There is a world-wide drive to optimize maintenance decisions in an increasingly competitive manufacturing industry. Preventive maintenance if often the most organized and cost efficient strategy to follow, but a decision still has to be made on the optimal instant to perform preventive maintenance. Use based preventive maintenance decisions have been optimized through statistical analysis of failure date while predictive preventive maintenance (condition monitoring) has been optimized by utilizing more sophisticated technology. Very little work has however been done to combine the advantages of the two schools of thought. This thesis originated from a realization of the potential improvement in maintenance practice by combining use based preventive maintenance optimization techniques with high technology condition monitoring. In this thesis an approach is developed to estimate residual life of industrial equipment dynamically by combining statistical failure analysis and sophisticated condition monitoring technology. The approach is based on failure intensity proportions determined from historic survival time information and corresponding diagnostic information such as condition monitoring. Combined Proportional Intensity Models (PIMs) for non-repairable and repairable systems, containing the majority of conventional PIM enhancements as special cases, with numerical optimization techniques to solve for the regression coefficients, are derived. In addition to the residual life estimation approach, a user-friendly graphical method with which residual life estimates can be presented was also developed. This method is natural and easy to comprehend, even by inexperienced data analysts. The residual life estimation approach is applied to a typical data set from a South African industry and results are compared to those obtained from a similar, established maintenance decision support tool. This comparison showed that the approach developed in this thesis is relevant, practical and marginally better than the established decision support tool for certain criteria. / Thesis (PhD (Industrial Engineering))--University of Pretoria, 2006. / Industrial and Systems Engineering / unrestricted

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.

Design of a repairable item and its logistic support system requires consideration of several interrelated decision problems. These decision problems concern the variables, controllable by the design engineer and/or system manager, which affect system performance. This research develops a framework for integration of these decision problems and evaluation of system design tradeoffs. These design decision problems are represented in the model base of a decision support system (DSS). Interrelationships between decision problems are defined using data flow diagrams. Data flows within and between these decision problems are integrated in the DSS database. A simulation capability, imbedded into the DSS permits short-term, accelerated time excursions into possible futures for decision-making purposes. Alternative system designs are evaluated using a multicriteria decision model which considers reliability, maintainability, availability, and life cycle costs. The logistic support system is modeled as a multilevel inventory system. These inventories include spare repairable items, spare parts, labor, maintenance equipment, and other support resources. Repairable item and logistic support system design decision problems affect the quantity and location of these inventories. Five decision problems identified by Moore [1986] were selected to demonstrate the utility of this framework. The selected decision problems are: 1) the equipment design problem; 2) the maintenance configuration problem; 3) the spare equipment problem; 4) the level of repair problem; and 5) the replacement policy problem. The framework developed supports integration of these decision problems throughout the item’s life cycle. A repairable item can be systematically divided into subelements until individual repairable components are identified. This systematic subdivision of the item produces an inverted, tree-like structure. This structure is used as the representational view of the DSS database. As the life cycle progresses and the item design becomes more detailed, the structure expands. The DSS database is designed to accommodate this expansion so that the framework can be used throughout the item’s life cycle. The initial fielding and the retirement of the repairable item population produces nonstationary demands on the logistics support system. A multistream model captures the nonstationary aspects of demand, eliminating the need for item-by-item tracking within the model. The framework developed is illustrated using a comprehensive case study. The case study addresses the design of a Side Loadable Warping Tug (SLWT) and its logistics support system. A population of SLWT’s must be deployed to meet demands in two different operating environments. The SLWT is a component of the U.S. Navy’s Container Offloading and Transfer System (COTS). / Ph. D.

