Maintenance Strategies Optimization

This assignment focuses on analyzing and optimizing maintenance strategies for industrial systems. Students will explore different maintenance approaches, including preventive, predictive, and condition-based maintenance. The analysis involves evaluating factors such as reliability, availability, risk, and cost associated with each strategy. Various tools and models, like simulation and decision support systems, may be utilized to assess the effectiveness of different maintenance plans. The goal is to develop a comprehensive understanding of maintenance strategies and their application in optimizing industrial system performance.

Maintenance
strategies

EXECUTIVE SUMMARY
There are different types of machinery tools and equipment’s which are been used in
engineering companies. Each of them requires maintenance so that it works properly and for
long time. Every organisation highly focuses on maintaining their physical assets so that
efficiency is not impacted. The report has described about maintenance strategy of Elphinstone
engineering and how they are able to maintain various assets. The company have made some
changes in their strategy by implementing principle of lean management.

Table of Contents
INTRODUCTION...........................................................................................................................1
QUESTION 1..................................................................................................................................1
1) Construct a process flow diagram and establish asset inventory in Elphinstone engineering 1
2) Detail asset operating characteristics and production policy..................................................3
3) Assemble identified maintenance task in unit life plan...........................................................3
4) Outline needs for spare parts...................................................................................................4
QUESTION 2..................................................................................................................................5
1) Optimisation process utilised to determine PM methodology for gear box............................5
2) Outline current preventative maintenance schedule for asset.................................................6
3) Evaluation and optimisation of current PM schedule.............................................................8
4) Table comparing previous and optimised PM schedule..........................................................9
5) Discussion about PM tasks within a TPM program..............................................................10
QUESTION 3................................................................................................................................11
1) Discuss 5 lean principles.......................................................................................................11
2) Discuss application of lean principles utilised in maintenance strategies.............................12
3) Root cause analysis of asset..................................................................................................13
CONCLUSION..............................................................................................................................14
REFERENCES..............................................................................................................................15

INTRODUCTION
In a company asset are the most important part that can be easily converted into cash.
They are classified into two types that is tangible and non tangible. The overall asset of company
reflects its market value. It is essential to maintain those assets so that it can be used for long
term (Seecharan, Labib and Jardine, 2018). In order to do so, a proper maintenance strategy is
required which helps in evaluating and enhancing efficiency of asset. Besides this, in strategies
different types of risks are identified and mitigated. Furthermore, it enables in improving
efficiency of asset by making changes in its process. However, sometimes changes are required
in strategies so that it decreases cost, time and resources of maintenance. This report will give an
insight on maintenance strategy of Elphinstone engineering. It will discuss about lean principles
followed by firm in strategy. The company is engaged in manufacturing trailers and equipment’s
of trucks. of different types of machinery tools used in Elphinstone engineering. It was founded
in 1976 by Graeme Elphinstone.
QUESTION 1
1) Construct a process flow diagram and establish asset inventory in Elphinstone engineering
Definition of process flow diagram- A process flow diagram indicates how overall machinery
tools works. It briefly describes relationship between various equipment’s (Wakiru and et.al.,
2018). There are many steps included in it which defines how machine works. PFD are usually
used in engineering companies. this gives them an overview about from where process starts and
end and in which direction it moves.
Process flow in Elphinstone engineering
In Elphinstone engineering there are various types of machinery tools used. it is used in
manufacturing parts of heavy vehicles and also its components. They have to maintain them in
order to ensure its efficiency. For this, maintenance department ensure that they are properly
maintained. It helps in smooth running of functioning of asset within organisation. It has been
found that most of machinery used by company is gear box, electro motor, etc. The process flow
at Elphinstone engineering is described below :-
Assets Areas of Storage
1. Printing Machine Backoffice department
2. Plating Machine Factory
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3. Etching Machine Factory
4. Laminating Machine Factory
5. Tin Stripping Appliance Factory Ground
6. Packaging Equipment Packaging Department
7. Delivery Vehicles Delivery Department
8. Gear Box Factory
9. Engine and Electro Motors Factory
10. Assembling Equipment Assembling Department in Factory
11. Processing Machine Factory
From above mentioned asset, gear box is taken. this is because it is an essential tool for
company that is used in machines and manufacturing heavy vehicles. Moreover, Elphinstone
engineering also produced gear box for vehicles as well. So, maintaining this asset is very crucial
for organisation.
