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Volume 9 Number 4 2003 ISBN 0-86176-899-X ISSN 1355-2511
Journal of
Quality in
Maintenance
Engineering
Maintenance management and modelling: The IFRIM
conference, May 2002, Växjö University, Sweden
Guest Editor: Basim Al-Najjar
www.emeraldinsight.com
ISSN 1355-2511
Journal of Quality in
Volume 9
Number 4
Maintenance Engineering 2003
Maintenance management and modelling: the IFRIM conference
May 2002, Va¨xjo¨ University, Sweden
Guest Editor
Basim Al-Najjar
Access this journal online __________________________ 327
CONTENTS
Editorial advisory board ___________________________ 328
Abstracts and keywords ___________________________ 329
Editorial __________________________________________ 331
Towards a value-based view on operations and
maintenance performance management
Jayantha P. Liyanage and Uday Kumar _____________________________ 333
Adaptive model for vibration monitoring of rotating
machinery subject to random deterioration
Y. Zhan, V. Makis and A.K.S. Jardine ______________________________ 351
Design and development of product support and
maintenance concepts for industrial systems
Tore Markeset and Uday Kumar __________________________________ 376
Integration of RAMS and risk analysis in product
design and development work processes: a case study
Tore Markeset and Uday Kumar __________________________________ 393
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An analysis of economics of investing in IT in the
CONTENTS
maintenance department: an empirical study in a
continued cement factory in Tanzania
E.A.M. Mjema and A.M. Mweta ___________________________________ 411
Application and implementation issues of a
framework for costing planned maintenance
Mohamed Ali Mirghani __________________________________________ 436
Note from the publisher____________________________ 450
Call for papers ____________________________________ 452
Index to Volume 9, 2003 ___________________________ 453
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EDITORIAL ADVISORY BOARD Professor D.N.P. Murthy
JQME
Department of Mechanical Engineering, The
9,4 Professor Daoud Ait-Kadi University of Queensland, Brisbane, Australia
Director, Graduate Industrial Engineering Program,
Professor Dr Liliane Pintelon
Laval University, Quebec, Canada
K.U. Leuven, Centre for Industrial Management,
Dr Khaled S. Al-Sultan Leuven, Belgium
Systems Engineering Department, King Fahd
Professor A. Rahim
University of Petroleum and Minerals, Dhahran,
Faculty of Administration, University of New
328 Saudi Arabia
Brunswick, Fredericton, New Brunswick, Canada
Professor A.H. Christer
Professor Haritha Saranga
University of Salford, Salford, UK
Indian Institute of Management, Calcutta, India
Dr Ir Patrick De Groote
Professor D. Sherwin
Vice-President, ABB/DGS Maintenance
Department of Industrial Engineering,
Engineering, Antwerp, Belgium
Lund University, Lund, Sweden
Professor B.S. Dhillon
Dr Abdel Rahman N. Shuaib
Director of Engineering Management Program,
Mechanical Engineering Department, King Fahd
University of Ottawa, Ottawa, Canada
University of Petroleum and Minerals, Dhahran,
Professor V. Makis Saudi Arabia
Department of Industrial Engineering, University of
Dr Albert H.C. Tsang
Toronto, Toronto, Canada
Department of Industrial and Systems Engineering,
Professor L. Mann Jr The Hong Kong Polytechnic University, Kowloon,
Department of Industrial Engineering, Louisiana Hong Kong, China
State University, Louisiana, USA
Professor Hajime Yamashina
Professor F.G. Miller Department of Precision Mechanics, Kyoto
Department of Mechanical Engineering, University University, Kyoto, Japan
of Illinois at Chicago, Illinois, USA
Journal of Quality in Maintenance
Engineering
Vol. 9 No. 4, 2003
p. 328.
