Maintenance Strategy Selection for Continuously Operated Beverage Industry Utility Machines: A case Study
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Date
2020-06
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Addis Ababa University
Abstract
This research paper focuses on a case company where downtimes from set of utility machines are
a major setback to the main production lines due to extensive breakdowns. Nailing down the
management to focus on firefighting, the downtimes had an effect on the departments KPIs and
the company’s profitability.
Onwards, the research sets on finding the right maintenance strategy for each set of utility subsystem.
This
was
accomplished
by
first
filtering
the
information
gained
from
the
company’s
ERP
system
by
an
aid
of
AHP
and
Pareto
tools
to
select
the
downtime
causes
that
can
be
controlled
and
critically
affects
the
output
delivery
of
the
machines.
Thereafter,
the
data
gained
was
used
as
an
input
for
a
proved
maintenance
strategy
selection
tool
of
DMG
to
select
a
maintenance
strategy
for
each
set
of
machines
in
the
utility
system.
From the analysis, the most machines contributing to the downtimes were identified, and a
maintenance strategy as well as maintenance policy was suggested. A Design out Maintenance
was proposed from the DMG tool for the electric supply system and the HP compressor that mainly
contributed for most of the downtime accounting for a total of 71%.
Though the integration of AHP and DMG tool is new in the selection of maintenance strategy for
continuous operating utility set of machines, it matched the current situation with the management
decisions on modifying the design of the two mentioned systems, showing it can also be useful in
maintenance strategy selection of such continuous operating equipment.
The strategies selected for each sub plant and a continued use of this tool is expected to save 39
million birr and 26,106,000 bottles worth of production time. This estimate is considered to bring
the new downtime rate of the department to an acceptable level of 0.92%, which is below the
company standard of 2.5%. In addition, following a maintenance strategy aids management to get
rid of firefighting mentality to focus on proactive maintenance.
Description
Keywords
Industry Utility Machines, Beverage Industry, Maintenance, Strategy