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Illustr
ation 1: process flow diagram

2) Detail asset operating characteristics and production policy
Gearbox consist of spur Gear whose teeth are straight and parallel to shaft axis. It
transmits power and motion between two parallel rotating shafts. It also consists of helical gear
with twisted oblique to the gear axis and has higher strength then spur gear. It also consists of
annular gear that meshes with the external gear. It also has a pair of gears that connects two
shafts with axis intersect. Helical gear transmit power from one shaft to another and it is used to
reduce speed or increase speed. All these gears work together for smooth running of a vehicles.
3) Assemble identified maintenance task in unit life plan
Unit life plan
Item timing On-line or
off-line
frequency Time and
labour
Initial
maintena
nce action
Expected
frequency
Time and
labour
Rubber
lining
Touch and
visual
inspection
off 6 moths 2 fitters
and 2 days
In situ
repair
Overall 2
years
2 days and
2 fitters
Steel
casing
Statutory
inspection
off 1.5 years 2 fitters, 1
inspector
and 2 days
Joints
required
Overall 5
years
2 days and
2 fitters
gearbox
greasing
SPM trend
monitorin
g
on 1.5
months
Few
minutes
and 1
inspector
If required
replace
box
Overall 4
years
Few hours
and 2
fitters
Gearbox
bearing
Fixed time
lube rating
on 1.5
months
- - - -
Gears Monitorin
g,
lubrication
on 1.5
months
Few
minutes
and 1
inspector
If required
replace
box
No idea Few hours
and 2
fitters
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gland Visual
inspection
on 2 moths Few
minutes
and 1
inspector
Adjust
glands
Over all 6
months
-
4) Outline needs for spare parts
Spare parts in Gearbox are required as they are responsible for the speed of any
machinery or vehicles.
Output needs of gear box:-
 Spear gear- Firstly, Spur gear is one of the most commonly used spare part of Gearbox
used as a transmission component. This part increases the quality of Gearbox.
 Coaxial helical- It is inline is a type of gear box part which is used in heavy duty
appliances. They are used for maintaining the efficiency and quality of the gearbox. It
allows the gearbox to maximize load and increase transmission ratio.
 Extruder helical- The gearboxes are used in gearboxes of construction appliances or
machinery. It is used to maximize the torsion stiffness or for low noise appliances.
 Bevel helical – This part is used to provide rotatory motions between non parallel shafts
and mostly used in quarrier, mining industry.
 Bearing- In gearbox is the most common used part. It is mostly used for decreasing noise
in the machinery.
 Miter gear- It is also one of the most commonly used gear parts as it is used to change
the direction of shaft without changing its speed.
 Screw gear- It is used to provide high horse power to the gear box. It is the rarely
available part of the gearbox.
 Worm gear- This a part mostly used for smooth actions of a machinery. This is also one
of the most commonly used and available part of a gearbox.
QUESTION 2
1) Optimisation process utilised to determine PM methodology for gear box
Preventive maintenance is a process through which equipment efficiency and condition is
maintained. It helps in identifying failure in asset and taking corrective actions to improve it. It
includes different types of activities through which efficiency is improved. Basically, there are
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six steps in it that is identify, plan, schedule, execute, closeout and analyse (Azadeh and et.al.,
2016). It helps in establishing effective workflow and focusing in key steps of maintenance
activities. PM adds value to tasks either by using downtime, cutting cost, reducing wastage of
materials, etc. There are different types of preventive maintenance methods through which can
be applied in maintaining of machinery in organisation. Each method is different from one
another.
