Maintenance Performance Measurement Research Articles

An adaptable end-to-end maintenance performance diagnostic framework

PurposeThis paper proposes a progressive, multi-level framework for diagnosing maintenance performance: rapid performance health checks of key performance for different equipment groups and end-to-end process diagnostics to further locate potential performance issues. A question-based performance evaluation approach is introduced to support the selection and derivation of case-specific indicators based on diagnostic aspects.Design/methodology/approachThe case research method is used to develop the proposed framework. The generic parts of the framework are built on existing maintenance performance measurement theories through a literature review. In the case study, empirical maintenance data of 196 emergency shutdown valves (ESDVs) are collected over a two-year period to support the development and validation of the proposed approach.FindingsTo improve processes, companies need a separate performance measurement structure. This paper suggests a hierarchical model in four layers (objective, domain, aspect and performance measurement) to facilitate the selection and derivation of indicators, which could potentially reduce management complexity and help prioritize continuous performance improvement. Examples of new indicators are derived from a case study that includes 196 ESDVs at an offshore oil and gas production plant.Originality/valueMethodological approaches to deriving various performance indicators have rarely been addressed in the maintenance field. The proposed diagnostic framework provides a structured way to identify and locate process performance issues by creating indicators that can bridge generic evaluation aspects and maintenance data. The framework is highly adaptive as data availability functions are used as inputs to generate indicators instead of passively filtering out non-applicable existing indicators.

Efficiency measurement based on novel performance measures in total productive maintenance (TPM) using a fuzzy integrated COPRAS and DEA method

Total Productive Maintenance (TPM) has been widely recognized as a strategic tool and lean manufacturing practice for improving manufacturing performance and sustainability, and therefore it has been successfully implemented in many organizations. The evaluation of TPM efficiency can assist companies in improving their operations across a variety of dimensions. This paper aims to propose a comprehensive and systematic framework for the evaluation of TPM performance. The proposed total productive maintenance performance measurement system (TPM PMS) is divided into four phases (e.g., design, evaluate, implement, and review): i) the design of new performance measures, ii) the evaluation of the new performance measures, iii) the implementation of the new performance measures to evaluate TPM performance, and iv) the reviewing of the TPM PMS. In the design phase, different types of performance measures impacting TPM are defined and analyzed by decision-makers. In the evaluation phase, novel performance measures are evaluated using the Fuzzy COmplex Proportional Assessment (FCOPRAS) method. In the implementation phase, a modified fuzzy data envelopment analysis (FDEA) is used to determine efficient and inefficient TPM performance with novel performance measures. In the review phase, TPM performance is periodically monitored, and the proposed TPM PMS is reviewed for successful implementation of TPM. A real-world case study from an international manufacturing company operating in the automotive industry is presented to demonstrate the applicability of the proposed TPM PMS. The main findings from the real-world case study showed that the proposed TPM PMS allows measuring TPM performance with different indicators especially soft ones, e.g., human-related, and supports decision makers by comparing the TPM performances of production lines and so prioritizing the most important preventive/predictive decisions and actions according to production lines, especially the ineffective ones in TPM program implementation. Therefore, this system can be considered a powerful monitoring tool and reliable evidence to make the implementation process of TPM more efficient in the real-world production environment.

Winter Road Friction Estimations via Multi-Source Road Weather Data—A Case Study of Alberta, Canada

Road friction has long been recognized as one of the most effective winter road maintenance (WRM) performance measures. It allows WRM personnel to make more informed decisions to improve their services and helps road users make trip-related decisions. In this paper, a machine-learning-based methodological framework was developed to model road friction using inputs from mobile road weather information systems (RWIS) that collect spatially continuous road weather data and road grip. This study also attempts to estimate friction using data from stationary RWIS that are installed far from each other, thereby leaving large areas unmonitored. To fill in the spatial gaps, a kriging interpolator was developed to create a continuous friction map. Slippery road risk levels were classified to provide an overview of road conditions via a risk warning map. The proposed method was evaluated with a selected highway segment in Alberta, Canada. Results show that the models developed herein are highly accurate (93.3%) in estimating friction and identifying dangerous road segments via a color-coded risk map. Given its high performance, the developed model has the potential for large-scale implementation to facilitate more efficient WRM services while also improving the safety and mobility of the traveling public.

