JJMIE

Volume 5, Number 3, June 2011

ISSN 1995-6665
Pages 227 - 234
Jordan Journal of Mechanical and Industrial Engineering

Computer–Aided Maintenance Planning System for Industrial

Companies

A. Mukattasha, R. H. Fouad*,a, H. Kitanb, and M. Samhouria

a
Industrial Engineering Department, Hashemite University, Zarqa, Jordan
b
Production Engineering Department, University of Technology, Baghdad, Iraq

Abstract

Significant advances in computer hardware and software development have affected most areas of business and industry, and
the area of maintenance planning and management is no exception. The use of computerized maintenance management
systems, which are commonly referred to as CMMS, is no longer a luxury or frivolous business overhead; in many cases, it is
requirement. Enterprises that want to attain ISO, QS certification will discover that application of CMMS is a fundamental
requirement to successfully obtain and maintain such certifications.
A variety of software packages are available, and many have been around for a number of years. Today, CMMS are used for
all aspects of maintenance planning, management and control. CMMS must be flexible and adaptable, because every firm is
considered unique. A general guide has been developed, which can easily be applied to specific situations to assist in
justifying the computer for Maintenance System Evaluation (MSE). MSE has always required the manipulation of large
amounts of data and development of more cost-effective processing storage and database systems has brought the use of
computers to the fore in this area. Since, the relationships are complex between factors affecting maintenance activities and
their interactions; a computer-aided model is developed with main purpose of determining the evaluation factors and their
pointers. This model will approximate the complex relations for practical purposes. A model with eight various factors and
there pointers for MSE were proposed in this paper. The MSE approach uses the input data as well as the factors that reflect
unique operating conditions and specific objectives of the firm. The model would help in measuring the effectiveness of
maintenance activities in order to determine the deviations from the planned work. It will also perform instant corrective
actions required according to the degree of deviation and its effect on the production continuation and with the minimum
shutdowns possible.
© 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved

Keywords: Computerized Maintenance Management Systems (CMMS); Computer- Aided Maintenance; Maintenance System Evaluation
(MSE); Maintenance Activity Factors; Effectiveness of Maintenance Activities; and Maintenance Planning

second and equally pressing issue is to understand how to

implement the right maintenance tools and techniques,
1. Introduction based on the introduced theories and methodologies, to
solve problems in a very short time in order to guarantee
In today's global economy with fierce competition to success Lee and Wang, [13]. Today, leading firms
attain and maintain the competitive edge in productivity understand the necessity of linking production planning
and quality, a key factor often is neglected. The planning with resource supply using dependent demand techniques
and management of productive maintenance activities in like Enterprise Resource Planning (ERP) in order to
industrial manufacturing organizations rarely are given the provide the increasing business needs in more effective
attention they deserve Stephens [22]. Many solutions are and efficient ways Spathis and Constantinides [21].
being exposed, such as future automated factory, zero The knowledge that has been gained in linking
inventories and integrated manufacturing system. These production with maintenance planning is essential to
solutions cannot be successful without highly reliable compressing the computer- aided evaluating system for
machines and equipments. maintenance activities. Applying this knowledge will help
Two issues regarding computer-aided maintenance are reduce waste and greater productivity. It became apparent
addressed: The first is fundamental knowledge, including that maintenance was not just about keeping machinery in
both theories and methodologies required for practitioners a good working order but it involved learning by sharing
to perform maintenance activities effectively. The communal experiences, and feeding the result back into
revolutionary advances in information telecommunication, design, operation and maintenance itself [4].Maintenance
and computing technologies at modern factories forced the has always been in the business of dealing with large
need for new approaches in process design, materials amounts of data. The advent of the microcomputer in the
management, technologies, and human resources. The late 1970s began a revolution in maintenance systems.

*
Corresponding author. e-mail: [email protected]
228 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665)

