Condition monitoring and fault diagnosis for operational equipment are developing and bowing their potential for enhancing the effectiveness and efficiency of maintenance management, including maintenance decision-making. In this thesis, our aim is to model the condition of equipment items subject to condition-monitoring in order to provide a quantitative measure to aid maintenance decision-making. A key ingredient towards dealing with the modelling work is to define the state or condition of the equipment with an appropriate measure and the observed condition monitoring may be a function of the state or condition of the operational equipment concerned. This leads to the two elements that are important in our modelling development; the need to develop a model that describes the system condition subject to its monitoring data and a decision model that is based upon the predicted system condition.

The reduction of the shutdown maintenance cost, the shutdown maintenance frequency and the loss in production that occurs as a result of performing shutdown maintenance whilst maintaining shutdown maintenance purpose and without creating any operational, safety, or economic problems during normal operation represents one of the most important issues that supports the overall strategy in the continuous process industries. The importance of this issue stimulated the work in research to find ways and methods to reduce the cost and frequency of shutdown maintenance, in addition to, the loss in production without increasing the number of the unplanned shutdowns or creating interruptions to the production line.

The importance of effective maintenance of production facilities and systems has increased rapidly as many organisations aim to become world class. Even more so for Egyptian manufacturing organisations since in recent years, they have been faced with increasing national and international competition while struggling with issues such as high scrap levels, long lead times and many other sources of waste in production and processes, making it necessary for them to revise their maintenance strategies to effectively maintain their production facilities and systems if they seek to achieve world class status. Becoming world class requires building the right management environment and shop floor culture. Experience has shown that equipment and process problems are the root cause of many of the unplanned events that reinforce a reactive management style. Delivering reliable equipment on its own however, is not enough to deliver superior company performance. TPM has evolved to address wider management issues and company-wide TPM has shown itself to be an enabler capable of achieving world class manufacturing (WCM). This study explores the vanous issues involved ID implementing Total Productive Maintenance (TPM) in the Egyptian manufacturing context, with a particular focus on Egyptian organisational culture. The study focuses on the cultural factors that might arise from implementing TPM in an Egyptian manufacturing context rather than the technical aspects ofTPM implementation. Accordingly the research tackles two main issues: • Establishing the relationship between Egyptian maintenance culture and TPM implementation • Identifying the critical success factors for implementation of TPM in an Egyptian manufacturing context. The research strategies adopted in this study are primarily qualitative but with a combination of quantitative methods as well. First, a detailed literature review was conducted followed by unstructured interviews conducted with officials and consultants in the Egyptian Ministry of Industry and Trade, the Industrial Modernization Center and the Egyptian Organisation for Standardisation and Quality. Then a questionnaire survey and structured interviews were conducted in several manufacturing companies in the Borg El-Arab industrial zone. Finally, a single case study was carried out in an Egyptian manufacturing company that has been successfully implementing TPM for more than 5 years and steadily making progress in the direction of achieving world class status. The main contribution to knowledge from this thesis is the identification of the cultural factors that affect the success of TPM in Egyptian manufacturing organisations and the development of a framework for successful implementation of TPM in Egyptian manufacturing organisations. The limitations of this research are that the results cannot be generalised to all Egyptian manufacturing industries since the study was conducted in only one industrial zone with a small sample size and the case study in only one company, but rather it produces a snapshot of Egyptian maintenance culture and the critical success factors specific to the Egyptian manufacturing context.