Holistic multi-criteria performance measurement system for the maintenance function

Due to market globalization and technological development, companies are focusing more than ever on the performance of their maintenance function, which can only be achieved through a good performance measurement system. Although numerous works have been realized on this issue, there is still a lack of a flexible system that considers the particularities of each company and deals with all the performance measurement issues. For this reason, this paper introduces a maintenance performance measurement system, which allows the identification of all the relevant performance indicators using a hierarchical decomposition approach. Subsequently, the elementary performance indicators will be quantified using a measurement approach based on the fuzzy set theory, which deals with the unavailability and unreliability of data as well as time and resources limitation. Finally, an aggregation method based on the MACBETH method combined with the 2-additive Choquet integral was used in order to measure the global maintenance performance while considering the mutual interactions between the different criteria. Finally, to illustrate all these steps, the proposed system has been applied in a large Moroccan company operating in the chemical transformation sector.

Facility Maintenance Management and Its Effects on Employee Performance: A Positivist Approach

This study aims to investigate the role facility maintenance management plays on employee performance at a institution of higher learning in the Eastern Cape of South Africa.. This study employed a quantitative research approach, and the data were gathered from 150 employees who were chosen through a random sampling method. The data were analyzed using the Statistical Package for the Social Scientist (SPSS) Version 24.0. The analysis was of frequencies and standard deviations. The study findings revealed that the current facilities at the institution need an upgrade to a level that is conducive, suitable, and adequate for employees to perform their duties satisfactorily to reach the objectives of the institution. An efficient method for preparing, scheduling, and coordinating facility maintenance tasks needs to be applied to ensure effective maintenance service is performed effectively. This empirical study provided fruitful implications for academicians by making a significant contribution to the facility maintenance literature by systematically exploring the effect of facility maintenance management on the employee performance at a higher learning institution within the Eastern Cape province of South Africa. This study, consequently, stands to greatly add new knowledge to the existing literature related to maintenance performance measurement in Africa, a research setting that has been neglected by academic researchers of late.

Measuring sustainable cleaner maintenance hierarchical contributions of the car manufacturing industry

Sustainable cleaner maintenance (SCM) prevents waste and pollution by cost-effectively delivering the necessary maintenance activities and at the same time safe for the human. The presented study aimed to extend cleaner and sustainability by cascading down strategic business objectives by developing a balanced, integrated, and hierarchical Sustainable Cleaner Maintenance Performance Measurement Framework (SCMPMF). This framework enables a business strategy's functional alignment levels. The initial framework consists of 78 indicators concerning eight perspectives identified upon the reviews on previous research. Fourteen indicators are classified at the corporate level, 21 indicators at the tactical level, and 43 indicators at the functional level. The validation process is conducted by sending questionnaires to 200 car manufacturing companies (with a 50.5% response rate). Nine new perspectives (cost-effectiveness, quality, productivity, resource efficiency, pollution and waste, learning and growth, health and safety, employee satisfaction, and stakeholder satisfaction) were identified with 71 indicators. The Partial Least Squares – Structural Equation Modelling (PLS-SEM) approach is applied to validate this new structure of SCMPMF. This novel framework presents two main components, i.e. sustainable cleaner initiatives and hierarchical decision levels (corporate, tactical, and functional). This study provides empirical evidence regarding the ideal hierarchical structure of SCMPMF concerning three pillars of sustainability. The framework can assist decision-makers in capturing the important factors, perspectives, and indicators relevant for measuring the SCM contribution and align them with the corporate objectives.

