Using QFD and FMEA to Improve Maintenance Effectiveness in a Petroleum Refinery

Abstract

A case study is reported which Improve the maintenance effectiveness by combines Quality Function Deployment (QFD) and Failure Mode and Effects Analysis (FMEA), QFD was used to identify the critical technical attributes which affect the customer satisfaction the most. FMEA was adopted to identify potential failure models and causes of critical manufacturing processes. Customer requirements (CRs) were obtained through Internal MMIP team. Analytic Hierarchy Process (AHP) selections was used to sort the importance of CRs and then compared to the technical attributes (TAs) in the House of Quality (HoQ). FMEA were used to analyse the Maintenance activity which resulted the relative solutions from High Risk Priority Number (RPN) indices failure models. By the integration of FMEA into QFD, a new maintenance management model developed and implemented, has increase by 116% Mean Time Between Maintenance and Decrease by 41% Number of Breakdown Maintenance Intervention, 47.6% Mean Time To Repair and 82% of maintenance cost or Rp. 5,754,791,630.00 lower compare to the same period in the previous year maintenance cost.