Computerized Maintenance Management System in Process Industry of Pakistan
Abstract
Maintenance, a fundamental of reliable operations, has gone through an evolution from reactive to proactive strategies. In this evolution, the technology layer has been added in terms of computerized maintenance management system (CMMS). This paper aims to explore the current status of CMMS in the process industries of a developing country. For this study, data were collected via questionnaire from 62 publicly listed companies along with an analysis of their annual reports. Moreover, six interviews of CMMS consultants were conducted. It was found that 56% of the sampled companies had a CMMS running, while 44% had no such solution. The key performance indicator (KPI) of ‘% replacement asset value’ (%RAV) was further determined, which was found to be 3.74% for companies with CMMS and 5.67% for companies with no CMMS; considering the global benchmark of 2.5%. The challenges to CMMS implementation included unawareness about function of CMMS, erroneous data and weak change management. Even in companies that had CMMS, its utilization was found to be elementary. CMMS end users and consultants can use the findings of this study in enhancing the success of CMMS implementation and utilization.
References
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[33] Schneider, J., et al., Asset management techniques. International Journal of Electrical Power & Energy Systems, 2006. 28(9): p. 643-654.
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[37] Campbell, J.D. and J.V. Reyes-Picknell, Uptime: Strategies for excellence in maintenance management. 2015: CRC Press.
[38] Bradbury, M.E., P.C.K. Hsiao, and T. Scott, Summary annual reports: length, readability and content. Accounting & Finance, 2018.
[39] Saleem, A. and N. Ehsan, Status of performance measurement systems in infrastructure construction firms of Pakistan. Journal of Engineering and Applied Sciences, 2012. 31(2).
[2] Finance, M.o., Manufacturing and Mining, in Pakistan Economic Survey 2017-18. 2018. p. 16.
[3] Zeb, A., A. Qudoos, and H. Hanif, Identification and Analysis of Factors Affecting Machinery in the Construction Industry of Pakistan. International Journal of Sciences: Basic and Applied Research, 2015. 19(1): p. 269-278.
[4] Gulati, R., Maintenance and reliability best practices. 2 ed. 2013, New York: Industrial Press Inc.
[5] Fumagalli, L., et al., Evaluating the role of maintenance maturity in adoption of new ICT in the process industry. IFAC Proceedings Volumes, 2008. 41(3): p. 251-256.
[6] Fumagalli, L., M. Macchi, and M. Rapaccini, Computerized Maintenance Management Systems in SMEs: a survey in Italy and some remarks for the implementation of Condition Based Maintenance. IFAC Proceedings Volumes, 2009. 42(4): p. 1615-1619.
[7] Islam, Z.U., et al., GIS Enabled Condition Based Asset Management of Gas Distribution Network: A Case Study of Shahdara, Lahore Pakistan. Journal of Geographic Information System, 2015. 7(04): p. 358.
[8] Shehzad, A., et al. Implementation of TPM in a Process Industry: A Case Study from Pakistan. in 16th International Conference on Manufacturing Research. 2018. University of Skovde, Sweden: IOS Press.
[9] Rastgar, I., Industry 4.0 and predictive maintenance-How a local company is preparing pakistani textile industry. Pakistan Textile Journal, 2018. 67(6): p. 38-38.
[10] Haider, R., et al., Development of optimized maintenance system for vehicle Fleet. Journal of Engineering and Applied Sciences, 2015. 34(2): p. 21-27.
[11] Goti, A. and A. Arnaiz. The status of maintenance decision making under economic criteria: survey. in Proceedings of 34th Esreda Seminar, Supporting technologies for advanced Maintenance Information Management. San Sebastian. 2008.
[12] O'Hanlon, T., Computerized maintenance management and enterprise asset management best practices, in Asset management white paper series. 2005, Reliabilityweb.com. p. 11.
[13] Blackstone Jr, J.H. and J.F. Cox III, Designing unbalanced lines-understanding protective capacity and protective inventory. Production Planning & Control, 2002. 13(4): p. 416-423.
[14] Dennis, D. and J. Meredith, An empirical analysis of process industry transformation systems. Management Science, 2000. 46(8): p. 1085-1099.
[15] Fransoo, J.C. and W.G. Rutten, A typology of production control situations in process industries. International Journal of Operations & Production Management, 1994. 14(12): p. 47-57.