The emerging organizational role of the maintenance function: a strategic perspective

PurposeWith the growing importance of performance measurement and management, this exploratory study intends to examine the practices of maintenance managers with regards to maintenance measures, as used in their organizations. In this process, the study attempts to uncover the relevant maintenance performance dimensions from the perspectives of the surveyed managers. In addition, the mediating effect of information availability on the main performance measures utilization is studied.Design/methodology/approachThe research at hand is survey-based. It utilizes the responses of a sample of ninety-five (95) experienced maintenance managers to identify the most relevant maintenance performance measures. Factor analysis is then utilized to uncover the important dimensions of performance, as seen by the respondents. Additionally, using the Partial Least Squares method, several models were studied.FindingsThe findings of this exploratory research appear to suggest that maintenance managers are beginning to broaden their perspective with regard to performance management. While machine and plant-related performance measures are still emphasized, maintenance managers are slowly moving toward a wider organizational orientation. While the manufacturing organizations are becoming more and more customer-oriented open systems, the maintenance function of these organizations is still, for the most part, operating under the semi-open system orientation. Overall, it appears that an emerging maintenance strategy is slowly taking shape.Research limitations/implicationsFor the most part, performance measures and measurement related to maintenance have not received enough attention from researchers. Therefore, the literature dealing with the different facets of performance in maintenance has not been forthcoming. The study attempts to fill this apparent gap in the literature. This is important, as maintenance managers are being asked to contribute to the achievement of the competitive strategies of their organizations. Therefore, they must quickly learn how to view maintenance from a coherent strategic organizational perspective. Such a perspective should help in integrating the maintenance, resources, capabilities, and technical know-how in order to serve the strategic goal of their organization. The research at hand is limited to a sample from Portugal. Therefore, the results and conclusions must be interpreted accordingly.Practical implicationsAs maintenance managers struggle to move from a machine-orientation to a more organizational-wide strategic orientation, they are often left with many questions and few answers. This study attempts to bring this problem to the spotlight so that it can receive more systematic empirical and practical research. In this context, the role of maintenance managers in the process of organizational strategy formulation should be examined.Originality/valueThe study presented in this article has practical, as well as theoretical contributions. It deals with an area of performance measurement, which so far has been relatively ignored. It uses a system orientation (closed vs open), in addition to the strategic orientation (single vs multi-faceted strategy) in order to shed some light on the need to have consistency between the nature of the system and its strategic objective.

Maintenance Performance of Prison Facilities in Southwestern Nigeria

Maintenance performance measurement aims to assess and improve the value created after maintenance efforts, as it determines the impact of maintenance on the performance of a system or facility and its business process. As objects of maintenance, prison facilities ought to provide a safe and decent environment for prison staff and prisoners to work and live in, as well as for all others who interact with the facilities. This study evaluates the satisfaction ratings of maintenance performance on prison facilities in Southwestern, Nigeria. A survey approach was adopted to collect data from the relevant Nigerian prison staff population of 2,187 prison workers, excluding staff in the maintenance unit within a specific period. Stratified sampling technique was used to generate a sample of 1,094, which is representative of the entire population across the prisons. Three hundred and eighty (35%) out of the one thousand and ninety-four copies of the questionnaire were completed and returned. Data collected were analysed using the SPSS package. The study found that prison staff showed satisfaction with the level of cleanliness in the prison environment, quality of water and control of ventilation employing a window, as well as partial satisfaction with the twenty-nine other criterion assessed. Overall, the study indicated partial satisfaction for performance on prison facilities and established a significant agreement among prison staff regarding the perception of the performance of prison facilities. The research, therefore, suggests continuous evaluation of maintained prison facilities to ascertain their condition and performance levels.
 Keywords: Maintenance Performance Criteria; Prison Facilities; Prison Staff; Satisfaction Ratings

