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On Condition Based Maintenance and its Implementation in Industrial Settings
Publication Type:
Doctoral Thesis
Publisher:
Mälardalen University Press Dissertation
Abstract
In order to stay competitive, it is necessary for companies to continuously increase the
effectiveness and efficiency of their production processes. Production strategies such as Justin-
Time and Lean Production demand high availability of production equipment in order to
meet customer satisfaction. Therefore, maintenance has gained in importance as a support
function for ensuring equipment availability, quality products, on-time deliveries, and plant
safety. Maintenance, though, is a costly support function. It has been reported that as much
as 70% of the total production cost can be spent on maintenance. Further, as much as onethird
of the cost of maintenance is incurred unnecessarily due to bad planning, overtime cost,
limited or misused preventive maintenance, and so on.
Well-performed maintenance implies seeing as few corrective maintenance actions as possible
while performing as little preventive maintenance as possible. This might seem as a utopia,
but during the past decades strategies and concepts have evolved for support. One of these is
condition based maintenance. In condition based maintenance, critical item characteristics are
monitored (through, for example, vibration or temperature monitoring) in order to gain early
indications of an incipient failure. Research, though, has shown that condition based
maintenance has not been implemented on a wide basis. Therefore, the purpose of this
research is to investigate how a condition based maintenance approach can be implemented
in an industrial setting, and to develop a method that can assist companies in their
implementation efforts. Further, the research has been divided in three research questions.
The first focuses on condition based maintenance as an approach; seeking constituents
essential to take into consideration when implementing the approach. The second focuses on
the decision-making process prior an implementation can commence. Finally, the third
focuses on the implementation of the condition based maintenance approach in a company.
By using a systems approach and a case study process, how condition based maintenance can
be implemented as a routine has been investigated. The result is an implementation method
in which four suggested phases are presented. The method starts with a feasibility test. It then
continues with an analysis phase, an implementation phase, and an assessment phase. These
steps are taken in order, for example, to invest in the proper condition based maintenance
approach and to implement it gradually. The conclusions can be summarized as follows:
implementing condition based maintenance consists of many general enabling factors,
including management support, education and training, good communication, and motivation
etc.
Bibtex
@phdthesis{Bengtsson1457,
author = {Marcus Bengtsson},
title = {On Condition Based Maintenance and its Implementation in Industrial Settings},
number = {48},
month = {November},
year = {2007},
school = {M{\"a}lardalen University Press Dissertation},
url = {http://www.ipr.mdu.se/publications/1457-}
}