PART B

Introduction:

In today's competitive industrial landscape, the optimization of production processes is paramount for
ensuring operational efficiency, product quality, and customer satisfaction. Advanced maintenance
practices play a pivotal role in achieving these objectives by minimizing downtime, reducing costs, and
enhancing overall productivity. This introduction sets the stage for evaluating and implementing such
practices within the context of Polar Crush, a local beverage company facing challenges in its
production line operations.
This work aims to address the deficiencies in maintenance strategies observed at Polar Crush, focusing
on the implementation of advanced maintenance techniques to mitigate frequent breakdowns and
improve production line reliability. By critically analyzing the existing operations and maintenance
framework, this study seeks to enhance the company's understanding of its engineering operations
function and management components.
Key objectives include:
1. Assessing the current maintenance landscape and identifying areas for improvement.
2. Proposing and evaluating appropriate advanced maintenance strategies tailored to the specific needs
of Polar Crush.
3. Highlighting the potential benefits of adopting proactive maintenance approaches, such as predictive
maintenance and Total Productive Maintenance (TPM), in optimizing production processes and
minimizing disruptions.

Through this examination, the assignment endeavors to foster a deeper critical awareness of
engineering operations management principles and equip stakeholders with the knowledge and tools
necessary to enhance operational effectiveness and competitiveness in the market.
The Literature Review

- Reactive maintenance.

Reactive maintenance, also known as corrective maintenance or breakdown maintenance, is a strategy

where maintenance actions are taken after a failure has occurred. This approach is characterized by its
responsiveness to unexpected breakdowns rather than pre-emptive actions (Rukijkanpanich &
Mingmongkol, 2019). While reactive maintenance can minimize immediate costs in terms of
manpower and money, it can lead to unpredictability in maintenance schedules, fluctuating operations,
and increased overall maintenance costs when catastrophic failures happen (Solms & Meyer, 2021).
Over the centuries, maintenance strategies have evolved to include a mix of reactive, preventive, and
predictive maintenance approaches (Lundgren et al., 2021). Preventive maintenance, a proactive
strategy that involves scheduled inspections and maintenance tasks to prevent failures, has been
identified as a key component in maintaining high-rise residential buildings (Chua et al., 2018). In
contrast, reactive maintenance is often associated with increased costs and operational disruptions due
to its unplanned nature (Solms & Meyer, 2021).

Studies have shown that organisms, including humans, make trade-offs in their life history strategies
concerning growth, maintenance, and reproduction (Dishakjian et al., 2020). These trade-offs are
essential for understanding how different species allocate resources to ensure survival and reproductive
success. Reactive maintenance, as part of these strategies, reflects a balance between immediate
response to failures and the long-term maintenance of systems (Dishakjian et al., 2020).

- Planned maintenance, and Preventive maintenance.

Maintenance strategies have evolved over time to address the challenges of ensuring the longevity and
efficiency of various systems and structures. Two key maintenance strategies that have been
extensively studied are planned maintenance and preventive maintenance. Planned maintenance
involves setting long-term goals for maintaining buildings or components and making short-term
adjustments based on new information (Lind & Muyingo, 2012). On the other hand, preventive
maintenance focuses on improving the efficiency of maintenance actions to allow for less frequent
maintenance by increasing the time between actions (Dellagi & Darghouth, 2021).

Research has shown that maintenance activities are crucial, especially for older building stocks from
past decades that require renovation or demolition (Lind & Muyingo, 2012). Additionally, the
reliability-centered maintenance (RCM) strategy has been highlighted as an organized framework for
enhancing the reliability of power distribution systems and reducing maintenance costs through
cost/benefit analyses and reliability assessments (Firouz & Ghadimi, 2015).

In the context of manufacturing systems, integrated maintenance and spare parts management have
been explored to consider the impact of production rate variations on system degradation and optimal
maintenance strategies (Dellagi et al., 2020). Furthermore, the importance of establishing maintenance
strategies based on the service life of components has been emphasized for safety, cost-effectiveness,
and occupant satisfaction (Park et al., 2018).

The literature also discusses the significance of selecting suitable maintenance strategies, such as
proactive and aggressive approaches, using fuzzy logic modeling and historical data to improve
maintenance decision-making (Sharma et al., 2005). Moreover, studies have addressed the optimization
of maintenance strategies considering imperfect preventive maintenance and the hybrid hazard rate
model to enhance maintenance effectiveness (Li et al., 2021).

