reader with the main definitions connected with this research area and present few classifications of maintenance strategies with their historical background. The presented state of art was based on a review of available literature sources in the form of non-serial publications, scientific journals publications and conference proceedings. As a result, an overview of the literature includes the issues published in different times of the last forty years, and investigates the most well-known maintenance problems. Later, a simple case study on transportation company’s maintenance management issues is provided.
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Evolution of Technical Systems Maintenance
Approaches Review and a Case Study
Tomasz Nowakowski, Agnieszka Tubis ,
and Sylwia Werbińska-Wojciechowska
(&)
Wroclaw University of Science and Technology, Wroclaw, Poland
{tomasz.nowakowski,sylwia.werbinska}@pwr.edu.pl
Abstract. The importance of technical objects maintenance issues takes on
particular signicance in the area of increasing competition an increasingly
higher demands in the area of quality, reliability and productivity of performed
systems functions and tasks. The main objectives of maintenance have evolved
for the last fty years. Thus, the article is aimed at the investigation of main-
tenance approaches evolution. The authors focus on the presentation of basic
literature review covering the main maintenance approaches, from Maintenance
1.0 to Maintenance 4.0. First, the authors provide the reader with the main
denitions connected with this research area and present few classications of
maintenance strategies with their historical background. The presented state of
art was based on a review of available literature sources in the form of non-serial
publications, scientic journals publications and conference proceedings. As a
result, an overview of the literature includes the issues published in different
times of the last forty years, and investigates the most well-known maintenance
problems. Later, a simple case study on transportation companys maintenance
management issues is provided.
Keywords: Maintenance Technical system Review
1 Introduction
One of the most important issue when ensuring high availability and reliability during
assets life time is their maintenance performance [27]. Recently, maintenance is in a
huge area of interest and research for engineers [19], because poorly maintained
equipment may lead to more frequent equipment failures, poor utilization of equipment
and delayed operational schedules. Wrongly selected or scheduled maintenance strat-
egy of any equipment may result e.g. in scrap or products of questionable quality
manufacturing. Following this, more and more companies are undertaking efforts to
improve the effectiveness of maintenance functions [77].
Recently, a lot of researchers and publications in the eld of maintenance decision
models and techniques have been published to improve the effectiveness of mainte-
nance process (see e.g. [57] for review). The known solutions have evolved in time,
from Maintenance 1.0 level to at least Maintenance 4.0 level (that uses advances
analyses and big data). On the other hand, organizations are aimed at improving their
maintenance maturity. According to the authors of the report [65], which was aimed at
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survey research on maintenance strategies implementation in companies in Belgium,
Germany and the Netherlands, only 11% of the respondents (total of 280 respondents)
have already achieved level 4.0. Following this, it is of utmost importance to inves-
tigate the possibilities and limitations of different maintenance approaches imple-
mentation in practice.
The article is aimed at the investigation of maintenance approaches evolution. The
authors provide the reader with the main denitions connected with this research area
and present few classications of maintenance strategies with historical background.
Following this, the structure of the article is as follows: In the Sect. 2, the main
denitions and objectives of maintenance are presented. Later, the comprehensive
literature review on maintenance approaches is provided. The authors focus on the
presentation of basic literature review covering the main maintenance approaches, from
Maintenance 1.0 to Maintenance 4.0. This gives a possibility to present a case study of
passenger transportation company and its maintenance management issues. The article
ends up with a summary and conclusions for further research.
2 The Main Denitions and Scope of Maintenance
Maintenance theory has still been developing since 1960s of the XX century. Thus, in
the literature there can be found many denitions of terms of maintenance, maintenance
strategy, or maintenance policy. According to the European Standard PN-EN
13306:2010 [61], maintenance is a combination of all technical, administrative and
managerial actions during the lifecycle of an item intended to retain it, or restore it to a
state, in which it can perform the required function. The similar denition may be
presented based on [25,33] and is compliant with the PN-IEC 60300-3-10 standard
[63], where maintenance is dened as a combination of activities to retain a component
in, or restore it to, a state (specied condition) in which it can perform its designated
function. These activities generally involve repairs and replacement of equipment items
of a system and the maintenance decision is based on the system condition or on a
denite time interval [25].
