Maintenance Department Research Articles

RN61 – Mons – Tournai Road – Bury Braffe Section A modest renovation becoming a long life pavement

The Mons Highways Department has been researching and applying cement concrete road pavements for several decades, and one outcome of this is a particularly remarkable section of roadway which, after almost 40 years, still provides all the required characteristics of stability, comfort, and safety, in return for very low maintenance costs. In 1968, the state of the road, of which the pavement consisted of either simple cobblestones or cement concrete slabs, with no base layer, was quite appalling. The conditions for an experimental rehabilitation, consisting of laying a CRCP overlay over a length of 3 km, were defined jointly with the BRRC ( Belgian Road Research Centre ) and the Cement Industry Research Centre. This overlay was divided into 6 sections, all with different reinforcement characteristics. In 1996, in other words almost 30 years after this work had been carried out, a few localised repairs were carried out and the road, which by then had become regional highway N50, was covered with RUMG, an ultra-thin bituminous granular overlay 2 cm thick. This paper describes all the technical aspects of this project, the relevance of which is then examined using the design software designed in recent years by the Highways Maintenance and Transport Department of the Walloon Region, an application of which was presented at the 8th Colorado Springs Conference in 2005.

AN ANALYSIS OF CUSTOMIZED PRODUCT MANUFACTURING CYCLE TIME IN A FOOD COMPANY

This study aims to identify the factors contributing to the delay in the institutional product manufacturing cycle time in a food company in the Philippines. It examines the relationship between these factors and the job satisfaction of employees in the production, maintenance, and quality assurance departments. A preliminary interview was conducted to identify the factors causing cycle time delays, and data was collected on the frequency and average time duration of these occurrences. The data were assessed using a Pareto Diagram to determine the factors contributing to the most to the delay. Job satisfaction levels were measured using modified and validated questionnaires. Pearson and Chi-Square correlations were employed to determine the relationship between job satisfaction, demographic profiles, and the identified factors. ANOVA testing was conducted to determine the factor contributing the most to the cycle time delay. The study found that the availability of analysis results and production shutdown accounted for 80% of the cycle time delay, classified as the "vital few" factors. The remaining factors, such as turnover activity, maintenance and cleaning, and storage bin availability, were classified as the "useful many" and contributed to only 20% of the delay. The study also revealed a significant relationship between the shift and the contributing factors, with a correlation at the 0.01 level. This study provides a detailed analysis of the factors influencing the institutional product manufacturing cycle time at a food company. It also offers a process improvement plan with recommendations aimed at improving the company's operational efficiency.

INDUSTRIAL SNOW AND SELECTED ECONOMIC IMPACTS ON THE OPERATION OF KOSICE AIRPORT

The aim of the paper is to describe industrial snow as a meteorological phenomenon of anthropological origin and the physical principle of its formation in the context of Kosice Airport, with international traffic. The research also focused on selected economic impacts on the operation of Kosice Airport, which is located next to the large industrial complex U.S. Steel Kosice. There are only a few international airports in the world that are affected by industrial snow, which is why we also focus on the economic impact of maintaining the operational areas of the airport to the required extent according to standards. A solution to the problem is also proposed based on the scientific works of experts who focused their scientific activities on the issue of industrial snow production. In addition to the differences in the formation of industrial and natural snow, the article mentions the differences in the structure and properties of crystalline elements and their distribution according to the external meteorological conditions under which they are formed. The paper identifies meteorological situations that are favorable for the formation of industrial snow and due to the mutual location of the airport and the industrial complex, the airport is affected by industrial snow. This article describes the selected economic impacts of industrial snowfall on air traffic at Kosice Airport from 2017–2022. These were expressed after providing data from the airfield maintenance department of the Kosice Airport. At the same time, airport maintenance workers shared their unique experiences with this special meteorological phenomenon. The outcome of this research brings the unique method of industrial snow day occurrence and helps to explain this rare weather phenomenon and its impact on transport and social aspects.

Pengaruh Pengalaman Kerja dan Pelatihan Kerja Terhadap Kinerja Karyawan Engineering Maintenance PT XYZ

Company's excellence center will be achieved with competent human resources towards the company's rapid competitiveness. This study aims to investigate how work experience and job training affect employee performance in the Engineering Maintenance Department Organisation at PT XYZ. Population and sample for this study included Engineering and Maintenance employees at PT XYZ. The research utilized multiple linear regression analysis as the primary method to examine the relationships between the variables. A quantitative approach was employed. Research sample was chosen using saturated sampling technique, the study involved a total of 35 respondents. Data analysis results indicate that work experience and job training significantly impact employee performance. According to the coefficient of determination test results, training and compensation contribute 43.2% to employee performance. From this research it is recommended to PT XYZ increase investment in training and develop strategies to enhance employee performance. This should help improve the quality standards of employee performance through training, enabling employees to gain more valuable experience, maintain a smooth production process, and produce high-quality goods.