# MCB UP Limited
1355-2511
Towards a value-based view on This paper proposes a state-space model of
Abstracts and
operations and maintenance non-stationary multivariate vibration signals
keywords
performance management for the online estimation of the state of rotating
machinery using a modified extended Kalman
Jayantha P. Liyanage and Uday Kumar
filtering algorithm and spectral analysis in the
Keywords Oil industry, Gas industry,
time-frequency domain. Adaptability and
Operations management,
spectral resolution capability of the model
Maintenance programmes, Values,
have been tested by using simulated vibration 329
Balanced scorecard, Performance levels
signal with abrupt changes and time-varying
Most of the North Sea oil companies have spectral content. The implementation of this
recognized the need to adjust their model to detect machinery deterioration under
management processes, including those varying operating conditions for
concerned with operations and maintenance, condition-based maintenance purposes has
to the changed and changing business been conducted by using real gearbox
conditions in industry at large, particularly vibration monitoring signals. Experimental
due to the volatile oil price. This has been a results demonstrate that the proposed model
rationale to review organizational operations is able to quickly detect the actual state of the
and maintenance policies by many. This paper rotating machinery even under highly
describes findings from a research study on non-stationary conditions with abrupt
operations and maintenance performance changes and yield accurate spectral
conducted in the emerging operating information for an early warning of incipient
environment with close cooperation of fault in rotating machinery diagnosis. This is
leading oil and gas organizations in the achieved through combination with a change
Norwegian continental shelf. An attempt has detection statistic in bi-spectral domain.
been made to develop an architecture for
effective management of operations and
Design and development of product
maintenance performance linking results to
support and maintenance concepts for
performance drivers. This has further been
industrial systems
extended to apply the balanced scorecard
concept. The paper emphasizes the value Tore Markeset and Uday Kumar
rather than the cost of operations and Keywords Maintenance programmes,
maintenance in the emerging business Product management,
environment, and stress that there is a need Reliability management, Failure (mechanical),
to move from a plant-based policy to a more or Life cycle costs, Service delivery systems
less long-term business-oriented approach.
Product design and service delivery both affect
service performance, and therefore a product
Adaptive model for vibration support strategy must be defined during design
monitoring of rotating machinery stage, in terms of these two dimensions, to
subject to random deterioration ensure the delivery of “promised product
performance” to customers. Furthermore,
Y. Zhan, V. Makis and A.K.S. Jardine
product support strategy should not only be
Keywords Vibration measurement,
focused around product, or its operating
Autoregressive processes
characteristics, but also on assisting customers
Due to the non-stationarity of vibration signals with services that enhance product use and add
resulting from either varying operating additional value to their business processes.
conditions or natural deterioration of This paper examines various issues such as
machinery, both the frequency components reliability, availability, maintainability, and
and their magnitudes vary with time. However, supportability (RAMS), etc., which directly or
Journal of Quality in Maintenance
little research has been done on the parameter indirectly affect product support, maintenance Engineering
estimation of time-varying multivariate time needs and related costs on the basis of a case Vol. 9 No. 4, 2003
Abstracts and keywords
series models based on adaptive filtering theory study conducted in a manufacturing company.
q MCB UP Limited
for condition-based maintenance purposes. The main purpose of the study was to analyse 1355-2511
the critical issues related to the product support control, to reduce risk. A training program,
JQME
and service delivery strategy as being practised developed and implemented during the study to
9,4
by the company, and to suggest means for create awareness and to improve learning and
improvements. On the basis of the case study, understanding of RAMS’ aspects of existing
the paper presents an approach for design and and future products and processes, is also
development of product support and presented.
maintenance concepts for industrial systems in
330 a multinational environment. The paper
emphasizes that the strategy for product
An analysis of economics of investing in
support should not be centred only on
IT in the maintenance department: an
“product”, but should also take into account
empirical study in a cement factory in
important issues such as the service delivery
Tanzania
capability of the manufacturers, service
suppliers, the capability of users’ maintenance E.A.M. Mjema and A.M. Mweta
organization, etc.