Development of a model for maintenance performance measurement

Purpose The purpose of this paper is to develop a model that can measure the equipment maintenance performance of the energy company K-company. Design/methodology/approach The case study method was adopted for the investigation of maintenance performance indicators (MPIs). The development of a model for measuring maintenance performance suggested new ways to apply the methodologies of existing papers to evaluate the level of maintenance. Findings Maintenance indicators, which are managed differently for each plant, were assessed for their performance relevance, applicability and data reliability and then standardized into five key MPIs. The MPI model, which enables comprehensive and quantitative measurement of maintenance performance using the five selected MPIs, was presented, and the criteria for assessing the maintenance level were presented in five stages. Practical implications The authors selected MPIs that match the characteristics of the company and proposed a model that can comprehensively and quantitatively evaluate maintenance performance. The model also standardizes maintenance indicators that are individually managed and provides a basis for comparing and indexing the level of maintenance indicators at each plant. Originality/value The criterion for selecting the key MPIs considering the characteristics of the company and a model that can comprehensively and quantitatively evaluate maintenance performance were presented. In addition, a standard for evaluating the level of maintenance at the global level of maintenance management was suggested.

A coloured Petri net framework for modelling aircraft fleet maintenance

The aircraft fleet maintenance organisation is responsible for keeping aircraft in a safe, efficient operating condition. Through optimising the use of maintenance resources and the implementation of maintenance activities, fleet maintenance management aims to maximise fleet performance by, for example, ensuring there is minimal deviation from the planned operational schedule, that the number of unexpected failures is minimised or that maintenance cost is kept at a minimum. To obtain overall fleet performance, the performance of individual aircraft must first be known. The calculation of aircraft performance requires an accurate model of the fleet operation and maintenance processes. This paper aims to introduce a framework that can be used to build aircraft fleet maintenance models. A variety of CPN (coloured Petri nets) models are established to represent fleet maintenance activities and maintenance management, as well as the factors that have a significant impact on fleet maintenance including fleet operation, aircraft failure logic and component failure processes. Such CPN models provide an ideal structured framework for Monte Carlo simulation analysis, within which calculations can be performed in order to determine numerous fleet reliability and maintenance performance measures.

Zarządzanie utrzymaniem ruchu w zakładach komunikacji miejskiej w oparciu o zrównoważoną kartę wyników

Attending the important role of maintenance function in any production or service provider company, the measurement and assessment of maintenance performance is crucial for competitiveness and future survival. That situation is even more critical in urban transport fleets where some specific boundary conditions and special characteristics will affect maintenance policy and implementation. This paper presents a deep review of different studies worldwide to define the most proper and effective maintenance performance indicators, selecting and refining the most important ones to obtain a reduced maintenance management balanced scorecard. That balanced scorecard is proposed as a main tool for urban transport fleet maintenance managers to assess efficiency and effectiveness of maintenance processes and will be used as a basis for a future benchmarking process for this type of companies.

A systematic approach for maintenance performance measurement

PurposeThe purpose of this paper is to determine the maintenance performance indicators (MPIs) which are significant for maintenance decision making in the apparel industry through an accurate maintenance performance measurement.Design/methodology/approachA quantitative research approach was followed. A questionnaire survey was used to collect the data which were evaluated based on Mean Weighted Rating and Relative Importance Index.FindingsIn total, 15 significant MPIs were determined which can directly affect maintenance decision making. A systematic approach was finally developed by allocating weightages for each critical MPI.Practical implicationsThese results can be used to assist the decision-making process and as a performance measurement platform for maintenance management of the apparel industry.Originality/valueThe significance of maintenance has not been recognized and the value created through such massive efforts has remained hidden. Therefore, the need of adopting a performance-based approach for maintenance management in apparel industry exists. This research was aimed to provide a systematic approach to make decisions on maintenance management in the apparel industry in Sri Lanka.

Measuring the maintenance performance through fuzzy logic and analytical hierarchy process

The paper presents an innovative maintenance performance measurement system that organisations can adopt to identify those predictors that better contribute to achieve higher maintenance standards. Adopting a multi-level, multi-criteria decomposition technique designed to identify and classify key indicators, the study aims to support firms in their decision-making process. Using the fuzzy logic technique, the elementary performance measurement is quantified. Afterwards, by implementing the analytical hierarchy process (AHP) and the weighted arithmetic mean, these measures are aggregated to a holistic measure that quantifies the overall maintenance performance and identifies precisely the requirements to improve continuously and effectively the maintenance performance. Finally, the proposed model was applied to a Moroccan company leader in the chemical sector. The results show that the model effectively allows maintenance managers to properly measure and improve their maintenance performance and support managers in identifying the key actions to enhance their organisations' performance.