Understanding the Common Defects in Commercial Buildings: Types, Causes and Remedial Actions

Commercial building maintenance management constitutes a pertinent issue of global concern for all related stakeholders. In Malaysia, the management of commercial building maintenance plays a crucial role in achieving the goal of providing safety to occupants and the building itself. However, there is a paucity of studies that have comprehensively explored all dimensions of commercial building defects in relation to maintenance management. This research was also conducted to identify and analyze the typical defects that occur in commercial structures, understand their underlying causes, assess their impact on safety, functionality and propose effective remedial actions. The study utilized a qualitative approach for data collection. The findings indicated that cracked floors, floor tile failures, wall tiles failure, damaged ceiling, paint peeling and faulty light bulbs were some of the flaws that degrade commercial building. The study’s outcome revealed that defects not only deface the aesthetic appearance of the commercial buildings but also inhibit the functionality of the buildings and depreciate the overall satisfaction. The research limitations include using commercial buildings (shopping complexes or malls) that have been operating for more than 20 years. This study offers invaluable insights for maintenance organizations and maintenance department staff who are genuinely interested in improving commercial buildings’ maintenance management to optimize staff’s performance and enhance the user satisfaction of the buildings in Malaysia and globally.

Repair of Injection Moulds by Welding for Pre-Hardened 1.2714 Hh Steel

The welding of injection molds by laser deposition is a very common procedure in recent years in the maintenance departments of plastic injection factories. This is due to the advantages it has compared to traditional welding methods, namely the speed of the laser welding process, a lower deposition of the metal composition in the repaired area (small volume of deposited material), as well as the accuracy of the deposition on the surface the piece. But, in addition to these advantages, there are also a number of disadvantages compared to classic welding. As the main disadvantage in the case of laser welding of injection molds, the maximum weldable thickness is limited. This paper presents an analysis of weld quality and mechanical fracture of laser deposition according to deposition types and welding techniques of 1.2714 HH pre-hardened steel. The material 1.2714 HH is a basic material used in recent years in the production of molds due to its hardness, namely 40-45 HRC units. In laser welding, different welding strings are possible, each influencing the laser deposition preparation process, the possibility of performing the deposition in the respective area, as well as obtaining a desired mechanical stability. Starting from these considerations, a number of factors will be analyzed using 1.2714HH steel samples: welding strings, welding strings depth, filler material and welding parameters. V – notches were made and filled for welded samples with laser welding deposits. V – notches were made and filled for welded samples with laser welding deposits.

Development of an application for training management of the maintenance team in a metallurgical industry in the suape industrial complex – cabo de Santo Agostinho

This work presents the development of an application designed to complement traditional training management methods within an organization. The application, developed on the PowerApps platform using a Low-Code approach, aims to facilitate the monitoring and management of employee training in the maintenance department of a company located in the Suape industrial complex, Cabo de Santo Agostinho. Its main objective is to provide a digital platform that allows for the verification of the training status of maintenance technicians, identifying which are in "Attention," "Expired," and/or "OK" status. Traditionally, this data is managed manually, in a time-consuming and error-prone process. The transition to a digital system ensures data accuracy, reduces the time required to access and update information, and improves the overall efficiency of the department's activity scheduling process. During the testing phase, conducted between January and August 2024, comparative data was collected on the training consultation process, before and after the implementation of the application. Preliminary results indicated a significant improvement in the efficiency and productivity of the maintenance department, comparable to other works that used PowerApps as a quick and low-cost solution.

A framework for conceptualizing integrated prescriptive maintenance and production planning and control models

Goal: This study aims to support researchers and managers in conceptualising new integrated prescriptive maintenance (PxM) and production planning and control (PPC) models. Design / Methodology / Approach: We perform a systematic literature review based on Thomé et al. (2016) and analyse literary findings using qualitative content analysis and quantitative correlation analyses. Results: This work identifies 94 integrated PxM and PPC planning models and 47 outcomes, 16 decision variables and 34 environment entities. Based on the quantitative analyses of these components, we derive a normative framework to guide researchers and practitioners in conceptualising integrated models. Limitations of the investigation: The study is limited to only one scientific database. Additionally, the quantitative analyses might be sensitive due to a low sample size for some components, and we only measure the linear dependency between two components. Lastly, we do not address solution algorithms. Practical implications: The framework constitutes a tool for managers to construct integrated models tailored to their specific planning problems, fostering alignment between production and maintenance departments, plans and controls. Originality / Value: We provide a descriptive overview and normative guidance in the selection of components that can or should be used for future PxM-aligned PPC planning studies, pinpointing possible research gaps.