Study project (MComm)--University of Stellenbosch, 2000. / ENGLISH ABSTRACT: The purpose of this assignment is to develop a method for rate making of construction machines and vehicles. An analysis of the fixed and variable cost of machines and vehicles are made together with the allocation of overhead costs. After anal ising the various cost components a model is developed for the determination of depreciation and finance charges by using the utilization of the relevant plant item. The figures obtained from this model are then used in an asset register. The information needed by the Receiver of Revenue is also included in this register for calculating the depreciation value at the end of the financial year. The maintenance and replacement of plant equipment are also discussed. Before the conclusion the necessity of keeping accurate records and the use of budgets for managing are looked at. / AFRIKAANSE OPSOMMING: Die doel van die werkstuk is om 'n raamwerk daar te stel wat gebruik kan word vir tariefvasstelling van konstruksiemasjiene en - voertuie. In Ontleding van die vaste en veranderlike koste van masjinerie en voertuie word gemaak, asook die hantering van oorhoofse koste in die onderneming. Nil die bespreking van die verskillende kostekomponente waaruit 'n tarief bestaan, word die klem geplaas op die berekening van waardevermindering. 'n Model vir waardeverminderingen finansieringskostebepaling aan die hand van die benutting van toerusting word ontwikkel. Die inligting sodoende verkry word saamgevat in 'n bateregister tesame met die inligting noodsaaklik vir die Ontvanger van Inkomste om waardeverminderingafskrywings te maak aan die einde van elke finansiele jaar. Die onderhoud en vervanging van toerusting word ook bespreek. Ter afsluiting word rekordhouding en die opstel van begrotings bespreek en die nut daarvan vir bestuur uitgewys.

Thesis (MBA)--Stellenbosch University, 2004. / ENGLISH ABSTRACT: Richards Bay Minerals (RBM) went through a restructuring process in 2002. The effect that these changes had on the life expectancy of the heavy earthmoving equipment (HEME) at the company’s sand dune mining operation situated at Richard’s Bay on the north coast of KwaZulu-Natal, was unknown. This study explores these, and various other factors, that influence the life expectancy of the HEME in this highly corrosive environment. During the last number of years there has been no equipment replacement philosophy at RBM and this has resulted in the average age of HEME at the mine being extremely high. This study suggests that when restructuring is implemented in the wrong way, the process can have significant negative implications. The study determines how the behaviour of especially drivers and maintenance personnel (maintainers) impacts on the expected life of the HEME at RBM. The hidden cost element of driver and maintainer unhappiness, however, is not included as part of this study. In the first part of this study project, the writer focuses on what may have caused the unhappiness, and makes suggestions for further studies aimed at addressing this unhappiness and changing the behaviour of drivers and maintainers. These suggestions should be seen as guidelines, as measures that work in one company may not necessarily work in another. The second part of the study project deals with the replacement philosophy regarding HEME at RBM. The mine has various types of equipment, but the main focus of this research falls on the following: Caterpillar 966- 980 (payloaders), track type equipment Caterpillar D7R/H (dozers), Caterpillar 988- 992 (heavy duty payloaders) and Bell B25 articulated dumptrucks (dumptrucks) Four different replacement models are investigated and discussed in detail. The model that was best aligned with the Caterpillar proposed best replacement practice, as stipulated by the Caterpillar replacement expert, is identified. Finally, a replacement cycle for the different types of equipment is proposed. / AFRIKAANSE OPSOMMING: Richardsbaai Minerale (RBM) het in 2002 deur ‘n herstruktureringsprogram gegaan. Die uitwerking wat die gevolge daarvan op die swaar grondverskuiwingsvoertuie (SGV) gehad het was onbekend. Gedurende die laaste aantal jare was daar geen vervangingsbeleid by RBM nie, en dit het meegebring dat die gemiddelde ouderdom van die SGV op die myn buitengewoon hoog is. Dit is belangrik om te bepaal wat die invloed van menslike gedrag van veral die drywers en herstelpersoneel op die verwagte leeftyd van SGV is. Die versteekte koste wat verbind word met ongelukkige drywers en herstelpersoneel maak nie deel uit van hierdie studie nie. As herstrukturering op die verkeerde manier toegepas word kan dit ‘n negatiewe impak hê. In die studie sal daar aandag gegee word aan wat die negatiewe elemente is en wat is die moontlike oorsaak daarvan. Daar word ook sekere voorstelle gemaak vir toekomstige studies om die ongelukkigheid aan te spreek en ‘n gedragsverandering na vore te bring. Die voorstelle is slegs riglyne en, wat in een maatskappy werk sal nie noodwendig in ‘n ander een werk nie. Die tweede deel van die werkstuk fokus op vervangingsteorieë met betrekking tot die SGV op RBM. Die myn het verskeie tipes SGVs maar die fokus het geval op vier soorte SGV. Hulle is Caterpillar 966- Caterpillar 980 (gemiddelde laaiers), spoor tipe toerusting Caterpillar D7R/H (stootskrapers), Caterpillar 988- Caterpillar 992 (swaargewig mobiele laaiers) en Bell B25 geartikuleerde stortings trokke (stortings trokke). Vier verskillende modelle is ondersoek en deeglik bespreek. Die model met die beste uitslae wat die mas opgekom het ten opsigte van die Caterpillar se voorgestelde beste vervangings praktyk, soos aangedui deur die Caterpillar voertuig vervangings kenner, is ge-identifiseer. Laastens word die vervangingsiklus vir die verskillende tipes toerusting voorgestel.