Only now, in the mid-1980s, are we beginning to saw a Two issues regarding computer-aided maintenance are
mature system which addresses the following maintenance addressed: The first is fundamental knowledge, including
tasks Carter [4] and Retterer and Kowallski [19]. System both theories and methodologies required for practitioners
Fault Reporting / Repair Control, Labor Control and to perform maintenance activities effectively. The
Reporting, Equipment / Spare Parts Inventory Control, revolutionary advances in information telecommunication,
Maintenance Data Recording Analysis. and computing technologies at modern factories forced the
This research aims in developing a computerized need for new approaches in process design, materials
program for evaluating maintenance system’s activities so management, technologies, and human resources. The
that the maintenance performance level can be evaluated second and equally pressing issue is to understand how to
as well. In the age of minimal inventories and highly implement the right maintenance tools and techniques,
automated complex machinery, automated maintenance based on the introduced theories and methodologies, to
systems are required to truly accomplish the goals of a solve problems in a very short time in order to guarantee
Computer-Aided Manufacturing (CAM) and Computer- success Lee and Wang, [13]. Today, leading firms
Integrated Manufacturing an automated and maintenance understand the necessity of linking production planning
planning and diagnostics system can provide a rapid with resource supply using dependent demand techniques
planning and scheduling response to changing system like Enterprise Resource Planning (ERP) in order to
conditions (CIM) Lin and Chen [14]. provide the increasing business needs in more effective
Lee and Wang [13] and Candy [3] both suggested that and efficient ways Spathis and Constantinides [21].
the overall goal of the maintenance function is to make The knowledge that has been gained in linking
capacity available to production in a reliable and stable production with maintenance planning is essential to
manner. This should enable organizational objectives such compressing the computer- aided evaluating system for
as the following to be met; 1) Responsive customer maintenance activities. Applying this knowledge will help
service, 2) Consistent product quality, 3) Reliable product reduce waste and greater productivity. It became apparent
output, 4) Cost efficient operations, maintenance and that maintenance was not just about keeping machinery in
supported departments, and 5) High utilization of a good working order but it involved learning by sharing
equipment and other resources. communal experiences, and feeding the result back into
In the past two decades, changes in the production design, operation and maintenance itself [4].Maintenance
environment have made the task of making decisions about has always been in the business of dealing with large
allocating maintenance resources and scheduling amounts of data. The advent of the microcomputer in the
maintenance work more difficult. An information- late 1970s began a revolution in maintenance systems.
processing model is applied by Laura Swanson [11] to Only now, in the mid-1980s, are we beginning to saw a
study how the maintenance function applies different mature system which addresses the following maintenance
strategies to cope with the environmental complexity. tasks Carter [4] and Retterer and Kowallski [19]. System
Computer-Aided Reliability-Centered Maintenance Fault Reporting / Repair Control, Labor Control and
(RCM) a based plant maintenance management system has Reporting, Equipment / Spare Parts Inventory Control,
been studied and investigated by Hossam A. et. al. [8], and Maintenance Data Recording Analysis.
Jesu´s Carreteroa et.al.[10]. A survey of models and This research aims in developing a computerized
algorithms for winter road maintenance system design for program for evaluating maintenance system’s activities so
snow disposal was developed by Nathalie Perriera et.al that the maintenance performance level can be evaluated
[17].Implementation and benefits of introducing a CMMS as well. In the age of minimal inventories and highly
into a textile manufacturing company is investigated in automated complex machinery, automated maintenance
C.D. O’Donoghue, and J.G. Prendergast [18]. Recently; systems are required to truly accomplish the goals of a
Celso et.al. [5] presented a model for preventive Computer-Aided Manufacturing (CAM) and Computer-
maintenance planning by genetic algorithms based in cost Integrated Manufacturing an automated and maintenance
and reliability. Similarly genetic algorithms for integrated planning and diagnostics system can provide a rapid
preventive maintenance planning and production planning and scheduling response to changing system
scheduling for a single is presented by N. Sortrakul, H.L. conditions (CIM) Lin and Chen [14].
Nachtmann, and C.R. Cassady [23]. (Farhad Kianfar [7] Lee and Wang [13] and Candy [3] both suggested that
proposed a numerical method to approximate optimal the overall goal of the maintenance function is to make
production and maintenance plan in a flexible capacity available to production in a reliable and stable
manufacturing system. Hsu-Hua Lee [9] presents a manner. This should enable organizational objectives such
cost/benefit model for investments in inventory and as the following to be met; 1) Responsive customer
preventive maintenance in an imperfect production system. service, 2) Consistent product quality, 3) Reliable product
This paper is an extension of the initial research on the output, 4) Cost efficient operations, maintenance and
English system used in batteries industry at General supported departments, and 5) High utilization of
Company for liquid Battery Industries was carried out by equipment and other resources.
Mukattash and Kitan [1]. In the past two decades, changes in the production
In today's global economy with fierce competition to environment have made the task of making decisions about
attain and maintain the competitive edge in productivity allocating maintenance resources and scheduling
and quality, a key factor often is neglected. The planning maintenance work more difficult. An information-
and management of productive maintenance activities in processing model is applied by Laura Swanson [11] to
industrial manufacturing organizations rarely are given the study how the maintenance function applies different
attention they deserve Stephens [22]. Many solutions are strategies to cope with the environmental complexity.
being exposed, such as future automated factory, zero Computer-Aided Reliability-Centered Maintenance
inventories and integrated manufacturing system. These (RCM) a based plant maintenance management system has
solutions cannot be successful without highly reliable been studied and investigated by Hossam A. et. al. [8], and
machines and equipments. Jesu´s Carreteroa et.al.[10]. A survey of models and
 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665) 229