Keywords Maintenance, Computers, Quality
The main objective of this study was to analyse
the economics of introducing IT in the
Integration of RAMS and risk analysis maintenance department. The economics in
in product design and development this case was determined by conducting a
work processes: a case study quantitative analysis on the reduction of
Tore Markeset and Uday Kumar operational costs, on increase in productivity
and on quality improvement. A comparison was
Keywords Reliability management,
made to analyse company performance in the
Life cycle costs, Risk analysis,
maintenance before and after the introduction of
Customer requirements,
IT in the maintenance department. The analysis
Dissemination of information
shows that there were reductions of operational
Most industrial customers are looking for
and inventory holding costs. Likewise, it was
products that meet the functional performance
shown that there was also improvement in
needs and have predictable life cycle cost (LCC).
product quality and productivity.
Due to design problems and poor product
support, these systems are not able to meet the
customers’ requirements. Major causes of
customer dissatisfaction are often traced back Application and implementation issues
to unexpected failures, leading to unexpected of a framework for costing planned
costs. However, with proper consideration of maintenance
reliability, availability, maintainability and
Mohamed Ali Mirghani
supportability (RAMS) in the design,
Keywords Preventive maintenance,
manufacturing, and installation phases, the
Cost effectiveness, Maintenance costs
number of failures can be reduced and their
consequences minimized. Based on a case study This paper develops a case study on the
in a manufacturing company, an approach for application and implementation issues of a
integration of RAMS and risk analysis in framework for costing planned maintenance. It
design, development and manufacturing is outlines the methodology for the development
presented. The importance of LCC analysis, of the case study and presents the major
use of feedback information, and integration of findings of the existing maintenance-costing
various information sources to facilitate easy system of the organization under study. It
RAMS implementation, in combination with presents the results of a pilot study of the
risk analysis in the design phase, is discussed. application of the proposed costing framework
An approach is suggested for integration of to a sample of planned maintenance jobs. It
RAMS in the Stage Gate model for project and provides recommendations and identifies
work process management, coordination and critical issues for a successful implementation.
Editorial
Editorial
About the Guest Editor Basim Al-Najjar is a Professor of Terotechnology and Department
Head of Terotechnology (Systemekonomi) at the School of Industrial Engineering, Va¨ xjo¨ , Sweden.
The concepts of the available maintenance strategies focus mainly on reducing 331
failures and their consequences. But, maintaining the condition of machinery to
fulfil production requirements demands an efficient maintenance policy that
can participate in the continuous enhancement of a company’s profitability and
competitiveness. In order to achieve an effective integration of relevant
working areas it is necessary for maintenance management to select the most
cost-effective maintenance policies, models, performance measures, life-cycle
cost and assess maintenance technical and financial impact on the company’s
profitability and competitiveness.
This special issue of the Journal of Quality in Maintenance Engineering is
devoted to the advances, developments and applications of maintenance
management, mathematical modelling, performance measure, life-cycle cost
and maintenance technical and financial impact on the company’s profitability
and competitiveness. The papers included in this issue are some of the papers
presented at the Conference IFRIM Maintenance Management and Modelling,
May 2002, Va¨xjo¨ University, Sweden. These selected four papers cover the
following topics:
. Describing findings from a research study on operations and maintenance
performance conducted in the emerging operating environment with close
cooperation of leading oil and gas organizations in the Norwegian
continental shelf. We have made an attempt to develop an architecture for
effective management of operations and maintenance performance
linking results to performance drivers, which has further been extended
to apply the balanced scorecard concept.
. Modelling a state-space model of non-stationary multivariate vibration
signals for the online estimation of the state of rotating machinery using a
modified extended Kalman filtering algorithm and spectral analysis in the
time-frequency domain. In addition, testing adaptability and spectral
resolution capability of the model by using simulated vibration signal
with abrupt changes and time-varying spectral content.
. Examination of various issues such as reliability, availability,
maintainability, and supportability (RAMS), etc., which directly or
indirectly affect product support, maintenance needs and related costs on
the basis of a case study conducted in a manufacturing company. The Journal of Quality in Maintenance
main purpose of the study was to analyse the critical issues related to the Vol. 9ENnog.in4e,e2r0in0g3
product support and service delivery strategy as being practised by the pp. 331-332
q MCB UP Limited
company, and to suggest means for improvements. 1355-2511
JQME . An approach for integration of RAMS and risk analysis in design,
development and manufacturing is presented. The importance of
9,4
life-cycle cost (LCC) analysis, use of feedback information, and
integration of various information sources to facilitate easy RAMS
implementation, in combination with risk analysis in the design phase, is
discussed.