Application of PS-InSAR and Diagnostic Train Measurement Techniques for Monitoring Subsidence in High-Speed Railway in Konya, Türkiye

Large-scale man-made linear structures like high-speed railway lines have become increasingly important in modern life as a faster and more comfortable transportation option. Subsidence or longitudinal levelling deformation problems along these railway lines can prevent the line from operating effectively and, in some cases, require speed reduction, continuous maintenance or repairs. In this study, the longitudinal levelling deformation of the high-speed railway line passing through Konya province (Central Turkey) was analyzed for the first time using the Persistent Scatter Synthetic Aperture Radar Interferometry (PS-InSAR) technique in conjunction with diagnostic train measurements, and the correlation values between them were found. In order to monitor potential levelling deformation along the railway line, medium-resolution, free-of-charge C-band Sentinel-1 (S-1) data and high-resolution, but paid, X-band Cosmo-SkyMed (CSK) Synthetic Aperture Radar (SAR) data were analyzed from the diagnostic train and reports received from the relevant maintenance department. Comparison analyses of the results obtained from the diagnostic train and radar measurements were carried out for three regions with different deformation scenarios, selected from a 30 km railway line within the whole analysis area. PS-InSAR measurements indicated subsidence events of up to 40 mm/year along the railway through the alluvial sediments of the Konya basin, which showed good agreement with the diagnostic train. This indicates that the levelling deformation of the railway and its surroundings can be monitored efficiently, rapidly and cost-effectively using the InSAR technique.

Does job satisfaction mediate the effect of teamwork and organizational citizenship behavior on job performance?

In an increasingly competitive business situation, employee performance is something that is increasingly becoming the main concern of organizations. Therefore, this research aims to find a model for improving employee performance through increasing teamwork and organizational citizenship behavior with job satisfaction as an intervening variable. This study was carried out in Merak Banten at an agrochemical company by distributing questionnaires to 50 respondents representing production, maintenance, warehouse, laboratory, and general departments. This kind of research is known as explanatory research, and it uses hypothesis testing to explain the link between variables. The collected questionnaire data was then analyzed using SEM statistical methods and PLS analysis with SmartPLS 4 software. The analysis outcome showed that the job satisfaction variable had a direct effect on performance, teamwork had a direct or indirect effect on performance and organizational citizenship behavior had no direct or indirect effect. on performance. This research implies that companies are advised to increase the value of organizational citizenship behavior to increase job satisfaction and employee performance.

Analisis Potensi Bahaya Terhadap Program Kerja Departemen Maintenance Di Stasiun Sterilizer Menggunakan Metode Job Safety Analysis (JSA) di PT. X Nagan Raya

The Sterilizer Station at PT X Nagan Raya is a company facility that requires regular maintenance by the maintenance department to ensure its smooth operation. This facility has potential hazards that need to be analyzed in detail. This study aims to evaluate the potential hazards associated with the maintenance department's work program at the Sterilizer Station using the Job Safety Analysis (JSA) method, where potential hazards are evaluated for theassociated risk levels, namely low risk, medium risk, high risk, and extreme risk. The research approach used is qualitative with a descriptive design. Data was collected from the maintenance department's work program for the July-December 2023 period at the Sterilizer Station through direct observation and interviews using the JSA form. The informants in this study were 6 informants consisting of maintenance employees, maintenance assistants, HSEofficers and Assistant Mill Managers. The results of this study indicate that there are several potential hazards that can occur during the implementation of the maintenance department work program, such as the danger of falling on work equipment, slipping, electric shock, exposed to sparks, exposed to mesingerinda, iron cutters and electric welding machines. Based on the JSA analysis, several risk control measures are suggested, such as the use of appropriate and correct Personal Protective Equipment (PPE), routine maintenance of equipment, conducting daily monitoring, and paying attention to conditions.

