M.Ing. / Companies are seeking innovative ways of enhancing their competitiveness in their markets. Currently, one of the ways used to improve competitiveness by companies in a process environment is to implement an Enterprise Resource Planning system. An Enterprise Resource Planning system is a software system that automates and integrates data and information captured in an organisation. An analysis of the impact of implementing a maintenance management system depends on a number of factors that may include capabilities of chosen system, effective application and ownership of the system by those who use it. Central to implementation of a maintenance system is the maintenance philosophy adopted by an organisation, information system in place, availability of skilled maintenance personnel and execution of developed maintenance program. The implementation process itself also has a bearing on acceptance of the system by those who are supposed to use it. A review of literature on these important factors and on development of an Enterprise Resource Planning system was conducted to show influence each factor has in making maintenance activities effective. To determine the impact of implementing an Enterprise Resource Planning system in a process environment a case study on a company that has recently implemented such a system was conducted. From this case study recommendations on a number of issues were made.

M.Phil. (Mechanical Engineering) / The coal mining industry plays a major role in the global economy. Coal is required for the provision of primary energy needs, generation of electricity and production of steel. Hence, there is a high demand of coal worldwide. For the continuous supply of coal, mining equipment should be in good working conditions and the maintenance teams should be highly equipped and motivated to perform their maintenance activities ...

This treatise investigates the underlying factors that are hindering the improvement of Overall Equipment Effectiveness at the Ford Struandale Engine Plant. In January of 2008 the Ford Motor Company announced plans to invest more than R1.5 billion to expand operations for the production of Ford's next-generation compact pickup truck and the PUMA diesel engine. Ford will use the investment to expand operations both in Silverton for the production of 75 000 units of a new bakkie and in Port Elizabeth for 220 000 units of its new-generation PUMA diesel engines (http://www.autoblog.com /2008/01/31/ford-to-invest-209m-in-south-africa-for-new-ranger-pickup/). Only five Ford plants globally will be producing the PUMA engine (Turkey, UK, Thailand, Argentina and South Africa – Ford Struandale Engine Plant). The Ford Struandale Engine Plant will be the only plant which will have the I4 assembly, I5 assembly and 3C (Crank, Cylinder Block, and Cylinder Head) machining and the expectations of operating in a lean environment is high. The management team at the Ford Struandale Engine Plant needs to understand what the underlying factors that are hindering the improvement of Overall Equipment Effectiveness of the plant or, in other words, they need to be informed of the total benefits of TPM. A literature review was conducted to determine what the theory reveals about Overall Equipment Effectiveness, the three factors of OEE (Availability, Performance Efficiency, and Quality), the influence of Six Big Losses on each of the factors and the role of Total Productive Maintenance in improving OEE by eliminating these Six Big Losses. A Ford literature study was conducted to reveal the current literature being applied at Ford. This was then followed by an empirical survey conducted within the Ford Struandale Engine Plant. In addition, a task team formed to analyse the current maintenance operating strategy. Finally, the findings from discussions with the task team, the empirical survey, Ford Struandale Engine Plant literature survey and a general literature survey were amalgamated to draw conclusions relating to the Ford Struandale Engine Plant. These conclusions indicate what the underlying factors are that are hindering the improvement of Overall Equipment Effectiveness of the Ford Struandale Engine Plant facilities and equipment. Then recommendations are made as to how the Ford Struandale Engine Plant can improve the Overall Equipment Effectiveness of its facilities and equipment.