Measuring the maintenance performance through fuzzy logic and analytical hierarchy process

The paper presents an innovative maintenance performance measurement system that organisations can adopt to identify those predictors that better contribute to achieve higher maintenance standards. Adopting a multi-level, multi-criteria decomposition technique designed to identify and classify key indicators, the study aims to support firms in their decision-making process. Using the fuzzy logic technique, the elementary performance measurement is quantified. Afterwards, by implementing the analytical hierarchy process (AHP) and the weighted arithmetic mean, these measures are aggregated to a holistic measure that quantifies the overall maintenance performance and identifies precisely the requirements to improve continuously and effectively the maintenance performance. Finally, the proposed model was applied to a Moroccan company leader in the chemical sector. The results show that the model effectively allows maintenance managers to properly measure and improve their maintenance performance and support managers in identifying the key actions to enhance their organisations' performance.

Maintenance performance evaluation using an integrated approach of graph theory, ISM and matrix method

Operational performance of a plant and its competitiveness are dependent on reliability and maintainability of its equipment, which in turn are dependent on how these are designed and how effectively the maintenance activities are carried out. This paper proposes an integrated approach based on graph theory, interpretive structural modelling (ISM) and matrix method to quantitatively evaluate the maintenance performance leading to a numerical index, called as maintenance performance index (IMP). The approach is premised based on the fact that, the effectiveness of maintenance performance is a complex interaction of various factors prevailing in the plant. The index evaluates the maintenance performance by assessment of the individual maintenance functions, which the system is expected to fulfil. IMP is obtained from the Maintenance Performance Matrix by substituting the performance index, (IFP), of the individual maintenance functions and maintenance function’s interdependence values. Performance index of each individual maintenance function is obtained from the corresponding Function Performance Matrix, by substituting indicator characteristic values and indicator causal interrelationship values. This matrix is obtained by extracting the relationships among the indicators using the ISM approach. The ISM presents a hierarchy based model of the interrelated indicators and their significance in the measurement of maintenance performance. The methodology is demonstrated using a case study. The approach is premised based on the fact that, the effectiveness of maintenance performance is a complex interaction of various factors prevailing in the plant. The suggested methodology is convenient for the industry to hierarchically classify both subjective and objective performance parameters and in quantifying maintenance performance.

Machinery Maintenance Viewpoint: One Approach to an Improved Rural Road Traffic Safety in Southwest Nigeria

Local Governments (LGs), the third tier of government in Nigeria, are expected to maintain infrastructure facilities at the grass root level but most rural communities in Southwest Nigeria are characterized by poorly maintained roads. This study assessed conditions of Moveable Rural Road Maintenance Equipment (MRRME) under LGs in Southwest Nigeria vis-a-vis the safety levels on the rural roads. The study measured, impacts of roads conditions on commercial drivers/riders (cdr) and, level of usage of MRRME for the roads. Questionnaires were used to measure: accident rates and impacts among 250 cdr on 9 selected rural roads; Maintenance Performance Measures (MPM) of MRRME among 430 Senior Technical Officers (STOs) and Senior Finance Offices (SFOs) in 84 LG secretariats. The conditions of MRRME were carried out using observational method. More than 72% of cdr were involved in one crash or another and 89% of them attributed this to bad roads. Less than 26% of MRRME was functional with weak plans/tools put in place for correct maintenance program leading to a high level of MRRMEs’ failures and total neglect. T-test t (428) = -5.146, p = 0.421) found that the opinions of STOs (poor ratings for MPM policy implementation) were not different from that of the SFO. There is the need for safety attitudinal change among cdr. LGs also need empowerment to ensure proper maintenance of MRRME and enhances their availability. These measures among other will reduce accidents death counts on Nigeria rural roads.

