Optimistic Approach of Machine Maintenance in Paint Industry

A Progressive Report on optimistic approach of machine maintenance in
paint industry
Student Name:
Student Number:
26th May 2019
Supervisor’s Name:

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Abstract
Across the globe, various business sectors are directly or indirectly involved with an industrial
cost of machine maintenance. Operational efficiency a top priority so as to maintain their edge
and maximize profits, this is also applicable in the paint industry. Just like any industrial venture
paint industries rely on machines for sustained production. The maintenance organization is
faced with a myriad of difficulties which include quality improvement, decreased lead times, set
up time and cost reductions, capacity expansion, managing complex technology and innovation,
upgrading the reliability of systems, and related ecological matters. The paper confronts the role
of machine maintenance of a paint industry. An optimistic maintenance approach will markedly
improve maintenance performance in paint manufacturing industries. A few studies within the
paint industry have been discussed in the research. The incentive and significance of the research
has been analyzed in the paper. The goals of the research have been set going in the first chapter.
A qualitative approach has been integrated in the research. Interviews with various managers in
the paint industries was used in the in data collection. Examination of findings from the
maintenance assessment shows a significant progressive rise in the cumulative equipment
downtime hours which influenced increased maintenance cost and drop in plant output across
several paint manufactures. Strategic maintenance models will be developed as the critical
components of the optimum maintenance strategy for continuous improvement in maintenance
architecture across planning, methods and scheduling, resource utilization, manpower capacity
and safety, monitoring and evaluation.
Keywords: Plant maintenance management, maintenance Productivity, manufacturing
productivity equipment, downtime and maintenance Performance.

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Table of Contents
Abstract............................................................................................................................................2
1. Introduction..................................................................................................................................4
1.1 Introduction............................................................................................................................4
1.2 Objectives..............................................................................................................................5
1.3 Significance...........................................................................................................................5
1.4 Report Organization....................................................................................6
2.Background...................................................................................................................................7
2.1 Background..............................................................................................7
2.2 Paint Manufacturing Process..........................................................................8
3.Proposed Approach..........................................................................................9
3.1 Maintenance Assessment Questionnaire...........................................................10
3.2 Observed Timeline....................................................................................12
4. Preliminary Results & Discussion......................................................................18
4.1 Preliminary Results..............................................................................................................18
4.2 Risk Assessment......................................................................................21
4.3 Risk Register..........................................................................................25
4.4 Discussion..............................................................................................30
5. Conclusion.................................................................................................31
6. References................................................................................................32
1.

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1.1 Introduction
With the rapidly increasing population, so do the technological advances follow in a like
manner. This has necessitated engineers and manufactures to come up with technical means of
meeting maintenance services with the population. When optimal machine maintenance is
carried out regularly not only is proactive but it also creates additional value in maintenance
structures for enhanced maintenance productivity ((Ramdeen & Punet al., 2005The paint
industry is a significant part of the construction since almost all modern structure requires paints
for ascetic and maintenance purposes. Paints and other associated liquid paste and powder
products are usually applied on structural surfaces using several equipment and methods (Bui et
al., 2016).
Paint manufactures range from small operations to hundreds of tons of paint yearly produced
by large firms. The industry of paints is associated with several risks and threats leading to major
changes to occur within the sector, and also due to advances in technology (Schmitt et al., 2015).
A myriad of solvents are included in the production of paint such as propanol, toluene, xylene,
solvent mixtures including white spirits and chlorinated solvents, methylene chloride,
trichloroethylene, and perchloroethylene (Hong et al., 2017). These chemicals pause dangerous
health risks to workers who are constantly exposed to the toxins. Also acids and heat used in the
paint industry generates damage to the humans in the paint industry.
The main aspect of this research is the maintenance of the machinery in the paint
industry. Maintenance involves keeping machines working order by detecting and fixing
malfunctions before the machine or the end products it produces are destructed. This
significantly improves on productivity, once repaired; mechanics test a machine to safeguard that
it is operating rightly. Maintenance can be grouped into: breakdown maintenance and planned
maintenance (Hong et al., 2017). Breakdown maintenance is carried out when machines and
systems have been totally in collapse condition and repair is required. It is useful in small
industries and factories in the market. In case of planned maintenance, proper experts and
professionals are required for planning and repairing the machines. This kind of maintenance is
practiced in large industries. It requires relevant skills and knowledge exhibited by industrial
machinery mechanics and machinery maintenance workers (college grad, 2019).