Fuzzy FMEA-Resilience Approach for Maintenance Planning in a Plastics Industry ‎

The productivity and efficiency of industrial systems are highly affected by failures and machine breakdowns. Further, in asset-intensive industries, unexpected failures are considered the primary source of operational risk. In response, the maintenance department strives to calculate reliable estimates of the risk levels associated with such failures and develop resilient maintenance strategies that enable it to respond effectively to equipment failures. The research developed a framework for integrating fuzzy failure mode and effects analysis (FFMEA) with resilience engineering (RE) concepts for maintenance planning. The framework consists of four main stages: FFMEA, Risk iso-surface (RI), resilience assessment, and maintenance planning. In FFMEA, multiple sub-factors were considered for each main risk factor and evaluated using fuzzy logic. Then, in the RI stage, the risk priority number (RPN) was calculated through a fuzzy approach that considered the order of the importance of the main three risk factors. The fuzzy resilience assessment was applied through a survey of fifty-one questions related to the main four RE potentials to determine the need for resilient maintenance strategies. Finally, the RPN-Resilience diagram was employed to classify maintenance activities into six main maintenance strategies. A case study from a production line of plastic bags was used for illustration. The main advantage of the proposed FFMEA is that it divides the main risk criteria into sub-criteria to increase the accuracy of risk assessment and evaluate resilience potentials under fuzziness. In conclusion, the integration of the risk-resilience evaluation is a valuable tool for effectively planning maintenance activities.

PREVALENCE AND PATTERN OF WORK-RELATED DISORDER AMONG OIL AND GAS WORKERS IN KADUNA REFINERY, NIGERIA

This study examined the frequency and distribution of musculoskeletal problems among Kaduna Refining and Petrochemicals Company Limited (KRPC) engineers, desk workers, security. Data for the study were gathered using a modified online version of the Nordic musculoskeletal questionnaire. The prevalence and patterns of musculoskeletal disorder (MSD) were assessed and data from a survey given to KRPC employees was analyzed using SPSS. According to the survey, there were 62.4% of MSD cases among KRPC employees overall over 12 months. The prevalence of MSD was highest for lower back (%), followed by upper back (%) and the wrist (%). Years of experience and MSD were significantly associated (P >0.05). Employees with 16 to 25 years of work experience had a very high prevalence of MSD (84.9%). The power plant and quality control (PPQ and C) departments as well as the maintenance department had the highest rates of MSD. The findings can be used by KRPC management and any other refinery to address MSD problems among its employees and to close a gap in the body of knowledge regarding how MSD affects refinery workers in general.

Steam quality monitoring as a strategy to reduce wet packs and sterilization failure

Hospital articles processed by steam are widely used in the Central Sterile Supply Department (CSSD), responsible for due sterilization. Steam sterilization is discussed worldwide, aiming to protect patients. If steam is outside the specified requirements, the sterilization process may fail, resulting in the wet packs at the end of the sterilization cycle. The present study evaluated the steam quality at Santa Catarina Hospital (São Paulo, SP, Brazil) from 2016 to 2022. Saturated steam containing noncondensable gases, excess condensate, or even superheat was characterized using the methodology indicated in the European Standard EN 285:2015. From 2016 to 2020, qualification tests showed that the saturated steam quality does not achieve standardlimit parameters. Infrastructural maintenance actions were taken to adjust the saturated steam quality. In 2021, the steam quality followed technical standards, and its adequacy was confirmed in 2022. The points developed by the hospital's maintenance department, the adoption of appropriate devices for this purpose, and the correct preventive maintenance in the autoclaves, together with the correct qualification of the equipment and proof of the steam quality, contributed to improve the safety of the hospital sterilization process and reduce the incidence of wet packages.

A study on the prediction of service reliability of wireless telecommunication system via distribution regression

The reliability of wireless telecommunication service has become a major concern for the operation and maintenance (O&M) departments of the major telecommunication service providers. Consequently, reliability prediction has assumed a pivotal role for O&M department to furnish dependable services while simultaneously curtailing operational costs. However, predicting the service reliability is a challenging issue mainly attribute to the mobility characteristics of the end-users in the network. In tandem with the formulation of service reliability metrics, this study introduces a linear distribution regression model under Gaussian distribution and a kernel-based distribution regression model tailored for bimodal scenarios. The empirical validation of these proposed metrics and methodologies is substantiated through case studies employing both simulated data and real-world datasets derived from a wireless telecommunication system within an urban district. The outcomes of these case studies demonstrate the efficacy and applicability of the proposed metrics and methods.

Implementation of the Fp-Growth Algorithm on Spare Parts Supply Requests

Manufacturing companies rely on machines for operational activities to produce finished goods. Common factors constraining the demand and supply of spare parts are the high number of spare parts managed and irregular patterns of demand for spare parts. These varying quantities also require investment in spare parts inventory and longer response times than predicted. The research aims to apply the FP-Growth algorithm approach to find association rules and produce patterns of demand and supply of spare parts in lightweight brick manufacturing companies based on transaction data on demand and supply of spare parts from January – March 2023. The approach used is associated with the applied algorithm. In this research, the primary process of the FP-Growth algorithm is to create a combination of each item until no more combinations are formed using minimum support and minimum confidence parameters. Based on the results of making association rules using spare parts demand data from the machine maintenance department, it is stated that the regulations formed from processing the RapidMiner application with a confidence value of 100% recommend FD Regular Bolt spare parts, then the next rating with a confidence value of 94% is Steel Nuts, seven rules recommend Nuts. Steel. Therefore, it is recommended that FD Regular Bolts and Steel Nuts carry out safety stock to maintain stock availability and place them on shelves included in the fast-moving inventory category.

