Maintenance Performance Measurement Research Articles

Diagnosing Maintenance System Problems: Theory and a Case Study

Maintenance management is a well‐developed area in literature. Many strategies are available for implementing maintenance programs. However, there is an increasing concern about the function of maintenance and also the measurement of its performance practically. Maintenance performance measurement systems are of concepts developed in this regard. One reason many maintenance policies do not work properly, with regard to an organization's goals and performance measurement systems, is the lack of a systematic view on the maintenance system. In this paper, it is argued that it is important to take a broader view when dealing with maintenance problems in practice. An organizational perspective on maintenance is developed. The main idea behind this perspective is the organizational context of maintenance. This means that in addition to the traditional points for assessment and development of maintenance performance, other aspects need integrated attention as well. In order to develop a systematic viewpoint that comprehensively considers maintenance problem roots as well as leads to an increase in maintenance performance, a framework is developed in this paper. One of the main features of the framework is that it develops a systematic perspective on the design of a maintenance system. Besides, it leads to a comprehensive understanding of maintenance situations and factors that affect the performance of the system. Moreover, this study describes the result of a case study regarding the application of the organizational perspective to a practical maintenance problem. Copyright © 2012 John Wiley & Sons, Ltd.

Designing balanced scorecard for multi echelon repair inventory systems

PurposeA number of approaches have been suggested in the literature for maintenance performance measurement, including use of the balanced scorecard (BSC). However, its application towards assessing maintenance contribution to business objectives is limited. Currently, a framework integrating maintenance activities in a supply chain environment is lacking in the literature. The purpose of this paper is to develop a maintenance performance measurement framework using BSC for multi echelon repair inventory systems (MERIS) comprising of modular electronic equipment. The paper also suggests a large number of performance measures/indicators (PMs/PIs) pertaining to both maintenance and supply chain components including a few BSC implementation issues for such types of supply chains.Design/methodology/approachThe paper analyses a base model of a large maintenance organization and after carrying out SWOT analysis, identifies strategic themes/objectives for performance measurement. Performance measures for various objectives are identified for MERIS and implementation strategy including cascading of BSC is suggested. The developed performance measurement model is also validated using an action research (AR) based approach.FindingsA performance measurement system (PMS) for MERIS using BSC approach has been developed and an implementation strategy suggested. AR methodology is used for developing BSC for an organization using the selected performance measures. The importance of cause‐effect relationships between various performance objectives and measures is also established.Research limitations/implicationsQuantification of each of the developed PMs/PIs and establishing an effective information system for MERIS are the limitations of the present work and may be taken up for more research.Practical implicationsThe paper will be useful for practitioners in the field of MERIS of electronic repairables wherein relevant PMs/PIs can be selected for implementation as per the requirement of the application.Originality/valueThe paper is of value by being original, as no work towards performance measurement of MERIS using BSC concept (as applicable for non‐profit organizations like military, government, NGOs etc) is reported in literature so far. The paper is relevant in this context and its contribution lies in the area of performance measurement.

The customer satisfaction of maintenance as a factor in improving the performance of maintenance

This paper presents a case study fulfilled at the maintenance sector of a metallurgical company. The research problem addressed was the satisfactions level of customers of the maintenance. The objective was to quantify the performance of preventive and corrective maintenance, mechanical and electrical, in relation to customer satisfaction. To achieve this aim, we conducted an applied research, quantitative, developed by a case study. With the knowledge of some theoretical models of performance measurement, we adopted the Key Performance Indicators - KPI - as the most suitable method for measuring proposal. With this, it developed questionnaires to assess the satisfaction of the performance of maintenance. After the data collection, spreadsheets were created to quantify the answers to the questionnaires. The results of this study present the responses to the seven requirements that assess the satisfaction of preventive maintenance and six requirements that assess customer satisfaction of corrective maintenance services. It is concluded that the measurement of maintenance performance, by measuring customer satisfaction becomes important criterion for planning and ascertainment of industry guidelines for maintenance of the company.