algorithms for winter road maintenance system design for • Required corrective actions.
snow disposal was developed by Nathalie Perriera et.al Different evaluating systems to maintenance activities
[17].Implementation and benefits of introducing a CMMS have been developed in industrial countries (Ettlcin and
into a textile manufacturing company is investigated in Jahing, 1986, Mann and Coates, [16] ,(Simith [20] and
C.D. O’Donoghue, and J.G. Prendergast [18]. Recently; Malek and Kaitan, [15]. Any firm can use an evaluating
Celso et.al. [5] presented a model for preventive system according to nature of their industrial function.
maintenance planning by genetic algorithms based in cost Some of these systems used on the national levels such as,
and reliability. Similarly genetic algorithms for integrated The English system used in automobile industries , The
preventive maintenance planning and production American system used in engineering industries , The
scheduling for a single is presented by N. Sortrakul, H.L. Egyptian system used in chemical industries, The Soviet
Nachtmann, and C.R. Cassady [23]. (Farhad Kianfar [7] system used in metallurgical industries , The Yugoslavian
proposed a numerical method to approximate optimal system used in mechanical industries and The English
production and maintenance plan in a flexible system used in batteries industry. All of these systems for
manufacturing system. Hsu-Hua Lee [9] presents a measuring and evaluating maintenance activities are used
cost/benefit model for investments in inventory and to annually evaluate the efficiency of maintenance plan
preventive maintenance in an imperfect production system. execution according to certain determined goals.
This paper is an extension of the initial research on the
English system used in batteries industry at General
Company for liquid Battery Industries was carried out by 5. Case Study
Mukattash and Kitan [1].
The English system used in battery industries has been
applied in the one of the Middle East companies called
2. Experimental Measurements General Company for Liquid Battery Industries. A
computer program written in visual basic was built as an
Traditionally, maintenance organizations have evaluation system for maintenance activities in this
operated in a “fire-fight” mode. “Preventing fires” has company and the results for each factor and their pointers
often been given a minor or causal emphasis. are compared with the standard values at “Chloride”
The fire-fighting mode (fix it when it breaks) is called company. It was found necessary to modify it with regard
Corrective Maintenance, while the latter (fix it before it to:
breaks) is called Preventive Maintenance (PM) as shown • Factors and pointers for planning efficiency.
in Fig.A1 appendix Lindbeck and Wygant, [12] and • Factors and pointers for loading efficiency.
Burton et. al. [2]. A key distinction among these three • Factors and pointers for costs.
perspectives relates to the time interval between the • Factors and pointers for productivity.
recognition of the need to perform a maintenance activity The modified approach in applying “Chloride” system
and the time the maintenance activity is performed. is based on identifying two pointers for each factor. This
modifying method depends on four parameters, which
reflect the own production environment of battery Industry
3. Evaluating Factors Scoring for Maintenance Company as follows:
Activities • Size of company and the type of functional
organization to production department.
The evaluation approach of maintenance activities • Varieties and continuity of production type.
usually categorizes a given maintenance system by scoring • Work nature, time and operating environment.
its activities more often on a scale of one to four. The • Skills, number, stability of maintenance
higher the category scores for a factor, the greater the workforce.
importance of the other categories. This is usually done The actual measured values for the major (4) factors
with the objectives of: (planning, loading, costs, and productivity) depend on the
• Labor usage efficiency improvement. determined pointers for each factor. These eight pointers
• Unexpected breakdowns reduction. represent the basic for measuring the maintenance
• Downtime reduction. activities. A flow chart that illustrates the algorithm steps
• Maintenance scheduling improvement. required for measuring the efficiency of maintenance
• Preventive maintenance program improvement, activities in the chosen company is shown in Fig.1 below.
Dhavale and Otterson, [6]:
The user has the choice to eliminate some of the
factors entirely, adding new factors, changing, adding or
deleting pointers in a given factor and changing their
scores. The user should examine critically according his
firm conditions.