[16] Shah, N., Process industry supply chains: Advances and challenges. Computers & Chemical Engineering, 2005. 29(6): p. 1225-1235.
[17] King, P.L. and J.S. King, The product wheel handbook: creating balanced flow in high-mix process operations. 2013: CRC Press.
[18] Tawfik Mady, M., The effect of type of industry on inventory investments and structure: the Egyptian case. International Journal of Operations & Production Management, 1991. 11(6): p. 55-65.
[19] Crama, Y., Y. Pochet, and Y. Wera, A Discussion of Production Planning Approaches in the Process Industries. Production and Inventory Management, 2001. 31(3).
[20] Wienker, M., K. Henderson, and J. Volkerts, The Computerized Maintenance Management System an Essential Tool for World Class Maintenance. Procedia Engineering, 2016. 138: p. 413-420.
[21] Weinstein, L., R.J. Vokurka, and G.A. Graman, Costs of quality and maintenance: Improvement approaches. Total Quality Management, 2009. 20(5): p. 497-507.
[22] Cato, W.W. and R.K. Mobley, Computer-managed maintenance systems: a step-by-step guide to effective management of maintenance, labor, and inventory. 2001: Elsevier.
[23] Suman, R., S. Chaudhary, and P. Preet, Computer Govern Maintenance System for a Process Industry. Computer Engineering and Intelligent Systems, IISTE, 2014. 5(3).
[24] Dedrick, J., V. Gurbaxani, and K.L. Kraemer, Information technology and economic performance: A critical review of the empirical evidence. ACM Computing Surveys (CSUR), 2003. 35(1): p. 1-28.
[25] Braglia, M., et al., AHP-based evaluation of CMMS software. Journal of manufacturing technology management, 2006. 17(5): p. 585-602.
[26] Swanson, E.B. and N.C. Ramiller, The organizing vision in information systems innovation. Organization science, 1997. 8(5): p. 458-474.
[27] Kans, M., An approach for determining the requirements of computerised maintenance management systems. Computers in industry, 2008. 59(1): p. 32-40.
[28] Petter, S., W. DeLone, and E.R. McLean, Information systems success: The quest for the independent variables. Journal of Management Information Systems, 2013. 29(4): p. 7-62.
[29] Mobley, R.K., L.R. Higgins, and D.J. Wikoff, Maintenance engineering handbook. 2008: Mcgraw-hill New York, NY.
[30] Weber, A. and R. Thomas, Key performance indicators, in Measuring and Managing the Maintenance Function. 2005, Ivara Corporation, Burlington. p. 16.
[31] McNair, S., Budgeting for Maintenance: A Behavior-Based Approach. 2011, Life cycle engineering.
[32] van de Kerkhof, R.M., H.A. Akkermans, and N.G. Noorderhaven, Knowledge lost in data: organizational impediments to condition-based maintenance in the process industry, in Logistics and Supply Chain Innovation. 2016, Springer. p. 223-237.
[33] Schneider, J., et al., Asset management techniques. International Journal of Electrical Power & Energy Systems, 2006. 28(9): p. 643-654.
[34] Nickerson, G. and D. Hall. Research imperatives for condition based maintenance. in on Condition Monitoring and Diagnostic Engineering Management, Proceedings of 8th International Congress on (COMDEM95), Kingston, Ontario. 1995.
[35] Moubray, J., Reliability-centered maintenance. 1997: Industrial Press Inc.
[36] Ahuja, I.P.S. and J.S. Khamba, Total productive maintenance: literature review and directions. International Journal of Quality & Reliability Management, 2008. 25(7): p. 709-756.
[37] Campbell, J.D. and J.V. Reyes-Picknell, Uptime: Strategies for excellence in maintenance management. 2015: CRC Press.
[38] Bradbury, M.E., P.C.K. Hsiao, and T. Scott, Summary annual reports: length, readability and content. Accounting & Finance, 2018.
[39] Saleem, A. and N. Ehsan, Status of performance measurement systems in infrastructure construction firms of Pakistan. Journal of Engineering and Applied Sciences, 2012. 31(2).
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Published
2021-01-19
Issue
Section
Mechanical Engineering, Automotive, Mechatronics, Textile, Industrial and Manufacturing Engineering