FRACAS in gear box- Failure reporting and corrective action system (FRACAS) is a method
which helps in eliminating failure in asset. this is done by analysing reports generated from
reliability software and then eliminating failures. The reports can be related to cost variance,
mean time, etc. The FRACAS for gear box is defined below:-
Figure 1 FRACAS loop
(Source: W. Edwards Deming, 2018)
In gear box there are many components that needs to be maintained. So, any fault in one
result in affecting on further process and decrease in efficiency of asset. FRACAS is the best
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method for PM optimisation in gear box. this is because it assists in analyse each component and
failure, then reasons are identified and compared with its functioning (Reina and et.al., 2018).
Furthermore, by doing root cause analysis in efficient way strategies can be developed to
improve faults or errors. Alongside it, this method is basically used by manufacturing industries
in maintaining their machinery. Consequently, the method works in a loop which makes it easy
to analyse and improve process in systematic and repetitive way. Furthermore, by working in
loop it gives a clear understanding about how gear box initially works and which bearings are
used in it.
2) Outline current preventative maintenance schedule for asset
The company is already having certain methods included in maintenance strategy through
which they are able to remove deviation in machinery equipment’s. This has enabled in
increasing life expectancy of asset, Furthermore, it has supported in removing obstacles in
process flow. The current schedule is as follows :-
Tasks Preventative maintenance
Rating Gear box is been regularly checked to maintain
its efficiency with load. Then, measures are
taken to solve it. It is done on monthly basis.
House keeping The gear boxes are cleaned frequently during
maintenance (Medina-Oliva, Weber and Iung,
2015). It is been kept is safe environment. the
cleaning and oiling is done 3 time within a
month.
Shaft seals Here, asset is checked and, in each shaft, oiling
is done. The leakage part is removed or
repaired. the dirt, dust, debris, etc. are
removed. the are checked within 2 months.
Breather Breather is maintained by cleaning gear box
with ease. it is done monthly.
Lubrication While maintaining asset, lubrication is done. it
helps in smooth flow of gear box. It is done
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quarterly.
Temperature check The temperature of gear box is checked, then
burnt areas are repaired by painting or oiling it.
temperature is checked within 3 months
Gear wear In gear box wear and tear parts are detected
and removed. bearings are changed and
alignment is checked. this is done every month
(Scheffer and et.al., 2016)
Backlash and shaft end play The shaft end play areas are identified and
rolling elements of bearings are repaired. it is
done every 4th month.
Vibrations analysis The vibration of gear box is recorded through
analysis. then, accordingly changes are made in
internal bearings. it is done within 6 months.
3) Evaluation and optimisation of current PM schedule
As mentioned above there are many preventative tasks which are done to maintain
efficiency of gear box. The schedule is followed in proper manner. But there are some tasks
which resulted in creating problems in asset. They are lubrication, temperature check and
housekeeping.
Ambiguity of tasks
Lubrication- this task fails to add any specific value in the entire PM schedule. It is because of
this task only requires bearings to get lubricated and hence it can be removed. Thus, it is
important to optimise thee cost effectiveness by combining lubrication with shaft end play under
an integrated framework. It will help in proper maintenance.
House keeping – this task can also be referred under the task that creates problem while
conducting the intrusive works (Mattern and et.al., 2016). it means this can be eliminated or
combined on a small scale to maintain economies of company. Additionally, the asset that is,
gear box must be checked during regular interval of time to keep working conditions of it in
proper and safe manner.
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Temperature check – this is one of the important variables to be considered while checking
working condition of asset that is gear box. Here, it might be considered as a wasteful task due
to intrusive factor which add no value to entire preventative maintenance. It consumes lot of time
that ultimately leads to delay in production process of products. However, this task can be
combined with one of the other tasks such as rating one and shaft end. It will be easy in
maintaining gear box along with it provides a better platform for PM and help in reducing delay
or uncertain time.