The methodology and the processes that are followed in the maintenance of government-operated district hospitals in the Eastern Cape Province of South Africa are outlined while the strategies that are employed to roll-out the maintenance plan have been investigated. The challenges in managing hospital maintenance are identified so that it can be improved and advice be given on the strategies currently being used. The objectives of the research were to determine the effectiveness of machinery maintenance in government-operated district hospitals. The study has been carried out by investigating 50 district hospitals within the Eastern Cape Province, with the aim of obtaining knowledge of practices in relation to the strategic plans and best practices in the maintenance industry. The following factors identified by the maintenance staff were found to be most important in maintenance management practices; realistic budgets, adherence to occupational health and safety regulations, engagement of qualified and skilled maintenance staff, good record management in relation to the equipment under maintenance, availability of tools and materials and keeping abreast with the latest technologies and trends of machinery advancement. The study also revealed that the majority of the hospitals use a combination of in-house and outsourced personnel during maintenance, the outsourced part being under contract from the National Department of Public Works Repair and Maintenance Plan (RAMP) projects. Service kits and recommended replacement parts for machinery are rarely stocked on the hospital premises while only minor spare parts that include replacement bulbs, electrical fittings, plumbing fittings and paint are readily available. In addition, the maintenance staff members have little or no input in maintenance budgeting, this aspect is controlled by hospital management. For maintenance to be effective, strategic planning that takes into account carefully thought-out maintenance management systems is the first step in the direction of setting out definite tangible objectives and goals. The real challenge lies in the implementation and sustainability of the maintenance management system and the monitoring thereof.

Nesta dissertação é apresentada a análise, desenvolvimento e aplicação de ferramentas para melhoria no sistema de gestão da manutenção de subestações do sistema elétrico de uma empresa do ramo de bebidas composta por algumas dezenas de plantas que trabalham em regime ininterrupto. O sistema de gestão da manutenção aplicado nesta empresa é condizente com o que sugere a literatura e apresenta resultados satisfatórios em vários setores. No entanto, pode-se constatar algumas dificuldades e fatores negativos na gestão do sistema elétrico da empresa, que funciona em três turnos. As limitações impostas ao sistema de gestão da manutenção comprometem sua eficiência gerando um nível indesejado de indisponibilidade por energia elétrica. A manutenção preventiva é realizada em paradas de fabricas de tempo reduzido. A localização geográfica bem como a extensão do sistema elétrico das plantas impõe que sejam contratadas diversas empresas para realizar estas manutenções. Esta diversidade traz grande dificuldade no tratamento dos dados de ensaios e de anomalias detectadas e apresentados nos relatórios de manutenção. O objetivo principal desta dissertação é apresentar uma análise crítica do sistema atual de gestão da manutenção das subestações do setor elétrico e uma proposta para melhorar este sistema de gestão quanto à sua aplicação no setor elétrico. Esta proposta se baseia na correção das distorções no índice de indisponibilidade e em uma ferramenta para aperfeiçoar o tratamento das informações resultantes da manutenção preventiva para sua utilização tanto no monitoramento do sistema quanto para embasar o processo decisório de priorização das manutenções corretivas e de investimento. O trabalho apresenta ainda o emprego dos conceitos que fundamentam a ferramenta proposta antes da aplicação da mesma e os impactos em indisponibilidade resultantes da aplicação destes conceitos. / This work presents the analysis, development and application of tools to improve the electrical substations maintenance management system of a beverage company composed of dozens of plants working continuously. The maintenance management system used in this company is consistent with what the literature suggests and provides satisfactory results in various sectors. However, we can notice some difficulties and negative factors in managing the electrical system of the company, which operates in three shifts. The limitations imposed on the maintenance management system compromise their efficiency generating an undesirable level of electrical power unavailability. Preventive maintenance is carried out in short time factory interruptions. The geographical location and the extent of the electrical system of the plants requires several companies to be hired to perform these maintenances. This diversity brings great difficulty in the treatment of tests and deficiencies data presented in the reports. The main objective of this dissertation is to present a critical analysis of the current substations maintenance management system in the electrical sector and a proposal to improve the management system in its application in the electrical sector. This proposal is based on correcting the distortions in the unavailability index and a tool to enhance the processing of information resulting from preventive maintenance to be used both for monitoring the system and to support the decision making process of prioritization of corrective maintenance and investment. The paper also describes the use of the concepts on which the proposed tool is based before implementation and impact on unavailability resulting from the application of these concepts.