Achieving sustainable development through maintenance excellence

Sustainability has been broadly defined as providing goods and services for current and future generations. Industries play a main role in that definition so more and more industries are working today to achieve sustainable development for their industry. Achieving a sustainable development needs strategic and continuous efforts involving the entire organization, where maintenance efforts play an important role. The management needs to understand and develop an appropriate strategic approach to understand the challenges involved and preparing all involved groups and personnel to achieve the sustainable development through application of maintenance performance measurement. Maintenance performance needs to be measured for managing and achieving the business objectives with a sustainable development goal. Maintenance plays a vital role in managing safety, energy saving, plant and machineries failure and productivity amongst others. To manage these activities, appropriate policy and planning is required to be developed enveloping the entire organization and necessary performance indicators are required to be identified to meet the unique requirements of the organization. In this paper, the authors have tried to discuss the issues and challenges associated with sustainable development with reference to maintenance performance measurement to achieve maintenance excellence.

A literature review of maintenance performance measurement

PurposeThis research aims to examine the relevant literature related to maintenance performance measurement in the manufacturing sector. In the process, innovative approaches and models utilized to measure and manage maintenance performance in manufacturing operational settings are classified and examined. Based on this investigation, future research directions and themes are identified.Design/methodology/approachA database of 251 peer‐reviewed publications, published during the last 30 years, was utilized for the purpose of this research. The published works included contributions from both practitioners and scholars.FindingsThis literature review‐based research revealed important themes related to evolution of maintenance performance management. These themes focus on the effective utilization of maintenance resources, information systems support, and human factor management. Based on this literature review, a conceptual framework, which traces the different operational and organizational facets of the evolution of maintenance performance management, is offered.Research limitations/implicationsBased on the findings of this study, it is concluded that the area of maintenance performance and management is in need of more future systematic research efforts aimed at solidifying theoretical constructs and promoting the utilization of more practical applications.Practical implicationsFindings derived from this investigation have relevant manufacturing implications. In this context, understanding the different approaches to maintenance performance measurement and management, as utilized in manufacturing organizations, is critical to these organizations' performance improvement efforts.Originality/valueUnderstanding the types and scopes of the different approaches and models utilized to manage and measure maintenance performance in manufacturing operational settings is important in light of the growing competitiveness of the manufacturing sector.

Identification and Tracking of Highway Bridge Maintenance

An overview of practices for highway bridge maintenance of state transportation departments (DOTs) in the United States is presented. DOT practices are given in the areas of identification of maintenance needs, numbering systems for maintenance actions, performance and priority measures related to maintenance, and data systems engaged by maintenance. The overview finds that DOTs have similar work procedures for identification and tracking of maintenance needs and somewhat similar approaches to performance and priority measures, but dissimilar practices in numbering systems for maintenance actions. Most DOTs use one or more individualized data systems to track maintenance work, monitor network-level performance, and evaluate maintenance work plans. The information presented is one product of studies of bridge maintenance decision making and bridge database development.

Data and Modeling Issues Faced during the Efficiency Measurement of Road Maintenance Using Data Envelopment Analysis

Within the past two decades, the road maintenance concept has been gaining tremendous attention. This has brought about new institutional changes, predominant of which is the challenge for maintenance managers to achieve maximum performance from the existing road system. Such challenge makes it imperative to implement comprehensive systems that measure road maintenance performance. However, as pointed out by the Transportation Research Board, even though the road maintenance performance measurement systems developed and implemented by the state departments of transportation elaborate on the maintenance level of service (i.e., effectiveness of the road maintenance), the fundamental relationships between the maintenance level of service and the budget requirements (i.e., efficiency of road maintenance) need more investigation. This is mainly because not knowing how “efficient” state departments of transportation are in being “effective” can lead to excessive and unrealistic maintenance budget expectations. ...

LA PROBLEMÁTICA DE LA MEDICIÓN DEL RENDIMIENTO EN LA FUNCIÓN MANTENIMIENTO.

The measurement of maintenance performance comes from a lack of basic concepts in the maintenance department of the company, and consequently, the lack of appropriate objectives emanating from the overall mission and vision towards it. It produces metrics not adapted to the real needs of the company due to the lack of knowledge about them, with a major human factor load and with no roadmap for the amount of data to collect, its processing and its use in decision making. For this purpose we propose a mixed model that combines the qualitative aspects of surveys, with the quantitative aspects of indicators, these ones grouped according to a framework in the form of balanced scorecard, adapted to the user or hierarchical level responsible for them.