Elimination of tasks- The above tasks are eliminated then directly strategy can be implemented.
this will be useful in monitoring of condition in effective way. The lubrication can be done along
with breather and gear wear. So, if during breather gear wear is checked and eliminated then
lubrication can be applied at same time. These two current tasks can be completed and monitored
within same time.
Refinement of task- This can be done by using total productive maintenance method. In this,
gear wear and temperature check can be integrated in machine by improving their quality. Here,
processes are eliminated thus value can be generated (Darghouth, Chelbi and Ait-kadi, 2017).
By utilising TPM maintenance task are refined. In simple terms, introduction of technologies or
use of software can be preferred in implementing TPM program. such refining techniques would
be beneficial in decreasing the additional burden on the manual labour and also help in time
efficiency with improved cost effectiveness in all the operation’s related to the maintenance of
gear boxes. There is a need to incorporated such refining task so that the ambiguous and
unwanted task like house keeping, temperature check, etc. can be eliminated and help in
enhancing utility of TPM.
4) Table comparing previous and optimised PM schedule
Due to change in optimisation of preventive maintenance schedule a new and optimised
one is deigned. this will help in maintaining efficiency of gear box by performing tasks. the
optimised PM schedule is made by using TPM method which is described below:-
Task Previous PM schedule Optimised PM schedule
Rating In previous rating was given
on monthly basis.
Here, rating can be given on
weekly basis. It can be done
by
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Shaft seals The gear box each shaft was
checked and oiling was done.
Repairing was done on
leakage part and dust was
removed in 2 months
(Chemweno, Pintelon and
Muchiri, 2016).
In this oiling and removing of
dust can be done every month.
It will help in maintaining
each shaft properly.
Breather This task was performed every
month. the gear box was
maintained.
Now, temperature check and
house keeping is done after
lubrication. through this,
efficiency of gear box is
enhanced and maintained.
Backlash and shaft end play The shaft end play areas are
identified and rolling elements
of bearings are repaired. it is
done every 4th month.
This task is optimised with
lubrication one. Here, rolling
elements are repaired. this is
done in two months.
Vibrations analysis The vibration of gear box is
recorded through analysis.
then, accordingly changes are
made in internal bearings
within 6 months.
In optimised PM, vibrations
analysis of gear box is
recorded in 3 months (Ge and
et.al., 2017).
5) Discussion about PM tasks within a TPM program
A TPM program is process of improving efficiency and quality of machine and systems
through implementation of processes or method. it also helps in maintaining machines by
preventing failure. There are seven basic pillars of TPM which focuses on productive
maintenance. The main aim of TPM is to bring continuous improvement in maintenance
methods. In this each task problem is identified and then changes are done in its functions. In
Elphinstone engineering a TPM program is developed in PM which is as follows :-
Tasks Changes through TPM program
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Shaft seals Here, gear box is checked and oiling is done.
The faults are identified and debris are
removed. Overall cleaning is done by painting
it. Also, each tooth of bearing is checked by
measuring its alignment.
Backlash and shaft end play Each shaft backlash is checked and monitored.
then, rolling of bearings are checked with its
motion. the combining of shaft play with rating
can be useful in reducing manual work load
and maintaining asset in proper way (Olsen,
2017).
Lubrication The damages parts are repaired by putting
lubrication on it. this helps in direct applying of
lubricant without doing cleaning. this task can
be integrated with technology so that
lubrication cost is reduced and it consumes less
time. Here, standards can be set in software
while doing lubrication task.
QUESTION 3
1) Discuss 5 lean principles
Lean management is applied for the purpose of reducing waste and smoothing the
process. It helps in increasing efficiency by reducing cycle time, costs, materials required, etc.
Usually, there are five principles on basis of which lean management works. they are applied by
organisation while implementing lean management. the principle gives an insight on how to
effectively use this approach (Lambert and et.al., 2015). In addition to it, by working on these
principles it becomes easy to develop or make changes in process. It mainly focuses on
increasing efficiency of process by eliminating unnecessary activities.