Thesis (D.Tech. - Electrical Engineering, Dept. of Process Control and Computer Systems, Faculty of Engineering and Technology)--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.

No description available.

M. Tech. Business Administration / The research reviews how the implementation of total productive maintenance (TPM), as a maintenance strategy, can be adopted at DCD Wind Towers (Pty) Ltd., a wind tower manufacturing company in South Africa. It also focuses on maintenance management programmes, identifies obstacles, barriers and challenges to the implementation of maintenance management programmes.

Orientador: Gabriel Alves da Costa Lima / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica e Instituto de Geociências / Made available in DSpace on 2018-08-21T23:40:04Z (GMT). No. of bitstreams: 1 Cesca_IgorGimenes_M.pdf: 2631356 bytes, checksum: 457c322ac2cc3cffc8315b485825f863 (MD5) Previous issue date: 2012 / Resumo: No setor energético (mineração, energia elétrica e petróleo), o conhecimento do comportamento dos custos dos equipamentos em seus ciclos de vida se torna muito importante devido a: (1) alto custo de aquisição e (2) elevadas despesas de manutenção. Dessa maneira, a aquisição de um ativo físico não deve ser decidida somente com base no custo inicial, mas sim por meio do custo do ciclo de vida desse ativo. Para esta dissertação foi elaborado um modelo matemático para encontrar a vida econômica e realizar previsões de custos de manutenção de um grupo de ativos físicos empregados no setor energético. Sendo assim, isso ocorre por meio de: (1) programação dinâmica, utilizando o modelo clássico de Bellman para reposição de equipamentos; (2) engenharia econômica, de tal forma que a vida econômica dos equipamentos é modelada por meio da função W de Lambert e (3) técnicas econométricas de previsão, tal que a relação entre os custos de manutenção e a idade dos equipamentos é testada por formas funcionais de regressões lineares simples. Com isso, para modelagem de vida econômica, foi possível estabelecer teoremas e, para previsão de custos de manutenção, foi possível perceber que as variáveis possuem uma relação não linear entre elas. Portanto, foi possível concluir que os equipamentos podem ser utilizados de maneira mais eficiente e com menores custos de ciclo de vida incorporados, uma vez que seja aplicada uma gestão econômica com base no modelo proposto nesta dissertação e, consequentemente, também possibilitar obter melhores indicadores financeiros para as empresas do setor energético / Abstract: In the energy sector (mining, oil and electricity), the knowledge of the asset's behavior in their life-cycle costs becomes very important because of: (1) the high cost of acquisition and (2) the high maintenance expenses. Thus, the acquisition of a physical asset should not be decided only on the basis of its initial cost, but through the consideration of its entire life cycle cost. In this dissertation a mathematical model of economic life and maintenance costs forecasts of a group of physical assets is developed and employed in the analysis of problems in the energy sector. The model considers the following: (1) dynamic programming, using the classical Bellman model for equipment replacement; (2) engineering economics, using to model the economic life of the equipment the equivalent cost theory and Lambert W-function and (3) econometric forecasting techniques, such that the relationship between the maintenance costs and equipment age are tested for functional forms of linear regressions. Therefore, on economic life modeling, it was possible to establish theorems and on maintenance costs forecasting. It was revealed that the variables have a nonlinear relationship between them. To conclude, physical assets can be used more efficiently and at lower life-cycle costs incorporated with the application of models developed in this dissertation and, consequently, contribute to obtain better financial indicators for companies in the energy sector / Mestrado / Reservatórios e Gestão / Mestre em Ciências e Engenharia de Petróleo

The purpose of this project was to develop two-semester unit plans for the auto electronics course in the automotive technology program at Fontana High School.