On Condition Based Maintenance and its Implementation in Industrial Settings

University dissertation from Västerås : Mälardalens högskola

Abstract: In order to stay competitive, it is necessary for companies to continuously increase the effectiveness and efficiency of their production processes. High availability has, thus, increased in importance. Therefore, maintenance has gained in importance as a support function for ensuring, e.g., quality products and on-time deliveries. 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 one-third of the cost of maintenance is incurred unnecessarily due to bad planning, overtime cost, limited or misused preventive maintenance, and so on. In so, condition based maintenance is introduced as one solution for a more effective maintenance.In condition based maintenance, critical item characteristics are monitored 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. They focus on: constituents of a condition based maintenance approach, decision-making prior implementation of condition based maintenance, and finally, the implementation of condition based maintenance 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. 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.