Based on these denitions, the main objective of maintenance, which is linked to
the overall organizational objectives, should be to maximize the protability of the
organization by performing activities which retain working equipment in an acceptable
condition, or return the equipment to an acceptable working condition [73]. Thus,
following [mono] the principal objectives of maintenance are connected with (Fig. 1):
ensuring system basic functions (availability, efciency and reliability),
ensuring system life through proper connections between its components (asset
management),
ensuring safety for human operators, environment and system itself,
ensuring cost effectiveness in maintenance, and
enabling effective use of resources, energy and raw materials.
The acquisition of these goals is possible taking into account opportunities and
constraints that are connected with the main maintenance research areas, like
162 T. Nowakowski et al.
maintenance strategy selection, maintenance planning, spare parts provisioning, or risk
management. The short summary is given in Table 1.
The authors focus on the rst subdomain connected with maintenance strategy
selection. Thus, maintenance strategy is a systematic approach to upkeep the technical
objects [29]. The maintenance strategy involves identication, researching and exe-
cution of many repair, replacements, and inspect decisions and may vary from facility
to facility [29] (Fig. 2).
Fig. 1. Maintenance of technical systems the scope, Source: [88]
Table 1. The short summary of maintenance studies, Source: Based on [88]
The main maintenance
subdomains
The main problems analysed in subdomains Basic
references
Maintenance strategy
selection
Selection of the maintenance policy for an
element/system (CM, PM, PdM, CBM, RCM, )
Maintenance optimization modelling
Maintenance integration
[2,4,69,79]
Failure
prediction/degradation
modelling
Aging management
RUL estimation
Uncertainty analysis
Accident analysis
[10,31,68,
75,86]
(continued)
Evolution of Technical Systems Maintenance Approaches 163
Selecting the best maintenance strategy always depends on several factors such as
the goals of maintenance, the nature of the technical object to be maintained, opera-
tional process patterns, and the work environment [56]. Following this, in the next
Subsection the authors focus on the main maintenance strategies and investigates the
four maturity levels of maintenance evolution.
Table 1. (continued)
The main maintenance
subdomains
The main problems analysed in subdomains Basic
references
Maintenance planning Maintenance tasks scheduling
Determining the right components to be maintained
Resource allocation and dimensioning of maintenance
resources
[13,60]
Spare parts
provisioning
Spare parts classication
Spare parts reliability modelling
Demand forecasting
Inventory management
Spare parts allocation
[9,11,39,
80,84]
Risk management in
maintenance
Risk-based maintenance modelling
Safety indicators
Risk informed asset management
Human factor in maintenance
[68,20,40,
53]
Warranty and
maintenance
Warranty optimization,
Maintenance logistics for warranty servicing
Outsourcing of maintenance for warranty servicing
Warranty data collection and analysis
[54,55,66,
72,91]
System design Design for maintenance
LCC approach
Redundancy modelling
Components dependence analysis
Dynamic reliability
Human factor in the design phase
Impact on health and environment
Logistic support planning
[21,22,44,
52,89,92]
Maintenance
performance
measurement
Benchmarking analysis
Performance indicators assessment
Best practices identication
Customer satisfaction surveys
Maintenance process diagnosis and audits
Quality in maintenance
Maintenance reengineering
[42,59,67,
76]
164 T. Nowakowski et al.
3 Maintenance Approaches Evolution
The evolution of maintenance approaches in the last fty years may be presented by a
simple graph, given in the Fig. 3.