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Figure 2 Lean principles
(Source: Mark Crawford, 2016)
Principles of lean management
Value- It refers to needs of customers. In this information is evaluated to analyse whether it will
be useful or not. Alongside, requirements are determined and included in process.
Value stream- It reflects on designing of overall process or steps which is required on
manufacturing specific product that is from converting raw materials into finished goods. Value
stream gives an insight about flow of product into the process. Basically, it is referred as business
process reengineering. through this, it gives an understanding about overall business process.
Flow – In this principle it is ensured that the overall process runs smoothly after waste has been
eliminated (Rinaldi and et.al., 2017). It can be done by breaking steps into more sub sets. this
helps in increasing efficiency and more fast production. Apart from it, the flow of overall process
is identified and its evaluation is done. this gives an insight to how process starts and ends.
Pull – This principle focuses on improving the delivery process. It is different from just in time
manufacturing. So, it assures that what customer requires has to be produced. Thus, materials are
not manufactured in advance. It results in saving cost and expenses incurred on materials.
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Perfection – This is most important principle of lean management. it is because in this effort are
made to implement practices of lean within organisation culture. The employees are responsible
for continuously practising and involving in lean manufacturing so that efficiency is improved.
2) Discuss application of lean principles utilised in maintenance strategies
Lean principles in an organisation results in the proper usage of machinery within the
organisation as it helps to produce customer specific products minimizing manufacturing errors
in an organisation. It helps the organisation in raising the reliability of the parts in manufacturing
units which will reduce the cost of expenses on the wear and tear of machines in an organisation
(Seecharan, Labib and Jardine, 2018). By applying those principles, it can overcome from the
problems of over manufacturing preventing an organisation from producing excess products
which prevent unnecessary use of machines in an organisation. Lean principle results in the
proactive maintenance of the equipment failure in an organisation which prevent chances of the
failure of machinery in an organisation. The principles embrace the concept of total productive
maintenance which improve the integrity of production and quality systems through use of
machines, employees, equipment and supporting processes. A lean management is implemented
to eliminate wastage from process so that efficiency is enhanced and productivity is maintained.
The above principles are also utilised in maintenance strategies. Also, Elphinstone engineering
has been successfully able to apply lean principles in strategies. Here, before developing any
manufacturing process, the value is generated by creating a proper plan. this is done by creating
time plan. Moreover, value stream principle is applied which has given an insight about what
activities will be required in maintaining system. So, through this it has been easy in selecting
only those activity which is required. Thus, it has been useful in increasing efficiency of process.
Apart from it, another lean principle utilised is in Elphinstone engineering the flow of
process is kept systematic manner. Here, several other small tasks are added in process through
maintenance strategy. This has resulted in keeping flow but fastening of process. this has assisted
in rising productivity of products (Darghouth, Chelbi and Ait-kadi, 2017). Moreover, by
breaking down process it has been easy in maintaining each stage in effective manner. In
addition to it, the maintenance strategies are been implemented in overall organisation. Through
this, culture has been improved while implementation of maintenance strategy. Moreover,
employees are able to define process and implemented lean management.
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3) Root cause analysis of asset
a) Description of asset- Gear box is a tool which is used to provide power to machine. the main
function of gear box is to change speed and torque of machine. in Elphinstone engineering
Helical gear box is used in high power machines that provide efficiency and handling maximum
load. the main components in gear box which are shaft, gears and bearings.
b) Unplanned event- There occurred a failure in gear box that was micro pitting. It occurred due
to surfaces which contacted with each other and having high amount of sliding. This led to
ineffective working of gear box. Also, it resulted in failure of asset and further process on
Elphinstone engineering. In order to solve problem of micro pitting the cost required would be
$250.
c) Investigation team and its members- There were many people who was involved in
investigating gear box and conducting root cause analysis. In this team members were head
engineer, executive engineer. The main role was to determine create a plan on how to conduct
analysis and to assign roles and responsibilities to each executive engineer (Chemweno, Pintelon
and Muchiri, 2016). In addition to it, timeframe was designed that in how much time each
activity will be completed.