Maintenance performance measurement – a case of the sugar industry

PurposeThe purpose of this paper is to present an empirical investigation of maintenance performance (MP) management practices from the sugar industry in India.Design/methodology/approachEmpirical data for this study were collected through field visits, interviews and published reports. Statistical methods including correlation, multiple regression and cluster analysis are utilized to accomplish the objective of the study.FindingsExplanation with multiple regression analysis showed that the sugar industry MP is significantly and positively related to maintenance approach (MA), continuous improvement (CI), financial approach and spare part management (SPM). Cluster analysis showed that sugar industries focusing on MA, CI and policy development and organization are having higher MP. The cluster analysis also pointed out that there is a substantial variation in MP due to the type of ownership (private and cooperative) while no variation has been observed due to installed capacity (low and high).Research limitations/implicationsThe generalization of the results obtained in this work for the sugar industry can be possible through a larger sample size.Practical implicationsThe study contributes to the better understanding of maintenance measures in the sugar industry and provides insights on the role of maintenance managerial practices in enhancing the MP.Originality/valueThe findings provide empirical evidence that maintenance practices across the sugar industry are important to improve MP.

Fuzzy Performance Measurement System for the Maintenance Function

Maintenance aims to sustain the manufacturing process by ensuring that the production tools are well managed. However, modern production means are more automated and therefore more complex, so they require a performing maintenance for which planning and implementation are increasingly difficult. This paper, therefore, emphasizes the elaboration of a maintenance performance measurement system. Therefore, for an appropriate and reliable performance evaluation, we adopt a multi-level multi-criteria approach where every criterion influencing the maintenance performance either indirectly or directly are specified. Thereafter, indicators for the specified criteria would be measured using fuzzy logic to overcome limitations due to lack of available resources and data. For a global maintenance measurement, the elementary measurements will be aggregated into a total measurement through a multiple-criteria decision-making method such as MACBETH.

Observing the effect of a policy: a maintenance case

Purpose– The purpose of this paper is to show that maintenance performance is potentially better predictable from recording routines.Design/methodology/approach– An attempt is made to observe an effect of a policy. Maintenance cases seem exceptional because of the efficiently obtainable evidence about policy violations which potentially provides access to the counterfactual reality to be avoided by the decision maker. The approach followed in this work is to use maintenance policy compliance to observe the effect of a maintenance policy.Findings– Conventional maintenance scorecards are not geared to accommodate maintenance performance predictions. The proposed alternative representation of maintenance performance indicators much better accommodates maintenance performance predictions.Research limitations/implications– This work focuses on the operationalisation and the sampling procedure of maintenance performance indicators; the selection of a predictive model is not considered.Practical implications– This work demonstrates that maintenance decision makers have the possibility to observe the effects of their policy, which potentially enables them to better control their objectives. This work provides guidelines to construct performance indicators that much better accommodate maintenance performance predictions than conventional maintenance performance indicators.Originality/value– The approach to make the effects of maintenance policy compliance observable is an original contribution to normative decision theory. To construct a maintenance scorecard that accommodates maintenance performance predictions is an original contribution to the field of maintenance performance measurement.

A MAINTENANCE PERFORMANCE MEASUREMENT FRAMEWORK THAT INCLUDES MAINTENANCE HUMAN FACTORS: A CASE STUDY FROM THE ELECTRICITY TRANSMISSION INDUSTRY

Over the past two to three decades, maintenance management has undergone a paradigm shift; it is no longer seen as a necessary evil, but as an integral part of the business process that creates value for the organisation. The next step in the evolution of maintenance management is a maintenance performance measurement that includes human factors. The human factors in maintenance are well- known in the aviation industry, as it gained momentum in the early 1990s after a series of serious aviation accidents. Other industries, however, have been slow to integrate the human factor in their maintenance performance measurements. This paper discusses the results of a research project that investigated the use and importance of maintenance management performance measurements that focus specifically on human factors as part of the overall performance management system. From the research presented in this paper, ‘motivation’ and ‘competence’ were identified as the most important human performance factors in the maintenance of electricity transmission systems.