The rst approach to maintenance (the Maintenance 1.0), often called as run to
failureor corrective maintenance (CM) strategy, was very popular in the time period
19401960 [1]. CM is reactive and regards to any maintenance action that occurs when
a system has been already failed, so there is no possibility to optimize its performance
Fig. 2. The main problems in maintenance of technical systems, Source: [88]
Fig. 3. The main maintenance approaches, Source: [87]
Evolution of Technical Systems Maintenance Approaches 165
with respect to a given economic or reliability criteria [57]. While, a failure is dened
as an event, or inoperable state, in which any item or part of an item does not, or
would not, perform as previously specied [47]. This type of maintenance cannot be
planned and has the associated consequences connected with system unavailability
being the result of the failure. Therefore, using this type of technical system mainte-
nance policy, there is no possibility to make any optimization of operational and
maintenance parameters (see e.g. [30,35,36]). On the other hand, this maintenance
strategy is still popular due to the low cost of its implementation.
In the situation, when it is necessary to avoid system failures during operation,
especially when such an event is costly or/and dangerous, it is important to perform
planned maintenance actions. Thus, we may choose the Maintenance 2.0 level con-
nected with preventive maintenance (PM) performance. PM, according to MIL-STD-
721C [47], means all actions performed in an attempt to retain an item in a specied
condition by providing systematic inspection, detection and prevention of incipient
failures. Basically, this approach tries to forecast or predict the wear and tear of life of
equipment by using different approaches and recommends a corrective action. In this
area the most commonly referred strategies in the literature are time-based PM and
condition-based maintenance (CBM) [29]. Moreover, the difference between CM and
PM is illustrated e.g. in [45] and the comparison of the main maintenance strategies is
given e.g. in [48].
Time-based inspection and maintenance are still ones of the dominant maintenance
policies used in an industry for certain types of assets that cannot be condition-
monitored or maintained on a predictive basis [85]. For complex systems such as
transportation systems, production systems, or critical infrastructure systems, the time-
based inspection and maintenance policies can improve performance, increase relia-
bility and capability of assets concerned, and reduce the cost of assets running [85].
More information can be found e.g. in [2,18].
At the second maintenance level usually is classied inspection maintenance. Many
components may become defective prior to failure and still remain operable. These
types of components may benet from an inspection policy whereby a component is
inspected for the defect and consequently replaced at inspection to prevent failure [17].
Recent reviews on inspection maintenance modelling issues are presented e.g. in works
[15,16,34,78].
Condition-based maintenance is treated as the rst maintenance strategy that can be
included to the Maintenance 3.0 level. CBM bases on monitoring operating condition
of a system or its components [41] by using diagnostic methods/measures [12,28].
When it is applicable, CBM gives the possibility to perform maintenance actions just
before the system/components failure occurrence. Hence, unlike CM and PM, CBM
focuses not only on fault detection and diagnostics of components but also on
degradation monitoring and failure prediction. Thus, CBM can be treated as the method
used to reduce the uncertainty of maintenance activities [74]. The literature review on
CBM policy is presented e.g. in works [2,3,18,32,64,74]. A framework for condition
monitoring and classication of decisions about appropriate maintenance actions per-
formance based on two decision criteria (average downtime per failure and frequency
of failure) are presented e.g. in [70].
166 T. Nowakowski et al.
Another maintenance policy, which usually is treated as a synonymous to CBM or
is named as risk-based maintenance, is predictive maintenance (PdM) [71,82]. This
maintenance policy is used in these sectors where reliability is paramount, like nuclear
power plants, transportation systems or emergency systems. Its main scope is to foresee
faults or failures in a deteriorating system in order to optimize maintenance efforts by
monitoring of equipment operating conditions to detect any signs of wear that are
leading to a failure of a component [71]. The goal of the PdM program is to track
component wear with a methodology that insures that any impending failure is detected
[51]. The most commonly used monitoring and diagnostic techniques include, among
others, vibration monitoring, thermography, tribology, or visual inspection [51]. The
advantages of predictive or online maintenance techniques in identifying the onset of
equipment failure are discussed e.g. in [37]. For more information, the author rec-
ommends reading e.g. [24,51]. The advantages of this maintenance policy imple-
mentation are presented e.g. in [14].