- Total Productive Maintenance (TPM).

Total Productive Maintenance (TPM) is a comprehensive culture and philosophy that revolutionizes the
approach towards maintenance (Ahuja & Khamba, 2008). The implementation of TPM involves key
constructs such as disciplined maintenance, information tracking, housekeeping, and operator
involvement, which are crucial for enhancing operational performance (Modgil & Sharma, 2016).
Reliable manufacturing equipment is essential for the performance and profitability of manufacturing
systems, emphasizing the importance of TPM in ensuring operational efficiency (Jain et al., 2015).

Furthermore, integrating TPM with methodologies like Total Quality Management (TQM) has been
explored to enhance manufacturing performance. While Just-In-Time (JIT), TQM, and Employee
Involvement (EI) are recognized for their contributions to manufacturing performance, synergistically
implementing TPM alongside these strategies can further elevate operational excellence (McKone et
al., 2000). Additionally, combining TPM with methodologies like Quality Function Deployment (QFD)
offers a novel approach to improving quality in maintenance engineering, demonstrating the versatility
and adaptability of TPM in various contexts (Pramod et al., 2006).
However, the successful implementation of TPM faces challenges such as organizational barriers
including political, financial, departmental, and inter-occupational hurdles, which can impede effective
adoption of TPM practices (Cooke, 2000). Overcoming these obstacles requires a concerted effort
towards managing commitment and organizational change, highlighting the need for a strategic and
holistic approach to TPM implementation (Hansson et al., 2003).

- Reliability Centred Maintenance (RCM).

Maintenance strategies have evolved over time, with various approaches developed to optimize the
upkeep of different assets. One prominent strategy is Reliability Centered Maintenance (RCM), which
focuses on identifying the most efficient maintenance tasks to ensure equipment reliability (Jiang,
2024). However, the application of maintenance strategies like RCM may have limitations, such as the
challenge of ranking maintenance alternatives to select the optimal solution (Emovon et al., 2015).

Studies have explored different paradigms and solution approaches for maintenance strategy selection,
emphasizing the need for comprehensive reviews to address research gaps and enhance decision-
making processes (Patil et al., 2021). Additionally, the use of hybrid models, such as those
incorporating the PROMETHEE method, has been proposed to optimize maintenance policies in
specific sectors like hydroelectric power plants (Özcan et al., 2021).

Furthermore, research has investigated the impact of maintenance interventions on heritage buildings
over centuries, underscoring the importance of understanding the effectiveness of maintenance,
rehabilitation, and other interventions on the functionality of historical structures (Prieto et al., 2019).
In the context of modern infrastructure, fuzzy logic models have been developed to benchmark
maintenance strategies for concrete structures, aiming to identify the best combination of maintenance
approaches (Peiris & Silva, 2019).

The selection of maintenance strategies involves complex decision-making processes, often utilizing
methods like decision-making grids and Jack-Knife diagrams to compare different approaches
(Seecharan et al., 2018). Moreover, the integration of maintenance data sets using manual and
computer-based tools has been observed in various industries, highlighting the importance of
standardization and knowledge management in optimizing maintenance practices (Wakiru et al., 2021).
- Condition monitoring applications in the advances of Industry 4.0
Maintenance strategies have evolved over time, with various paradigms and solution approaches being
developed to address challenges in different industries. The selection of maintenance strategies
involves a comprehensive review of current practices and methodologies (Patil et al., 2021). These
strategies encompass a range of approaches, including condition monitoring, which has advanced
significantly with the emergence of Industry 4.0 technologies.

Recent research has focused on the application of condition monitoring within the context of Industry
4.0. The integration of technologies such as predictive maintenance, IoT sensors, and data analytics has
transformed maintenance practices, enabling real-time monitoring and predictive maintenance
interventions (Cauchi et al., 2018). This shift towards data-driven decision-making has enhanced the
efficiency and effectiveness of maintenance strategies, particularly in smart buildings and industrial
settings.

Studies have highlighted the importance of energy efficiency in maintenance strategies, emphasizing
the relationship between maintenance practices and energy consumption (Firdaus et al., 2023).
Sustainable maintenance approaches are crucial for optimizing energy usage while ensuring equipment
reliability, leading to cost savings and environmental sustainability goals.