332
The Guest Editor would like to acknowledge the efforts made by Professor
David Sherwin in planning this special issue. The authors’ and the referees’
contributions to this issue are highly appreciated.
Basim Al-Najjar
Note from the Editor
The special issue was planned to be exclusively from papers presented at
IFRIM conference. The Guest Editor managed to accept four papers from
IFRIM for the special issue. Four papers are not sufficient for the special issue
and I have added two papers to complete the issue. Papers 1-4 in this issue are
from the IFRIM conference and papers number five and six from the regular
accepted pool of papers. Paper number five quantifies the economic benefits of
introducing information technology (IT) in the maintenance department. The
economic benefits have been quantified through quantitative data analysis
prior and after introducing IT. The sixth paper presents, through a case study,
the application and the implementation issues of a framework for costing
planned maintenance. It outlines the methodology for development of the case
study and presents the major findings as a result of adopting such a costing
system.
The Editor acknowledges the authors for their valuable contributions to
Volume 9. He is also grateful to all the referees who graciously participated in
the review process. In many situations they made improvements to the papers.
The skill and the follow-up made by the Managing Editor of JQME are
instrumental in preparing the volume.
The Rector of King Fahd University of Petroleum and Minerals Dhahran,
Saudi Arabia, and his administration are acknowledged for the continuous
support provided and the excellent facilities made available.
Salih O. Duffuaa
The Emerald Research Register for this journal is available at The current issue and full text archive of this journal is available at
http://www.emeraldinsight.com/researchregister http://www.emeraldinsight.com/1355-2511.htm
Towards a
Towards a value-based view on value-based view
operations and maintenance
performance management
333
Jayantha P. Liyanage
School of Science and Technology, Stavanger University College,
Stavanger, Norway, and
Uday Kumar
Division of Operations and Maintenance Engineering,
Lulea University of Technology, Lulea, Sweden
Keywords Oil industry, Gas industry, Operations management, Maintenance programmes,
Values, Balanced scorecard, Performance levels
Abstract Most of the North Sea oil companies have recognized the need to adjust their
management processes, including those concerned with operations and maintenance, to the
changed and changing business conditions in industry at large, particularly due to the volatile
oil price. This has been a rationale to review organizational operations and maintenance
policies by many. This paper describes findings from a research study on operations and
maintenance performance conducted in the emerging operating environment with close
cooperation of leading oil and gas organizations in the Norwegian continental shelf. An attempt
has been made to develop an architecture for effective management of operations and
maintenance performance linking results to performance drivers. This has further been
extended to apply the balanced scorecard concept. The papers emphasize on the value rather
than the cost of operations and maintenance in the emerging business environment, and
stresses that there is a need to move from a plant-based policy to a more or less long-term
business-oriented approach.
Practical implications
How operations and maintenance performance (O&M) makes good business
sense has become an important issue lately, and has drawn the attention from
various corners of oil and gas (O&G) production business in particular. This
calls for a more holistic view of O&M and an appropriate basis to show its link
to the core business. Furthermore, a comprehensive performancfe assessment
system has to accommodate a balanced view on overall performance involving
not only results but also drivers of those results, and also should be able to
provide some understanding about the causal relationships between them. A
notable interest in this regard is to seek ways whereby the popular balance
Journal of Quality in Maintenance
scorecard concept can be applied within O&M process. This paper looks into Engineering
these aspects in respect of emerging O&G business environment and elaborate Vol. 9 pNpo..343,32-030530
how O&M becomes a value-added process to the core business, extending our q MCB UP Limited
1355-2511
understanding beyond its pure financial implications. DOI 10.1108/13552510310503213