The last maintenance approach is Maintenance 4.0. One of the rst maintenance
strategy being classied at this level is RCM (Reliability Centered Maintenance).
According to the MIL-STD-3034 [46], RCM is a method for determining maintenance
requirements based on the analysis of the likely functional failures of systems/
equipment having a signicant impact on safety, operations, and lifecycle cost. RCM
supports the failure-management strategy for any system based on its inherent reliability
and operating context. RCM uses different tools (e.g. FMECA) to determine the rela-
tionships between the system elements and the level of its operation and then develops
the effective maintenance management strategy (RCM Task Selection) [17,49].
A comprehensive overview of this concept is presented e.g. in [deAlme15, 24,38,43].
The main principles are, however, given in the PN-EN 60300-3-11 standard [62].
Moreover, the authors in their work [23] discuss the optimal maintenance policies for
manufacturing companies introducing two other approaches aimed at improvement,
namely autonomous maintenance and design out maintenance. The authors investigate
the maintenance models and classify them based on the certainty theory.
Recently, based on the relevant research studies, the next level in predictive
maintenance is connected with Proactive maintenance, often called as Predictive
Maintenance 4.0 and incorporates the principals of continuous improvements method.
One of the used concept here is Internet of Things that takes machine-to-machine
technology to the next level by including a third element: data. According to the [90],
all the machine data are to be available in one virtual network, which gives the
producers the ability to aggregate and analyze the data to generate better predictive
analytic models. For more information the author recommends reading e.g. [65,81].
The main classication of maintenance strategies is given in the standard PN-EN
13306 [61]. The overview of maintenance approaches may be found e.g. in [26,50,58,83]
and analysis of maintenance philosophies development is given in [5]. General classi-
cation of maintenance strategies may be found in [88]. Following this, the next step is to
investigate how these maintenance approaches may be implemented to the real-life
technical systems performance.
Evolution of Technical Systems Maintenance Approaches 167
4 Case Study
Many Polish enterprises still apply basic maintenance strategies in their everyday
performance activities. Among the arguments in favor of maintaining the current status
quo are usually:
no costs for spare parts warehouse management,
lack of knowledge and good practices in the area of other maintenance strategies
implementation,
lack of competence to prepare quantitative analyzes that improve the decision-
making process in higher-level maintenance strategies,
no data available in the electronic version that could be the basis for the preparation
of quantitative analyzes.
Many maintenance managers are not aware that a strategy that seems to them to be
simple and cost-effective (costs of repair and new spare parts purchasing are incurred
only when the failure occurs), in fact generates numerous additional and hypothetical
costs. Lack of this awareness often results from the lack of physical registration of these
cost elements in the accounting system and their actual attribution to a given hazard
event. A good example here is the company, in which the authors conducted research
in the area of vehicle eet maintenance.
The surveyed passenger transport company is a leading carrier on the Polish public
transport market. Currently 156 vehicles are used to carry out transport tasks. These
buses from the point of view of the service process can be divided into the following
groups according to the criterion of the service life (Table 2).
The transport company for the implementation of basic tasks (regional transport
provided within the framework of collective public transport and regular employee and
school transport) uses its transport eet in 95%. Any surplus transport capacity is sold in
the course of occasional additional orders, e.g. in order to support mass events, trips, etc.
Such a high operating coefcient of transport base indicate that in the event of
failure of any vehicle, the company seeks to minimize the time when the bus is out of
service. This is particularly the case when the company does not have a spare vehicles
that may substitute the failed one. The situation is signicantly hampered by the fact
that the current vehicle maintenance strategy on which the company is based is a
reactive strategy. This means:
1. lack of spare parts necessary to remove the occurred failure - necessary elements are
acquired at the moment of demand occurrence,
Table 2. The number of vehicles with the dened service life
Vehicles service life Number of vehicles
Less than 10 years 16
1020 years 101
More than 20 years 39
168 T. Nowakowski et al.
2. partial repairs carried out in the jump system - partial removal of the failure, in order
to allow short-term operation, and re-repair at the time of receiving the necessary
parts,
3. extended waiting period for materials being necessary to carry the repair, resulting
in an extended time of shutting the vehicle out of use.