En el presente trabajo de investigación se hace un estudio de la problemática de una empresa del rubro químico, la cual cuenta con un proceso básico y empírico de mantenimiento, en el que no se aplica planificación . Este proceso es muy importante ya que es un proceso de apoyo al proceso central. Debido a ello se propone la implementación de un sistema de gestión de mantenim iento, utilizando la filosofía del TPM (mantenimiento productivo total). En el primer capítulo se realiza un marco teórico, en el cual se desarrollan conceptos concisos de sistemas de gestión de mantenimiento, e strategias en la cual se desarrollan los conceptos de los tipos de mantenimientos, ciclos de vida de los equipos y fallas. Asimismo, indica que se hace énfasis en conceptos desarrollos e implementación del TPM, basados en libros, publicac iones de revisitas, papers, etc. En el segundo capítulo se describe el estado actual de la empresa en la cual se desarrolla la investigación, observando la misión, visión y valores de la misma. Asimismo, de acuerdo a herramientas de ingeniería, cómo histogramas, diagramas causa – efecto, Pareto se pueden encontrar las posi bles causas del problema final. En el capítulo 3 se desarrolla la metodología de solución al problema encontrado en el capítulo previo, definiendo el panorama de la tesis según la metodología a trabajar, el desarrollo de las actividades, teniendo presente los recursos y definir como optimizar los mismos utilizando aspectos de tecnología e innovación, con el fin de ser más productivos en el proyecto en curso. Asimismo, se revisarán los resultados de los análisis, actividades, recursos propuestos, para validar el desarrollo de la tesis se deben simular los resultados haciendo las comparaciones del antes y el después de la mejora, utilizando un software simulador; lo cual se deberá reflejar la mejora propuesta en costos, es decir impacto económico. Por último, se realizarán las recomendaciones y conclusiones del estudio realizado, de acuerdo los objetivos planteados. / In this thesis a study is made of the problem of a company in the chemical field, in which they only have an empirical basic maintenance area, in which optimal maintenance controls are not carried out, which is reflected in costs and low productivity. Due to this, the implementation of a maintenance management system is proposed, using the philosophy of TPM (total productive maintenance). In the first chapter a theoretical framework is made, in which concise concepts of maintenance management systems are developed, strategies in which the concepts of maintenance types, equipment life cycles and failures are developed. It also indicates that emphasis is placed on concepts of development and implementation of the TPM, based on books, magazine publications, papers, etc. The second chapter describes the current state of the company in which the research is carried out, observing its mission, vision and values. Also, according to engineering tools, how histograms, cause - effect diagrams, Pareto can find the possible causes of the final problem. In chapter 3 the methodology for solving the problem found in the previous chapter is developed, defining the thesis panorama according to the methodology to be worked, the development of the activities, taking into account the resources and defining how to optimize them using aspects of technology and innovation, in order to be more productive in the ongoing project. Likewise, the results of the analysis, activities, proposed resources will be reviewed, to validate the development of the thesis, the results must be simulated by making comparisons of the before and after the improvement, using a simulator software; This should reflect the proposed improvement in costs, that is, economic impact. Finally, the recommendations and conclusions of the study will be carried out, according to the objectives set. / Trabajo de Suficiencia Profesional