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research based on the simulated results. Finally, the final chapter of this research will cover
the recommendations made are on the discussion and conclusion chapter.
2. Background
The maintenance of manufacturing machinery and equipment and assurance of
availability of spare parts are becoming increasingly important. Maintenance is grouped into:
breakdown, routine, planned, preventive, predictive corrective, design out maintenance, total
productive maintenance and contracted out maintenance (Westerkamp et al., 1999). There
various maintenance techniques that can be used in a paint industry dependent on the
maintenance agendas of an industry. Hence, the existing maintenance structures mainly
breakdown and highly inconsistent lack quality in content, implementation and monitoring
needed to create value and cost-effectiveness needed to stimulate maintenance productivity.
There various maintenance management approaches present in literature but due to differences in
the form of industries, specific production objectives and plant capacity, no specific maintenance
management approach can proffer the general relevance needed to sustain uninterrupted
production in the wide range of diverse industries.
Paint manufacturing firms are often faced with the problems of poor maintenance
management constituted by low degree of maintenance planning, poor maintenance
implementation, poor monitoring and evaluation of maintenance activities, inadequate
maintenance resources. These challenges have necessitated maintenance managers to adopt tools,
methods, and concepts that could stimulate performance growth and minimize errors, and to
stretch resources effectively towards making the organization a high-performance manufacturing
plant (Tsang et al., 2002). To curb breakdown, failures and efficient utilization of maintenance
resources and sustain effective flow of production without interruption in the industries being
studied, a maintenance model should be developed to provide a comprehensive and strategic
approach to maintenance management within paint industries.
The existing model is characterized by lack of well-defined strategies for proactive
maintenance decision and associated actions required for correctly identifying breakdowns,
failures, defects and causes and plans for their elimination, monitoring and constantly improving
maintenance performance. Maintenance of machines used in the paint industry is an important

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aspect of the study. The goal is to actualize maintenance resources effectively, significantly
minimize equipment downtime associated with breakdowns, failures and defects and as well
reduce maintenance prices.
This paper aimed at developing an optimum maintenance strategy to improve
maintenance productivity which in turns translates to manufacturing productivity in paint
manufacturing industries. Also the research has overlooked the risks experienced in the paint
industries. Substances used in paint manufacturing include various volatile solvents such as
aliphatic and aromatic hydrocarbons, alcohols and ketones (Danenas & Garsva, 2015). These
substances can cause headache, euphoria and drowsiness and other neurologic symptoms. In high
concentration, disturbances in respiratory system can also occur to workers in paint industry and
worse still death.
2.2 Paint Manufacturing Process
Products of the surface-coating (paints) are necessary for the preserving various architectural
structures and manufactured goods from occurrences of weather. Paints are vitalizing and build
attractiveness of manufactured goods, as well as the aesthetic appeal of both interiors and
exteriors of architectural constructions. They can also be used to reveal information such as in
traffic symbols, road markings and information signs.
The paint industry is considered part of the chemical industries. Surface coatings (paints) are
divided into five product categories (Egyptian Environmental Affairs Agency [EEAA], 2002):
solvent-based paints; water-based paints; varnishes and clear coatings; printing inks; and resins
(used in manufacture of paints and varnishes). Thus a paint factory can have different production
lines for each category. Paint manufacturing firms can poses as few as one or two product or
several lines. Identifying appropriate performance indicators for any process requires a basic
understanding of the process. This section describes the materials used in paint and allied
products manufacturing, the paint manufacturing process.
Paint manufacturing involves five major processes (Torrey Hills Technologies, 2012) as shown
in as illustrated in the figure below.