Ce travail de thèse a été initié par Renault, en collaboration avec le Centre de Recherche en Automatique de Nancy (CRAN), dans le but de poser les bases d'une méthodologie générique permettant d'évaluer l'état de santé de moyens de production. Cette méthodologie est issue d’une réflexion conjointe machine - produit en lien avec les exigences industrielles. La méthodologie proposée est basée sur une approche PHM (Prognostics and Health Management) et est structurée en cinq étapes séquentielles. Les deux premières étapes sont développées dans ce travail de thèse et en constituent les contributions scientifiques majeures. La première originalité représente la formalisation des connaissance issues de la relation machine-produit. Cette connaissance est basée sur l'extension de méthodes existantes telle que l’AMDEC et l’HAZOP. La formalisation des concepts de connaissance et de leurs interactions est matérialisée au moyen d'une méta-modélisation basée sur une modélisation UML (Unified Modelling Language). Cette contribution conduit à l'identification de paramètres pertinents à surveiller, depuis le niveau du composant jusqu'au niveau de la machine. Ces paramètres servent ensuite d’entrée au processus d'élaboration du bilan de santé machine, qui représente la deuxième originalité de la thèse. L'élaboration de ces indicateurs de santé est basée sur des méthodes d’agrégation, telle que l'intégrale de Choquet, soulevant la problématique de l'identification des capacités. De cette façon, il est proposé un modèle global d'optimisation de l'identification des capacités multi-niveaux du système à travers l’utilisation d’Algorithmes Génétiques. La faisabilité et l'intérêt d'une telle démarche sont démontrés sur le cas de la machine-outil située à l'usine RENAULT de Cléon / This PhD work has been initiated by Renault, in collaboration with Nancy Research Centre in Automatic Control (CRAN), with the aim to propose the foundation of a generic PHM-based methodology leading to machine health check regarding machine-product joint consideration and facing industrial requirements. The proposed PHM-based methodology is structured in five steps. The two first steps are developed in this PhD work and constitute the major contributions. The first originality represents the formalization of machine-product relationship knowledge based on the extension of well-known functioning/dysfunctioning analysis methods. The formalization is materialized by means of meta-modelling based on UML (Unified Modelling Language). This contribution leads to the identification of relevant parameters to be monitored, from component up to machine level. These parameters serve as a basis of the machine health check elaboration. The second major originality of the thesis aims at the definition of health check elaboration principles from the previously identified monitoring parameters and formalized system knowledge. Elaboration of such health indicators is based on Choquet integral as aggregation method, raising the issue of capacity identification. In this way, it is proposed a global optimization model of capacity identification according to system multi-level, by the use of Genetic Algorithms. Both contributions are developed with the objective to be generic (not only oriented on a specific class of equipment), according to industrial needs. The feasibility and the interests of such approach are shown on the case of machine tool located in RENAULT Cléon Factory

Actuellement, la compétition entre les entreprises se traduit par la révision des stratégies industrielles courantes dans le but d’améliorer simultanément les plans de production et de maintenance. En réalité, la non-satisfaction du client dans les délais est due souvent à des critères aléatoires liés essentiellement à la demande et aux défaillances soudaines des systèmes de production. Par conséquent, il est nécessaire de développer des politiques de maintenance intégrées à la production en tenant compte des contraintes liées au stockage, à la demande et au taux de défaillance. Dans ce travail, nous nous intéressons à une problématique industrielle qui s’articule autour du développement de différentes politiques de maintenance intégrées à la production. Le système considéré consiste en une machine fabriquant plusieurs types de produits, dans l’optique de satisfaire des demandes aléatoire avec des niveaux de service donnés. On note que l’originalité de notre étude, par rapport à l’existant en littérature dans le domaine de la maintenance intégrée à la production, consiste à considérer un système à multi-produits. Dans cette étude nous avons développé et optimisé analytiquement des politiques de production pour un système à multi-produits devant satisfaire plusieurs demandes aléatoires caractérisant respectivement différentes clients. Ces politiques consistent à établir des plans périodiques de production pour chaque produit, minimisant les coûts liés à la production et le stockage tout en satisfaisant un taux de service prédéfini pour chaque produit. Par la suite, en tenant compte de l’influence des plans économiques de production obtenus sur l’évolution de la dégradation du système de production, nous avons développé des stratégies optimales de maintenance. Plusieurs scénarios ont été étudiés selon les durées des sous-périodes de production et le coût de setup de chaque produit. En fin, des études de cas ont été traitées afin de confronter les résultats analytiques établis / Currently, the competition between companies is reflected in the revision of the current industry strategies to improve the planning of production and maintenance. In fact, the non- satisfaction of the customer on time is often due to a random demand or a sudden failure of production system. Therefore, it is necessary to develop new maintenance and production strategies. In this memory, we treat some maintenance policies integrated with production for a manufacturing system. This paper deals with the problem of maintenance strategy and production planning for a multiple-product manufacturing system. The manufacturing system under consideration consists of one machine which produces several products in order to satisfy random demands corresponding to every product. The significance of the present study is that the study deals with the case of a system which produces several products. In this study we have developed and optimized analytically production policies for a multiple-product manufacturing system, in order to meet several random requests characterizing respectively different customers. These policies consist of establishing periodic production plans for each product, minimizing the costs of production and storage while meeting predefined service level for each product. Subsequently, we have developed optimal strategies of maintenance, taking into account the influence of economic production plans obtained, on the evolution of the degradation of the production system. Several scenarios have been studied according to the durations of the sub-periods of production and the cost of set-up of each product. In the end, case studies were treated in order to compare the developed analytical results