The selection of maintenance strategies involves complex decision-making processes. Various

methodologies such as Analytic Hierarchy Process (AHP), Genetic Algorithms, and Multiple-Criteria
Decision Analysis (MCDM) have been utilized to optimize maintenance strategy selection (Kurian et
al., 2019; Arjomandi et al., 2021; Emovon et al., 2015). These decision support tools assist in
evaluating criteria like cost, resources, failures, and safety to determine the most suitable maintenance
approach for specific industrial contexts (Jawwad & AbuNaffa, 2021).
CALCULATIONS
Hypothetical Data
ITEM DATA

Shift Length 9 hours = 540min

Short Breaks 2 @ 30 min = 60 min.

Meal Break 1 @ 30 min = 30 min.

Down Time 30 mins

Ideal Run Rate 57 pieces per minute

Total Pieces 21,045

Reject Pieces 305

Planned Production Time = [Shift length – Breaks] = [ 540 – 90] = 450mins

Operating Time = PPT – Down Time = 450 – 30 = 420mins
Good piece = Total piece – Rejected = 21045 – 305 = 20740 pieces

Availability = Operating Time / PPT = 420/450 = 0.9333 * 100 = 93.3%

Performance = (Total Pieces / Operating Time) / Ideal Run Rate = 21045 /420/57 = 0.879 = 87.9%
Quality = Good Pieces / Total Pieces = 20740 / 21045 = 98.5%
OEE = Availability x Performance x Quality = 0.933 x 0.879 x 0.985 = 0.807 = 80.7%

What should the company expect

The calculated Overall Equipment Effectiveness (OEE) of 80.7% for Polar Crush indicates that the
equipment is operating at 80.7% of its maximum potential efficiency. While the availability of 93.3%
suggests some room for improvement in minimizing downtime through preventive maintenance
schedules, improving equipment reliability, and promptly addressing root causes of failures, the
performance of 87.9% highlights potential inefficiencies in production processes. Streamlining
workflows, optimizing equipment settings, and eliminating bottlenecks can enhance performance.
Additionally, the high quality percentage of 98.5% underscores the need for further reduction of
rejected pieces through rigorous quality control measures, employee training, and ongoing process
improvements. By addressing these areas for improvement, Polar Crush can optimize maintenance
strategies and maximize efficiency effectively.

SUGGESTED MAINTENANCE APPLICATIONS

To optimize maintenance strategies and maximize efficiency and effectiveness at Polar Crush, the
following actions can be considered:
S/N Maintenance Internal Pillars Expected Impact Justification and
Strategies and Literature Reference
Their Internal
Pillars:

1 Predictive • Condition • Reduced • According to a

Maintenance Monitoring: Downtime: By study by Li et
(PdM): Implement sensors detecting issues al. (2017),
and monitoring before they predictive
systems at each escalate into maintenance
production station to failures, predictive has been shown
continuously collect maintenance helps to reduce
data on equipment minimize maintenance
health and unplanned costs by up to
performance downtime and 30% and
indicators such as production increase
temperature, disruptions, equipment
vibration, and thereby improving uptime by 20%
pressure. This data is overall equipment through
then analyzed using effectiveness proactive
predictive analytics to (OEE). identification of
anticipate potential • Cost Savings: By equipment
failures before they scheduling failures.
occur. maintenance • Similarly,
• Data Analytics: activities based on research by
Utilize advanced actual equipment Jardine et al.
analytics techniques condition rather (2006)
 to analyze the than arbitrary time highlights the
collected data and intervals, effectiveness of
identify patterns or organizations can predictive
anomalies indicative optimize resource maintenance in
of impending allocation and enhancing
equipment failures. reduce equipment
Machine learning unnecessary reliability and
algorithms can be maintenance costs. minimizing
employed to improve • Enhanced downtime by
the accuracy of failure Equipment identifying
predictions over time. Reliability: potential failure
• Asset Health Predictive modes and
Management: maintenance taking
Develop a centralized enables early preventive
asset health detection and actions
management system resolution of accordingly.
that integrates data equipment issues,
from various sources leading to
to provide real-time improved
insights into reliability and
equipment condition. longevity of
This allows for production assets.
proactive
maintenance
interventions based
on the prioritization
of critical assets.