The analysis of maintenance data carried out by the employees of the repair
workshop proved that the effect of the given maintenance strategy is:
1. longer holding times of buses in the repair shop - the maximum registered time is 15
weeks with the exclusion of use of the vehicle in relation to the spare part lead time,
2. multiple minimal repairs performance for keeping the buses in operation till the
required parts delivery,
3. implementation of repairs at a time when further use of the vehicle is not-possible.
As part of the risk assessment related to the adopted vehiclesmaintenance strategy,
the following hazards and their consequences have been dened in the company
(Table 3).
The company for many years records all information regarding performed repairs
and replacements and used for this purpose maintenance materials. This registration
was carried out so far in the written form, which signicantly hindered its analysis.
Table 3. The main hazards and their consequences identied in the transportation company
Hazards Consequences
Long-term exclusion from the use of the
vehicle
Multiple repairs of the same item in the
same vehicle
Multiple vehicles returns to the repair
shop for minimal repairs in the short term
Vehicle failure during transport services
performance
Partial repair costs, enabling the operation of
the vehicle to the required delivery time of
spare parts
Costs several returns to the workshop in order
to make further major repairs
Losses resulting from canceled courses
operated by a given vehicle
Loss of potential additional orders
Loss of passengerscondence due to
cancellations
Costs of external repairs in situations when the
vehicle is failed during the course performance
Towing costs of the vehicle
Additional costs of emergency purchases
carried out at the time of failure occurrence
(selection criterion is the time of delivery and
not the price)
The difference in the price of the spare part
resulting from the maintenance of the safety
margin for the carrier by the supplier
Costs related to the substitution of failed
vehicles
Evolution of Technical Systems Maintenance Approaches 169
However, for many years, the company uses IT system, which enables the collection
and storage of the same data in an electronic form only. Following this, the analysis of
data from 20162017 has proved that it is possible to determine the statistical
repeatability of the selected failures in vehicles belonging to the same brand and age
group. This allows the manager to estimate the possibility of selected failures occur-
rence. The consequences of their occurrence are also known. This is the basis for
considering the possibility of changing the current vehiclesmaintenance strategy to a
risk based maintenance strategy. This would reduce the waste currently occurring in the
enterprise related to the repair of vehicles and increase the security of services.
5 Summary
The results presented in this paper are a short summary of research conducted by the
authors in the area of maintenance management performance. The effects of this study
clearly demonstrate the need for detailed quantitative analyses performance in order to
properly choose the maintenance strategy. Every organization gathers and analyses
specic data whose acquisition is both time consuming and capital intensive. Thus, in
order to ensure the effectiveness of forthcoming analysis and its actuality, it is neces-
sary to dene the main requirements for performed maintenance and limitations of the
known maintenance approaches implementation in the analyzed company.
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... CM strategies have limitations such as, increasing downtime hours, and no possibility to optimise the operational performance with respect to cost and risk. Although most industries revised this strategy and gravitated to other maintenance strategies, this particular maintenance approach is still applied to low-risk engineering systems due to its low implementation cost [22]. Evolution of maintenance strategies [13] In an attempt to minimise avoidable CM costs, preventative maintenance (PM) was employed with EN 13306:2010 defining it as "maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning of an item" [21]. ...
... This approach employs planned strategies implemented at specific intervals of time to ensure continuous operational performance in the case of high-risk engineering systems. PM is the most common strategy applied in the industry and is further classified as time-based PM and condition-based PM [22]. ...
... Time-based maintenance dominated the second generation of the evolution of maintenance strategies. It entails administering maintenance of assets at regular intervals, irrespective of their current state [22]. Certain types of complex systems are difficult to monitor, and methods that consider only the condition of assets require substantive data, which might not be available or difficult to procure [22]. ...