Empirical analysis of maintenance performance measurement in Belgian industries

Performance measurement is a fundamental instrument of management. For maintenance management, one of the key issues is to ensure the maintenance activities planned and executed have given the expected results. This can be facilitated by effective use of rigorously defined key performance indicators (KPI) that are able to measure important aspects of maintenance function. In this paper, an industrial survey was carried out to explore the use of performance measurement in maintenance management. Based on survey responses, analyses were performed on popularly used KPI, how these KPI are sourced or chosen; the influence of manufacturing environment and maintenance objectives on KPI choice and effective use of these KPI in decision support and performance improvement. It was found that maintenance performance measurement is dominated by lagging indicators (equipment, maintenance cost and safety performance). There is lesser use of leading (maintenance work process) indicators. The results showed no direct correlations between the maintenance objectives pursued and the KPI used. Further analysis showed that only a minority of the companies have a high percentage of decisions and changes triggered by KPI use and only a few are satisfied with their performance measurement systems. Correlation analysis showed a strong positive linear relationship between degree of satisfaction and process changes/decisions triggered by KPI use, with the least satisfied people having the least decisions and changes triggered by KPI use. The results indicate some ineffectiveness of performance measurement systems in driving performance improvement in industries.

The effect of applying tacit knowledge on maintenance performance: an empirical study of the energy sector in the UK and Arab countries

The purpose of this paper is to examine the sharing of tacit knowledge among members of the maintenance team and to measure the level of maintenance performance, particularly by three maintenance performance measures: mean time between failures (MTBF), mean time to repair (MTTR), and mean waiting time (MWT). Moreover, the study is based on a questionnaire survey of the energy sector in both the UK and the Arab countries (96 companies in total, 48 from each region) to investigate the relationship between the sharing of tacit knowledge and maintenance performance, and to perform a comparison between the regions. The questionnaire was conducted through the postal service, online, and some interviews. This paper provides evidence that the sharing of tacit knowledge influences team maintenance performance, which enhances the efficiency of the measures offered. It also concludes that sharing of tacit knowledge and transferring it become explicit knowledge, which is stronger in the UK than in the Arab countries. The paper offers several applications to help maintenance managers begin to think about sharing tacit knowledge culture as an independent entity and, accordingly, being able to manage it. Furthermore, this approach should be considered by other sectors as well. Finally, the originality value of this paper suggests empirical support between technical knowledge (know-how) and their effects on performance measures of the maintenance function. There is a scarcity of research in this field.

Improving maintenance cost allocation process and performance measurement in the petroleum industry using activity based cost management approach "a field case study "

Improving maintenance cost allocation process and performance measurement in the petroleum industry using activity based cost management approach "a field case study "

An inflation-based maintenance profitability model

The maintenance profitability problem is an important but emerging concept of maintenance performance measurement that views the maintenance function as a value adding subsection of the organisation. The service provided by the maintenance system to production is charged as a price, which results in the monetary contribution of the maintenance department to the organisation. In the same way, as production would add financial benefits to the organisation the maintenance system is portrayed as adding profit to the organisation. In this work, we present a mathematical model that calculates the maintenance profitability of an organisation under the condition of inflation using a composite mathematical function. It is concluded that viewing maintenance from a profit-making orientation provides a challenge to the maintenance team, thus driving them towards improved performance.

Study and analysis of maintenance performance indicators (MPIs) for LKAB

PurposeThe purpose of this case study is to identify and develop maintenance performance indicators (MPIs) for a mineral processing plant producing high quality iron ore pellets, as well as studying and analyzing the short plant stops and planned maintenance stops.Design/methodology/approachAn action research approach was adopted for this study, with interactive process of interviews. The existing MPIs are analyzed and a set of MPIs are developed to measure the performance of balling area of the pelletization plant, where the effect of shorter stops in the process have been studied, analyzed and measured, and linked to the management's objectives. The utility of the MPIs are tested and validated within the framework of a multi‐criterion and hierarchical maintenance performance measurement (MPM) framework. The plant stop data of the plant were collected and analyzed for MPIs and for maintenance decision making. Some other criteria were also considered from a holistic, integrated and balanced viewpoint in the model.FindingsThis study resulted in identifying a set of MPIs for the operational level of the pelletization plant of LKAB, after analyzing the short plant stops and planned maintenance stops data, and the stakeholders' requirements. This study has identified nine MPIs at operational level or shop floor level that describe the status of plant and at the same time facilitates linking of plant performance with corporate strategy.Practical implicationsThe approach used in the paper to study, analyze and develop MPIs, can be useful for plant managers and asset owners to select and develop MPIs that can describe the health status of their plant and asset and that also can be linked to the corporate strategy. The framework used to verify the multi‐criteria hierarchical framework can also be used by similar asset managers and infrastructure owners. This study has also lifted the impact of short duration stoppages, thus highlighting the total influence in terms of reduced life length, quality and productivity. This approach can be used by plant engineers, asset managers and infrastructure owners to assess the performance of maintenance process.Originality/valueThis paper presents an approach for identifying MPIs relevant to the plant status and facilitating measuring maintenance performance at corporate level in a structured way.