El presente trabajo plantea una propuesta de mejora de la gestión de mantenimiento aplicado al área de producción de una empresa de artes gráficas, como una alternativa de solución para mejorar la efectividad global del equipo o de las maquinas principales (impresoras offset) de la planta, minimizando el nivel actual de horas máquina por paradas no programadas que ocurren durante el proceso de impresión. En la primera parte se describe la introducción para el desarrollo del proyecto en la empresa de artes gráficas. El capítulo 2 comprende el marco teórico que define los conceptos, metodologías y herramientas relacionados con la gestión de mantenimiento, haciendo énfasis en el “Mantenimiento Productivo Total” (TPM) y la metodología de 5S, base para el desarrollo de la propuesta de mejora; presentando casos de éxito de la implementación del TPM. El capítulo 3 desarrolla el diagnóstico de la situación actual de la gestión del mantenimiento relacionada con al área de producción, empleando data real proporcionada por la empresa, en base al cual se identifica las causas principales y secundarias del problema. El capítulo 4 comprende el diseño y desarrollo de la propuesta de mejora de la gestión del mantenimiento de las máquinas offset, aplicando las herramientas de la metodología TPM. En el capítulo 5, se realiza la evaluación económica de la propuesta de mejora y la validación con la simulación del sistema productivo usando el Software Arena. Finalmente, se desarrollan las conclusiones y recomendaciones. / This work presents a proposal to improve maintenance management applied to the production area of ​​a graphic arts company, as an alternative solution to improve the overall efficiency equipment of main machines (offset printers), minimizing the current level of machine hours for unscheduled stops that occur during the printing process. The first part describes the introduction for the development of the project in the graphic arts company. The second chapter includes the theoretical framework that defines the concepts, methodologies and tools related to maintenance management, emphasizing the "Total Productive Maintenance" (TPM) and the 5S methodology, the basis for the development of the improvement proposal; presenting success cases of the implementation of the TPM, to know its application and results obtained. The third chapter develops the diagnosis of the current situation of maintenance management related to the production area, using real data provided by the company, based on which the main problem and its main and secondary causes are identified. The fourth chapter includes the design and development of the proposal for improving the maintenance management of offset machines, applying the tools of the TPM methodology In the five chapter, the economic evaluation of the improvement proposal is carried out and validation with the simulation using the Software Arena. Finally, develops the conclusions and recommendations / Trabajo de Suficiencia Profesional

The uptime of machinery in continuous flow process industries such as steel manufacturing plants puts pressure on the maintenance function. This in turn contributes to sustaining reliable physical assets. As absence of reliable physical assets highly affects the competitive advantage. Turnaround maintenance is a common practice in such production setups and requires top-of-the-line managerial attention to be planned,executed and assessed in an efficient manner. By applying an abductive approach and combining the qualitative and quantitative research approaches, this thesis aims to explore the managerial issue of coordinating turnaround maintenance within a continuous flow process industry. The research questions that guide this thesis consist of describing how turnaround maintenance can be coordinated and its associated challenges. By comparing publicly available literature and empirical evidence provided by performing a case study, it is confirmed that the main challenges for conducting efficient turnaround maintenance comes down to the management in all stages associated with the turnaround. To coordinate turnaround maintenance activities in the most efficient manner, several challenges must be overcome. Aligning organisational goals and generating management commitment is the first prerequisite before any improvements can be done. It is necessary to define a common scope that strives for creating reliable physical assets to enhance the competitive advantage. The defined challenges in coordination are related to before, during and after the turnaround execution. These relate to creating a cyclical process for the turnaround where previously acquired knowledge is used for improving future turnarounds. While detailed planning is necessary for each turnaround, a high level of contingency is also necessary. To achieve this and succeed, it is argued that a high level of visibility during the turnarounds and the use of standardised methods is required. / Drifttiden för maskiner i industrier med kontinuerligt flöde, såsom ståltillverkningsanläggningar, sätter press på underhållsverksamenheten. Detta för att i sin tur bidra till att upprätthålla tillförlitliga fysiska tillgångar. Eftersom avsaknad av tillförlitliga fysiska tillgångar påverkar konkurrensfördelen i hög grad. Storaunderhållstopp där den kontinuerliga produktionslinan stoppas, är en vanligt förekommande praxis i sådana produktionsanläggningar vilket kräver ledningens uppmärksamhet för att planera och utvärdera på ett effektivt sätt. Genom att tillämpa ett abduktivt tillvägagångssätt och kombinera kvalitativ och kvantitativ forskningsmetodik, syftar detta examensarbete till att utforska den ledarskapsrelaterade frågan om att koordinera underhållsaktiviteter för stora underhållstopp inom processindustrier med kontinuerligt flöde. Forskningsfrågorna som vägleder detta examensarbete består av att beskriva hur större underhållstopp kan koordineras och dess associerade utmaningar. Genom att jämföra offentligt tillgänglig litteratur och empiriska bevis från en fallstudie, bekräftas att de största utmaningarna för att genomföra ett effektivt underhållstopp beror på ledningen i alla steg som är förknippade med underhållstoppet. För att samordna underhållsaktiviteterna på ett så effektivt sätt som möjligt måste flera utmaningar övervinnas. Att anpassa organisationens mål och skapa engagemang hos ledningen är den första förutsättningen innan fler förbättringar kan utföras. Det är nödvändigt att definiera gemensamma mål som strävar efter att skapa tillförlitliga fysiska tillgångar för att i sin tur öka konkurrensfördelen. De definierademanagementutmaningarna sammankopplas till före, under och efter underhållsstoppet. Utmaningarnahandlar om att skapa en cyklisk process för underhållsstoppen där tidigare förvärvad kunskap nyttjas för att förbättra framtida stopp. Även om detaljerad planering är nödvändig för varje underhållstopp, är en hög nivå av beredskap också nödvändig. För att uppnå och lyckas med detta krävs en hög grad av visibilitet under underhållsstoppen och användning av standardiserade metoder.