2 Total Productive • Autonomous • Increased • Research by

Maintenance Maintenance: Equipment Nakajima
(TPM) Empower operators to Availability: TPM (1988)
perform routine focuses on highlights the
maintenance tasks maximizing effectiveness of
 such as cleaning, equipment uptime TPM in
lubrication, and basic by involving improving
inspections to prevent operators in equipment
equipment proactive reliability,
deterioration and maintenance reducing
identify abnormalities activities, leading downtime, and
at an early stage. to improved asset enhancing
• Planned Maintenance: availability and overall
Develop a structured production output. equipment
maintenance schedule • Empowered effectiveness by
based on equipment Workforce: By involving
usage patterns, involving operators in
production schedules, operators in maintenance
and historical failure maintenance activities and
data. This involves activities, TPM fostering a
conducting preventive fosters a sense of culture of
maintenance activities ownership and continuous
such as component accountability improvement.
replacement and among employees, • Similarly, a
calibration at leading to study by Gijo
predetermined increased and Antony
intervals. engagement and (2014)
• Continuous morale. underscores the
Improvement • Reduced Defects positive impact
(Kaizen): Foster a and Waste: of TPM on
culture of continuous Continuous reducing
improvement among improvement defects,
employees to identify initiatives under improving
and address root TPM help identify productivity,
causes of equipment and eliminate and enhancing
failures, sources of defects employee
inefficiencies, and and waste in the morale through
 waste through production empowerment
systematic problem- process, resulting and
solving in higher product involvement in
methodologies. quality and maintenance
reduced rework. activities.

3 Reliability- • Asset Criticality • Enhanced • A study by

Centered Analysis: Conduct a Equipment Mobley (2002)
Maintenance comprehensive Reliability: RCM emphasizes the
(RCM) assessment of focuses on importance of
production assets to proactively RCM in
identify critical addressing optimizing
equipment that has a potential failure maintenance
significant impact on modes of critical strategies and
production output, equipment, maximizing
quality, or safety. This resulting in equipment
helps prioritize improved reliability by
maintenance efforts reliability, focusing on
and allocate resources availability, and proactive
effectively. performance. maintenance
• Failure Mode and • Optimal Resource tasks tailored to
Effects Analysis Allocation: By the specific
(FMEA): Analyze prioritizing needs of each
potential failure maintenance asset.
modes of critical activities based on • Similarly,
equipment and their asset criticality and research by
consequences on failure Nowlan and
production consequences, Heap (1978)
operations. Develop RCM helps demonstrates
proactive allocate resources the
maintenance more effectively, effectiveness of
strategies to mitigate ensuring that RCM in
or prevent these maintenance reducing
 failure modes through efforts are focused maintenance
appropriate on areas with the costs and
maintenance tasks. greatest impact on improving
• Maintenance production equipment
Optimization: operations. performance by
Optimize • Cost Savings: prioritizing
maintenance RCM helps maintenance
strategies based on minimize activities based
the identified failure unnecessary on asset
modes, taking into maintenance criticality and
account factors such activities and failure
as equipment reduce the risk of consequences.
reliability, cost of catastrophic
failure, and failures, leading to
consequences of cost savings
downtime. This associated with
involves selecting the maintenance labor,
most cost-effective spare parts, and
maintenance approach production
for each asset. downtime.

- Summary of Suggested maintenance applications:

1. Implement a proactive maintenance program: Regular preventive maintenance activities can

help minimize unplanned downtime and extend equipment lifespan, thus improving availability.
2. Utilize predictive maintenance technologies: Implementing predictive maintenance techniques,
such as condition monitoring and predictive analytics, can help anticipate equipment failures
and schedule maintenance activities more efficiently, enhancing availability and reducing
downtime.
3. Optimize production scheduling: Streamlining production schedules and minimizing
changeover times can improve equipment utilization and performance, leading to higher OEE.
 4. Invest in employee training: Providing comprehensive training programs for operators and
maintenance staff can enhance their skills and knowledge, leading to improved equipment
operation and maintenance practices.
5. Continuous improvement culture: Foster a culture of continuous improvement where employees
are encouraged to identify and implement efficiency enhancements and process optimizations to
drive OEE improvement over time.

Conclusion
In conclusion, implementing advanced maintenance strategies such as Predictive Maintenance, Total
Productive Maintenance, and Reliability-Centered Maintenance at Polar Crush can enhance equipment
reliability, minimize downtime, and optimize resource allocation. Continuous monitoring, employee
development, and data-driven decision-making are crucial for sustaining and improving these strategies
effectively.
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