Au cours des dernières décennies, avec un fort développement de l'économie mondiale et des nouvelles technologies, la structure des systèmes industriels devient de plus en plus complexe. Elle peut être une combinaison des structures élémentaires telles que structures séries, structures parallèles, structures séries-parallèles, etc. Dans la littérature, la plupart des travaux s'intéressent à développer des stratégies de regroupement en considérant des structures séries. Cette hypothèse est parfois très pénalisée et se limite l'application de ces stratégies dans la réalité. C'est pourquoi, l'objectif principal de cette thèse est de développer des stratégies de regroupement (dynamique et stationnaire) pour la maintenance des systèmes multi-composants avec structure complexe. Ces stratégies développées se basent sur des modèles de durée de vie avec la durée de maintenance non-négligeable. De plus, les conditions dynamiques (contextes dynamiques) telles que opportunités de faire la maintenance, changements de la structure, etc. sont étudiées et intégrées dans la planification de maintenance. Les études montrent la nécessité et les difficultés de la prise en compte de la structure complexe dans les décisions de maintenance. Exemples numériques confirment les avantages de nos stratégies de maintenance en comparant avec les autres stratégies existantes dans la littérature / In the recent decades, with a strong development of the global economy and new technologies, the structure of industrial systems is more and more complex. It can be a combination of elementary structures such as series structures, parallel structures, series-parallel structures, etc. In the literature, the most work focused on developing grouping strategies by considering series structures. This assumption is sometimes much penalized and limited the application of these strategies in reality. Therefore, the main objective of this thesis is to develop dynamic and stationary grouping strategies for the maintenance of multi-component systems with complex structure. These strategies have been developed for age-based models with non-negligible maintenance durations. In addition, dynamic conditions (dynamic context) such as maintenance opportunities, changes of the structure, etc., are considered and integrated into the maintenance scheduling.Our studies show the necessity and the difficulties of taking into account of the complex structure in the maintenance decisions. Numerical examples confirm the advantages of our maintenance strategies by comparing with other existing strategies in the literature

Thesis (D. Tech. (Electrical Engineering, Dept. of Process Control and Computer Systems))--Vaal University of Technology. / In recent years, industrial plant maintenance has changed dramatically. These changes are due to a considerable increase in the number and variety of physical plant assets, increased design complexity, new maintenance techniques and changing perspectives regarding on how to perform maintenance effectively. Managers at modern process plants are becoming increasingly aware of the extent to which equipment failure affects safety and the environment. Process plant personnel are limited in their ability to accurately and consistently evaluate the health of plant assets. Due to poor record keeping, maintenance staff often has little defence against aging equipment and asset failures. As a result companies have undertaken to implement planned equipment maintenance schedules and install new technology to allow for efficient tracking and analysing of equipment health across the board. The introduction of an integrated asset management solution is presented in this thesis. The integrated asset management solution will assist maintenance staff to cost-effectively predict the probability of asset failure prior to the occurrence of any actual plant incidents. The integrated solution documented in this thesis will be implemented at the Sasol Solvents site to enhance plant availability, maximum up time for all plant assets and plant safety. Strategic Asset Management Inc. (SAMI) uses the Operational Reliability Maturity Continuum model to improve profitability, efficiency and equipment reliability. The SAMI empirical model employs various stages to address improved performance and asset management and was used as a guideline to develop an integrated solution to optimise plant performance and profits. The integrated asset management solution, documented in this thesis, was developed with the intended function of bringing information from diverse plant based systems and field equipment to the maintenance personnel in an understandable interface so that the information can be used to improve the reliability and availability of all plant assets.