Development of a multi‐criteria hierarchical framework for maintenance performance measurement (MPM)

PurposeThe purpose of this study is to develop a multi‐criteria hierarchical maintenance performance measurement framework, which is balanced, holistic and integrated to various levels of the organization.Design/methodology/approachConsolidation of published research and current practices are combined to study, identify and develop this proposed framework.FindingsA framework for maintenance performance measurement is proposed for developing and implementing a relevant, timely, reliable, cost and time‐effective and user‐friendly system for stakeholders at various levels. The indicators at the subsystem/component level, plant level and corporate level are linked with the MPIs for the organizational objectives and strategy.Practical implicationsManagement of maintenance performance is critical for long term economic viability of business and industry. Development of an integrated, balanced and holistic MPM system needs to consider various issues to measure the contribution of maintenance towards total business goals. In this paper, a multi‐criteria hierarchical MPM framework has been developed. This framework can be used by the operating managers for their maintenance decisions at various levels of an organization.Originality/valueThe paper presents a proposed MPM framework, which is integrated, and focuses on both internal and external effectiveness.

Performance‐based maintenance partnering: a promising concept

PurposePerformance‐based maintenance partnerships promise benefits compared to traditional tendering of maintenance projects. The paper aims to give process models and examples of performance requirements and measurement methods for buildings and facilities managers.Design/methodology/approachCase studies of housing associations' current procurement and outsourcing methods have been performed, including an examination of initiatives for performance‐based partnerships. Purchasers and technical managers of housing associations and directors of medium‐sized maintenance contractors were interviewed, asking about the objectives, expected benefits and drawbacks of maintenance partnering. Maintenance performance requirements and measurement methods for the exterior envelope of housing estates were developed, based on the functions of building components. The maintenance partnering process has been modelled in three partnership forms, based on the case studies and interviews.FindingsThe process models and the decisive maintenance performance requirements for building components are interesting concepts for buildings and facilities managers, changing their orientation from cost of services to value and performance.Research limitations/implicationsThe process models were discussed with clients and maintenance contractor. Its validity is being tested in practice. Clients fear that price competition will be affected by entering into long‐term co‐operative arrangements with maintenance contractors and service providers. Thus, there is a need for studies that investigate the direct and indirect cost savings from performance‐based maintenance partnering.Originality/valueLong‐term performance‐based maintenance partnering for the entire exterior envelope is something new. It focuses on re‐design, construction, and maintenance by the maintenance contractor.

Maintenance performance measurement (MPM): issues and challenges

PurposeThe purpose of this study is to identify various issues and challenges associated with development and implementation of a maintenance performance measurement (MPM) system.Design/methodology/approachAn analytical approach is adopted to identify the issues and challenges associated with MPM.FindingsThe study finds that for successful implementation of MPM all employees should be involved and all relevant issues need to be considered. Furthermore, the traditional overall equipment effectiveness (OEE) used by the companies is inadequate, as it only measures the internal effectiveness. For measuring the total maintenance effectiveness both internal and external effectiveness should be considered.Practical implicationsWhat cannot be measured cannot be managed effectively. To manage maintenance process operating managers and asset owners need to measure the contribution of maintenance towards their business goals. This paper discusses issues and challenges associated with MPM system, there by helping the managers to take care of the pitfalls of the MPM system and advocates that managers should focus on measuring the total effectiveness of maintenance process.Originality/valueThe paper presents a concept of total maintenance effectiveness with focus on both internal and external effectiveness, and integration of the hierarchical levels and multi‐criteria maintenance performance indicators of MPM system.