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... The primary objective of a predictive maintenance is to anticipate potential faults or failures in a deteriorating system. This enables optimization of maintenance efforts through the monitoring of equipment operating conditions, allowing for the detection of any early signs of wear that could eventually lead to a component failure 23,24 . The early detection of failures is essential for ensuring the continuous operation of a system without the occurrence of failures, as well as for enhancing the overall reliability of the system 25 . ...
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... This research found that HVAC maintenance in the oil and gas industry faces problems in logistics and the evolution of technology. This finding supports the study (Nowakowski, Tubis & Werbińska, 2019) and shows the importance of technical like logistics, and the evolution of technology to meet increasingly higher demands in the quality area. A responsive logistics network can lead to increased quality maintenance services (Manikas, Sundarakani & Iakimenko, 2019). ...
... Maintenance of technical facilities is of particular importance at a time of increasing competition and higher demands on the quality, reliability and productivity of system tasks performed [23]. In [37] it was found that corrective maintenance does not affect the intensity of failures, while preventive maintenance has an impact on reducing the number of failures. ...
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One of the important factors affecting the technical condition of vehicles is driving style. This paper investigates the extent to which vehicle repair duration depends on different driving styles. Driving style was assessed based on average fuel consumption, which is an indicator of driving behavior. Three distinct driving styles were identified: mild, moderate, and aggressive, each characterized by different levels of average fuel consumption. The analyses were carried out on the basis of actual operating data of vehicles included in the fleet of one of the transport companies operating in the city of Lublin, Poland. The results of the study showed how vehicle repair time can be reduced by changing driving style from aggressive to mild, and can help answer the question of whether it is justified to increase drivers' competence in economical driving in order to improve vehicle reliability.
... In work [17] using the Lankarani-Nikravesh contact model, the behavior of a pin connection with a gap was studied. In a series of publications [43][44][45], the evolution of approaches to the maintenance and repair of technical objects that have been operating for a long time in difficult conditions was studied, and multifactor models were proposed for assessing the efficiency of production processes. ...
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... Provides man-machine industrial interac on Source(s): Adapted from Valamede and Akkari (2020) Figure 6. Kaizen 4.0 Lean 4.0 application As per Nowakowski et al. (2018) maintenance performance ensures the high availability and reliability of assets lifetime, and the organizations aim to improve their maintenance maturity. The maintenance solutions have evolved, where the Maintenance 1.0 often called "run to failure" or corrective maintenance strategy, appears in the first place. ...
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Conventional fault diagnosis systems have constrained the automotive industry to damage vehicle maintenance and component longevity critically. Hence, there is a growing demand for advanced fault diagnosis technologies to mitigate the impact of these limitations on unplanned vehicular downtime caused by unanticipated vehicle breakdowns. Due to vehicles’ increasingly complex and autonomous nature, there is a growing urgency to investigate novel diagnosis methodologies for improving safety, reliability, and maintainability. While Artificial Intelligence (AI) has provided a great opportunity in this area, a systematic review of the feasibility and application of AI for Vehicle Fault Diagnosis (VFD) systems is unavailable. Therefore, this review brings new insights into the potential of AI in VFD methodologies and offers a broad analysis using multiple techniques. We focus on reviewing relevant literature in the field of machine learning as well as deep learning algorithms for fault diagnosis in engines, lifting systems (suspensions and tires), gearboxes, and brakes, among other vehicular subsystems. We then delve into some examples of the use of AI in fault diagnosis and maintenance for electric vehicles and autonomous cars. The review elucidates the transformation of VFD systems that consequently increase accuracy, economization, and prediction in most vehicular sub-systems due to AI applications. Indeed, the limited performance of systems based on only one of these AI techniques is likely to be addressed by combinations: The integration shows that a single technique or method fails its expectations, which can lead to more reliable and versatile diagnostic support. By synthesizing current information and distinguishing forthcoming patterns, this work aims to accelerate advancement in smart automotive innovations, conforming with the requests of Industry 4.0 and adding to the progression of more secure, more dependable vehicles. The findings underscored the necessity for cross-disciplinary cooperation and examined the total potential of AI in vehicle default analysis.