Electrical production in Sweden today is mainly from nuclear and hydro power. However, there is large increase in renewable energy like wind power and the installed new capacity goals are large. Several electrical production sources are important for the sustainability of the energy system. Maintenance is an approach for keeping a system sustainable. The importance of structured maintenance for reliable electrical production systems triggers the development of qualitative and quantitative maintenance management methods. Examples of these methods are Reliability-Centered Maintenance (RCM) which is a structured qualitative approach that focuses on reliability when planning maintenance, and Reliability Centered Asset Management (RCAM) which is a development of RCM into a quantitative approach with the aim to relate preventive maintenance to total maintenance cost and system reliability. This thesis presents models, as applications of RCAM, based on the methods of Life Cycle Cost (LCC) and mathematical optimization, applied to wind and nuclear power plants. Both deterministic and stochastic approaches have been used and the proposed models are based on the Total Cost model, which summarizes costs for maintenance and production loss, and the Aircraft model, which is an opportunistic maintenance optimization model. Opportunistic maintenance is preventive maintenance performed at opportunities. The wind power applications in this study show on different ways to cover costs of condition monitoring systems (CMS) and further on economic benefits of these when uncertainties of times to failure are included in the model. The nuclear power applications show on that the optimization model is dependent on the discount rate and that a high discount rate gives more motivation for opportunistic replacements. When put into a stochastic framework and compared to other maintenance strategies it is shown that an extended opportunistic maintenance optimization model has a good overall performance, and that it, for high values of the constant cost of performing maintenance, is preferable to perform opportunistic maintenance. The proposed models, applied to wind and nuclear power plants, could be extended and adapted to fit other components and systems. / Reliability and cost centered maintenance methods

The purpose of this study is to examine the nature of performance measures utilised by the maintenance function in todays business organisations. In the process, the increasing variety and significance of these measures are addressed from operational and strategic perspectives. A survey-based research method was utilised to gather the research data. Several statistical procedures were utilised to analyse the data. The findings of this study point to the multifaceted nature of the maintenance measures and measurement. Multiple categories of maintenance measures were identified. These categories varied from the machine-specific, to measures impacting organisational performance. The relative lack of emphasis placed on the environment and strategic facets of maintenance is noted. The findings of this study have direct implications to organisations, which are attempting to measure the effectiveness of their maintenance efforts. The need to align the maintenance performance efforts with the organisational strategic direction is emphasised. In this context, the integration of the maintenance performance information systems with the overall organisational performance management information system might facilitate the needed alignment. This study utilises 120 maintenance measures. As such, it represents a comprehensive view of the maintenance effort.