Measuring maintenance performance using a balanced scorecard approach

PurposeThe purpose of this paper is to develop a strategic maintenance performance measurement system.Design/methodology/approachIn response to this purpose, a balanced scorecard framework was adopted to assess the contribution of support functions (such as maintenance) to strategic business objectives. A case study approach was used to test the suggested framework at a Swedish paper mill.FindingsIt was found that by using the suggested framework it was possible to measure and identify the cause‐and‐effect relationship of using an effective maintenance strategy, and assess its impact on the company's competitive advantages. For example, it was found that there is potential to, ideally, improve the company's return on investment (ROI) by 9 per cent. This figure represents a projected US$8.4 million in lost profits, which are caused by planned inoperative time and overall equipment effectiveness (OEE) elements. At least 14 per cent of the ROI potential improvements are directly related to the maintenance function as lost profit, which is due to unplanned stoppages and bad quality caused by maintenance‐related problems.Practical implicationsUsing the modified BSC provides a framework whereby the contribution of support functions (for example, maintenance) to the strategic business objectives can be assessed. The modified BSC makes it easier for the maintenance and production staff who are technically oriented to communicate with top management in terms that managers understand, i.e. in terms of money. Furthermore, this approach facilitates the making of cost‐effective decisions.Originality/valueThe present study contributes to our knowledge of this process by changing the status of the “maintenance function”. This is done by showing that maintenance is no longer a cost centre, but should be regarded as a profit generating function.

Simple Map-Matching Algorithm Applied to Intelligent Winter Maintenance Vehicle Data

Intelligent winter maintenance vehicles are equipped with automatic vehicle location (AVL) technology, including differential Global Positioning System (DGPS) receivers and various additional sensors that collect equipment status and material use data. DGPS data points are associated with the nearest roadway centerline by calculating minimum perpendicular distances between each roadway centerline representation and the DGPS data points. Highly accurate roadway centerline maps and DGPS measurements are not always available. Thus, spatial mismatches may occur at converging and diverging roadways, divided highways, and intersections. Decision makers use winter maintenance performance measures to evaluate achievement of goals and objectives and to improve winter maintenance operations in public agencies. These performance measures are sensitive to spatial mismatches, which need to be resolved before calculations are done. This paper presents a simple map-matching algorithm that resolves spatial ambiguities by determining the correct roadway centerline on which the vehicle is traveling. The algorithm computes shortest paths between snapped DGPS data points using network topology and turn restrictions. A path is considered viable, and locations for the snapped DGPS data points correct, if similarity exists between values of calculated and recorded vehicle speeds. If a path is not feasible, DGPS points are snapped to alternative roadway centerlines contained within their buffers, shortest paths are recalculated, and speeds are again compared. Examples are presented to illustrate the implementation and effectiveness of the algorithm.

Simple Map-Matching Algorithm Applied to Intelligent Winter Maintenance Vehicle Data

Intelligent winter maintenance vehicles are equipped with automatic vehicle location (AVL) technology, including differential Global Positioning System (DGPS) receivers and various additional sensors that collect equipment status and material use data. DGPS data points are associated with the nearest roadway centerline by calculating minimum perpendicular distances between each roadway centerline representation and the DGPS data points. Highly accurate roadway centerline maps and DGPS measurements are not always available. Thus, spatial mismatches may occur at converging and diverging roadways, divided highways, and intersections. Decision makers use winter maintenance performance measures to evaluate achievement of goals and objectives and to improve winter maintenance operations in public agencies. These performance measures are sensitive to spatial mismatches, which need to be resolved before calculations are done. This paper presents a simple map-matching algorithm that resolves spatial ambiguities by determining the correct roadway centerline on which the vehicle is traveling. The algorithm computes shortest paths between snapped DGPS data points using network topology and turn restrictions. A path is considered viable, and locations for the snapped DGPS data points correct, if similarity exists between values of calculated and recorded vehicle speeds. If a path is not feasible, DGPS points are snapped to alternative roadway centerlines contained within their buffers, shortest paths are recalculated, and speeds are again compared. Examples are presented to illustrate the implementation and effectiveness of the algorithm.

Enhancing a company's profitability and competitiveness using integrated vibration-based maintenance: A case study

In this paper a model is developed for identifying, monitoring and improving the economic impact of vibration-based maintenance (VBM). This model provides an additional possibility of identifying where, why and how much capital should be invested, and judges whether or not the investment was cost-effective. The model is further utilised to develop relevant maintenance performance measures. When the model was tested in a Swedish paper mill, the main results were: the average yearly maintenance profit achieved using integrated VBM was at least 3.58 million Swedish kronor (SEK) (approximately US$0.358 million), and average potential savings (economic losses) were around SEK 30 million (US$3 million). Furthermore, the model facilitated identification of problem areas and recognition of where investments should be made. The major conclusion is that the better the data coverage and quality, the greater control is possible over direct maintenance costs, savings and further profits in maintenance. Moreover, using the model it would be easier and more reliable to detect deviations in the maintenance performance and eliminate their causes at an early stage.