Book
This book provides a detailed introduction to maintenance policies and the current and future research in these fields, highlighting mathematical formulation and optimization techniques. It comprehensively describes the state of art in maintenance modelling and optimization for single- and multi-unit technical systems, and also investigates the problem of the estimation process of delay-time parameters and how this affects system performance. The book discusses delay-time modelling for multi-unit technical systems in various reliability structures, examining the optimum maintenance policies both analytically and practically, focusing on a delay-time modelling technique that has been employed by researchers in the field of maintenance engineering to model inspection intervals. It organizes the existing work into several fields, based mainly on the classification of single- and multi-unit models and assesses the applicability of the reviewed works and maintenance models. Lastly, it identifies potential future research directions and suggests research agendas. This book is a valuable resource for maintenance engineers, reliability specialists, and researchers, as it demonstrates the latest developments in maintenance, inspection and delay-time-based maintenance modelling issues. It is also of interest to graduate and senior undergraduate students, as it introduces current theory and practice in maintenance modelling issues, especially in the field of delay-time modelling.
Chapter
The chapter presents a literature review on delay-time modelling for single- and multi-unit (complex) systems. First, there are introduced the main definitions connected with this maintenance approach. Later, there is presented the analysis of known maintenance models being developed in this research area. The maintenance models for single-unit systems assume two-stage or three-stage failure processes implementation. The optimum policies are discussed, and their several modified and extended models are presented. The main extensions include imperfect inspection implementation, postponed replacement performance, or different types of failures investigation. The classification also includes optimality criterion, planning horizon, and used modelling method. In the case of complex systems, the discussed problems regard to e.g. models’ parameters estimation issues, case studies analysis, or hybrid modelling approach implementation. The main extensions of the developed models are discussed and summarized. At last, the main development directions in delay-time-based maintenance modelling are presented in a graphical form. The brief summary of the conducted literature review is provided with indicating the main research gaps in this modelling area.
Article
Maintenance and service logistics support are required to ensure high availability and reliability for capital goods and typically represent a significant part of operating costs in capital-intensive industries. In this paper, we present a classification of the maintenance and service logistics literature considering the key characteristics of a particular sector as a guideline, i.e., the maritime sector. We discuss the applicability and the shortcomings of existing works and highlight the lessons learned from a maritime sector perspective. Finally, we identify the potential future research directions and suggest a research agenda. Most of the maritime sector characteristics presented in this paper are also valid for other capital-intensive industries. Therefore, a big part of this survey is relevant and functional for industries such as aircraft/aerospace, defense, and automotive.
Chapter
In general, despite high quality control exerted, any product may have inherent weaknesses resulting in their failure. Instead of analyzing why the failures have occurred as a postmortem, we should always anticipate such failures and provide for their corrective action during the design stage itself. This is the principle behind failure modes and effects analysis and this chapter details several aspects, including the principles and procedures for this essential TQM tool.
Article
Condition-based maintenance (CBM) is a maintenance strategy that collects and assesses real-time information, and recommends maintenance decisions based on the current condition of the system. In recent decades, research on CBM has been rapidly growing due to the rapid development of computer-based monitoring technologies. Research studies have proven that CBM, if planned properly, can be effective in improving equipment reliability at reduced costs. This paper presents a review of CBM literature with emphasis on mathematical modeling and optimization approaches. We focus this review on important aspects of the CBM, such as optimization criteria, inspection frequency, maintenance degree, solution methodology, etc. Since the modeling choice for the stochastic deterioration process greatly influences CBM strategy decisions, this review classifies the literature on CBM models based on the underlying deterioration processes, namely discrete- and continuous-state deterioration, and proportional hazard model. CBM models for multi-unit systems are also reviewed in this paper. This paper provides useful references for CBM management professionals and researchers working on CBM modeling and optimization.