Technical planning, control and validation. Quality and effectiveness in public procurement action

This paper recounts the experience of the scientific collaboration agreement of the research group from DiAP, Sapienza University, Rome, with the municipality of Rome’s CSIMU (Coordination of Infrastructure Development and Urban Maintenance) Department to provide technical support in the phase of drawing up the DIP (Technical Project Brief) and of verifying and validating the PFTE (Technical and Economic Feasibility Design) within the Institutional Development Contract programme titled “CIS – Roma Scuole Verdi”. For its articulation of involved parties, complexity of the operative and regulatory framework, and size of interventions, CIS is considered a best practice of inter-institutional partnership and of capitalisation of technical know-how and skills aimed at achieving quality objectives in processes implementing strategic works.

Application of the FMECA method on the electro-hydraulic system for drilling machine type NKH45

This article focuses on the implementation of a preventive maintenance strategy, responding to a major challenge: the search for optimization in minimizing downtime of the radial drilling machine (NKH45). Crucially positioned at the heart of the mechanical manufacturing process, this machine holds significant influence on overall production performance and availability. In consideration of the strategic importance of this equipment within the framework of the mechanical manufacturing activity, an advanced methodology, in particular FMECA (Failure Mode Effects and Criticality Analysis), is implemented. FMECA represents one of the most recommended approaches in this context, based on reliability, allowing the meticulous identification of the main causes of functional failures of equipment. FMECA is a risk prevention method. It is used to improve the reliability of a product, a process or even a means of production. It makes it possible to assess the criticality of potential failures in a system. According to the recommendations of the maintenance department of the company specializing in the construction of agricultural equipment, this study will focus on a subsystem of the electro-hydraulic part of the NKH45 radial drilling machine, we use the FMEA Analysis method (Failure Mode Effects and Criticality Analysis). Thanks to this approach, it is possible to identify the main reasons for equipment breakdowns that affect production and to classify these breakdowns in order to develop an optimal maintenance strategy aimed at: reducing the number of breakdowns, preventing breakdowns, improving the preventive maintenance, reduce downtime, improve corrective maintenance, therefore the ultimate objective of this approach is to design an optimal maintenance action plan in order to significantly minimize downtime, which slows down production flow.

Research on safety condition assessment methodology for single tower steel box girder suspension bridges over the sea based on improved AHP-fuzzy comprehensive evaluation

In order to propose a reliable method for assessing the safety condition for single-tower steel box girder Suspension bridges over the sea, a condition monitoring system is established by installing sensors on the bridge structure. The system is capable of gathering monitoring data that influence the safety status of the bridge. These include cable tension, load on the main tower and pylon, bearing displacement, wind direction, wind speed, and ambient temperature and humidity. Furthermore, an improved Analytic Hierarchy Process (AHP) algorithm is developed by integrating a hybrid triangular fuzzy number logic structure. This improvement, coupled with comprehensive fuzzy evaluation methods, improves the consistency, weight determination, and security evaluation capabilities of the AHP algorithm. Finally, taking the No.2 Channel Bridge as an example and based on the data collected by the health monitoring system, the application of the safety assessment method proposed in this paper provides favorable results in evaluating the overall safety status of the bridge in practical engineering applications. This provides a basis for management decisions by bridge maintenance departments. This project confirms that the research results can provide a reliable method for assessing the security status of relevant areas.

Synchronisation of operations and maintenance in distributed unrelated parallel machine systems: a hierarchical optimisation framework

ABSTRACT Synchronisation of operations and maintenance means that production and maintenance departments work together effectively to achieve integrated optimisation of production scheduling and maintenance activities. This paper addresses such an integrated optimisation problem towards distributed unrelated parallel machine systems, where deteriorating processing time and machine failures are considered. For the trade-off between production and maintenance to obtain a minimal makespan in the worst-case scenario, a hierarchical optimisation framework with reinforcement learning-based encoder and knowledge-based intelligent optimiser (HOFRK) is developed. Experimental results show that HOFRK can be treated as an excellent optimiser for enterprise information systems to solve the proposed problem.