4. Measuring System of Maintenance Activities

The main objective for measuring and evaluating

maintenance activities in a firm is to determine the
followings:
• Performance level of maintenance system.
Figure 1: Flow chart of the steps of measuring maintenance
• Deviations from maintenance plan.
activities efficiency
230 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665)

5.1. Planning Efficiency Factor Calculations:

5.1.1. Workforce effectiveness (LE) Pointer:

L.E = (Z-Q) / Z x R

Where:

Z= Total operation hours,

Q= Total absenteeism hours,

and

R = Workforce skillfulness average.

The calculation procedure for LE is shown in Fig. 2 below.

Figure 3: Calculation procedure for executed / planning

maintenance hours.

5.2. Loading Efficiency Factor Calculations:

5.2.1. Total Preventive Maintenance Hours / Total

Maintenance Hours Pointer (KP):

KP = PT / AT × 100

Where:

PT = Preventive maintenance hours,

Figure 2: Calculation procedure for labor effectiveness.
AT = Total maintenance hours
5.1.2. Executed Maintenance Work/planning maintenance
Work Pointer (KT):
5.2.2. Corrective Maintenance Hours / Total Maintenance
Hours Pointer (KC):
KT = BT/AT × 100
KC = CT / AT × 100
Where:
BT = Number of actual maintenance hours,
The calculation procedure for preventive and
AT = Number of planned maintenance hours. corrective maintenance hours / total planning is shown in
Fig. 4 below
The calculation procedure of KI for each department and
KT for the overall company is shown in Fig. 3 below.
 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665) 231

Figure 5: Calculation procedure of costs factor pointers.

5.4. Productivity Factor Calculations:

5.4.1. Labors Utility pointer (LU):

LU = AW / TW × 100

Where:
Figure 4: Calculation procedure for preventive and corrective
maintenance hours / total planning maintenance hours
AW = Actual Work,
5.3. Costs Factor Calculations:
TW = Total Work.
5.3.1. Maintenance Costs / Capital Investment pointer The flow chart shown in Fig. 6 depicted the steps for
(KI): calculation of KI for each department and KT for the
overall company.
KI = TCM / CI × 100

Where:

TCM = Total maintenance cost,

CI = Capital investment

5.3.2. Direct and General Maintenance Cost / Total

Maintenance Costs pointer (K2):

K2 = (DMC + GMC) / TMC × 100 Figure 6: Calculation procedure of Labors utility (LU) pointer

Where: 5.4.2. Production Breakdown Time for Maintenance /

Total Operating Time (machine-hr) Pointer (MB):
DMC = Direct Maintenance Costs,
MB = TBhs / E
GMC = General Maintenance Costs.
Where:
The calculation procedure of costs factor pointers is shown
in Fig. 5. Bhs = Total breakdown hours,

E = total energy.

The calculation procedure of production breakdown for

maintenance is shown in Fig.7 below.
232 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665)

Figure 10: LE calculation menu

Figure 7: Calculation procedure of production breakdown for

maintenance
6. Results Analysis
An example of execution the algorithm steps The deviations of maintenance activities measurements
sequencing for maintenance system evaluation (MSE) is from targeted levels resulted from comparing the actual
illustrated through the different menus as shown in fig A2 results with standard values. These deviations for the
appendix and figs. (8, 9, and 10) below selected factors and their pointers are illustrated in Table 1.
The lack of labor effectiveness (LE) ranked as the first one
as the actual value is (58.5%) while the standard value is
(80%). Which means a deviation value around (58.5-80=-
21.5%). The production breakdown pointer for
maintenance has actual value of (7.8%) with a deviation
value of (7.8-3 = 4.8%).

Table (1): Results of MES maintenance activities factors and

pointers

Figure 8: English system menu

Figure 9: Selected pointers menus

 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665) 233

7. Conclusion [5] Celso Marcelo F. Lapaa, Cla´udio Ma´rcio N.A. Pereiraa, b,

Marcio Paes de Barros. “A Model for Preventive
Maintenance Planning by Genetic Algorithms Based in Cost
Maintenance management may be a key strategic
and Reliability”. Reliability Engineering and System Safety
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understand the necessity for linking production planning Priority” IE 1980.
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waste. Waste is inherently greater if production and Optimal Production and Maintenance Plan in Flexible
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followed closely. Computation Vol. 170, 2005, 924–940.
[8] Hossam A. Gabbar, Hiroyuki Yamashita, Kazuhiko Suzuki,
The knowledge that has been gained in linking
Yukiyasu Shimada. “Computer-Aided RCM-Based Plant
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234 © 2011 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved - Volume 5, Number 3 (ISSN 1995-6665)

Appendix

Figure A2: Main menu of the program.

Figure A1: Maintenance Management Perspectives.

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