Article
For certain critical equipment items in marine machinery systems, the optimum maintenance strategy would be a scheduled on-condition operation. This involves inspection of the equipment items in order to monitor their performance degradation and, invariably, carry out repair or replacement tasks. The main challenge with this type of maintenance approach is the determination of the appropriate interval for performing the inspection task. This paper presents a methodology which integrates multi-criteria decision making (MCDM) tools with a delay time model for the determination of optimum inspection intervals for marine machinery systems. With this approach, multiple decision criteria are modelled with the delay time concept and aggregated with MCDM tools such that different criteria can be applied simultaneously in the ranking of different inspection interval alternatives. The applicability of the proposed methodology is demonstrated using the case study of a water cooling pump of the central cooling system of a marine diesel engine.
Chapter
This chapter gives a complete overview of the predictive maintenance program. Predictive maintenance is monitoring the vibration of rotating machinery in an attempt to detect incipient problems and prevent catastrophic failure. The common premise of predictive maintenance is that regular monitoring of the actual crafts condition, operating efficiency, and other indicators of operating condition of machine trains and process systems provide the data required to ensure the maximum interval between repairs and minimize the number and cost of unscheduled outages created by machine train failures. It is the means of improving productivity, product quality, and overall effectiveness of manufacturing and production plants. A comprehensive predictive maintenance management program uses a combination of the most cost effective tools, that is, vibration monitoring, thermography, tribology, and the like, to obtain the actual operating condition of critical plant systems and, based on this actual data, schedules all maintenance activities on an “as needed” basis. Predictive maintenance using vibration signature analysis is predicated on two basic facts: all common failure modes have distinct vibration frequency components that can be isolated and identified and the amplitude of each distinct vibration component remains constant unless there is a change in the operating dynamics of the machine train. A wide variety of predictive techniques and technologies may provide benefit to a facility or plant. In most cases, more than one is needed for complete coverage of all critical assets and to gain maximum benefits from their use. In addition the chapter explains setting up a preventive/predictive maintenance program, visual inspection, vibration analysis, and many more concepts.
Book
Analyzing maintenance as an integrated system with objectives, strategies and processes that need to be planned, designed, engineered, and controlled using statistical and optimization techniques, the theme of this book is the strategic holistic system approach for maintenance. This approach enables maintenance decision makers to view maintenance as a provider of a competitive edge not a necessary evil. Encompassing maintenance systems; maintenance strategic and capacity planning, planned and preventive maintenance, work measurements and standards, material (spares) control, maintenance operations and control, planning and scheduling, maintenance quality, training, and others, this book gives readers an understanding of the relevant methodology and how to apply it to real-world problems in industry. Each chapter includes a number exercises and is suitable as a textbook or a reference for a professionals and practitioners whilst being of interest to industrial engineering, mechanical engineering, electrical engineering, and industrial management students. It can also be used as a textbook for short courses on maintenance in industry. This text is the second edition of the book, which has four new chapters added and three chapters are revised substantially to reflect development in maintenance since the publication of the first edition. The new chapters cover reliability centered maintenance, total productive maintenance, e-maintenance and maintenance performance, productivity and continuous improvement © John Wiley and Sons 1999. And Springer International Publishing Switzerland 2015.
Article
The trends in machines operation maintenance have been presented in the paper. Three methods and three periods of machines operation maintenance have been characterized. Among the concepts which have appeared, the most important ones are RCM (Reliability Centred Maintenance) - reliability oriented operation maintenance and TPM (Total Productive Maintenance) - general productivity oriented operation maintenance or operation maintenance integrated with production. Other contemporary concepts of operation maintenance as the 5S method and operator's own technical inspection have been presented too. At the end of the paper interrelationship of the quality of technological machines operation maintenance and the quality of products has been shown.