d) Root cause analysis- This technique used was failure mode and effect analysis (FMEA). In
this it was identified that what are the failure that occurs within system. It is classified into two
processes that is failure mode to refers to something that fails. It might be due to errors, faults,
etc. and effect analysis means to study why failure occurred. FMEA is a systematic procedure in
which there are certain standards used. Through this technique, it was useful in finding out what
changes are made in current process and what issues can occur. FMEA was helpful in evaluating
overall process of gear box.
e) Outcome of root cause analysis- By conducting root cause analysis through FMEA, it was
useful in evaluating gear box process and detecting faults and errors in it. The results obtained
was analysed and measures were taken to resolve errors. Moreover, it gave necessary details
about causes due to which gear box was not working effectively. Thus, accordingly changes
were made in maintenance strategy.
CONCLUSION
Hereby, it has been concluded that maintenance department effective maintain the overall
asset in Elphinstone engineering. The unit have made changes in functioning of gear box which
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has resulted in enhancing its efficiency. Besides this, huge investments are been made in
technology to make machine automatic. It has fastened the entire manufacturing process.
Elphinstone engineering uses Helical gear box to manufacture heavy vehicles and their
equipment’s. This provide them high torque and power to maintain efficiency of machines. In
preventative maintenance strategy is developed to maintain and improve efficiency of asset. It
has been summarised that to make changes in PM. TPM is a process which is used. this process
can be integrated with PM so that ambiguous tasks can be eliminated. Along with it, the five
principles of lean management are described which is used by company to eliminate unnecessary
task from process.
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REFERENCES
Books and journals
Azadeh, A. and et.al., 2016. A unique mathematical model for maintenance strategies to
improve energy flows of the electrical power sector. Energy Exploration &
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Chemweno, P.K., Pintelon, L. and Muchiri, P.N., 2016, February. Maintenance decision
support: a simulation approach. In Maintenance Research Day.
Darghouth, M.N., Chelbi, A. and Ait-kadi, D., 2017. Investigating reliability improvement of
second-hand production equipment considering warranty and preventive maintenance
strategies. International Journal of Production Research. 55(16). pp.4643-4661.
Ge, Y. and et.al., 2017. An integrated logarithmic fuzzy preference programming based
methodology for optimum maintenance strategies selection. Applied Soft Computing. 60.
pp.591-601.
Lambert, J.W.M. and et.al., 2015. Tools to support maintenance strategies under soft soil
conditions. Proceedings of the International Association of Hydrological Sciences. 372.
pp.529-531.
Mattern, H. and et.al., 2016. Simulation-based analysis of maintenance strategies for
mechanized tunneling projects. In World Tunnel Congress 2016.
Medina-Oliva, G., Weber, P. and Iung, B., 2015. Industrial system knowledge formalization to
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Artificial Intelligence. 37. pp.343-360.
Olsen, F.W., 2017. Assessment method for review of existing maintenance strategies based on
reliability, availability, risk, and cost parameters (Master's thesis, University of
Stavanger, Norway).
Reina, A. and et.al., 2018. Maintenance Planning Support Tool Based on Condition Monitoring
with Semantic Modeling of Systems. Enterprise Interoperability: Smart Services and
Business Impact of Enterprise Interoperability, pp.271-276.
Rinaldi, G. and et.al.,., 2017. A decision support model to optimise the operation and
maintenance strategies of an offshore renewable energy farm. Ocean Engineering. 145.
pp.250-262
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Scheffer, M. and et.al., 2016, December. Simulation of maintenance strategies in mechanized
tunneling. In Winter Simulation Conference (WSC), 2016 (pp. 3345-3356). IEEE.
Seecharan, T., Labib, A. and Jardine, A., 2018. Maintenance strategies: Decision Making Grid
vs Jack-Knife Diagram. Journal of Quality in Maintenance Engineering. 24(1). pp.61-78.
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