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Towards successful integration of maintenance and production
Linköping University, Department of Management and Engineering, Production Economics. Linköping University, The Institute of Technology.
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis focuses on the integration of maintenance and production in process industries. Earlier research shows that coordinating maintenance plans with production plans is more important in flow manufacturing. The overall aim of this thesis is to identify important factors when integrating maintenance with production, as well as to develop and improve the Crespo Márquez (2007) maintenance management framework.

Research is based on three multiple case studies at Swedish process industries. These cases provide a foundation for identifying the factors influencing integration of maintenance and production. The first multiple case study analysed whether process industries perform holistic maintenance management. It also shows what elements of maintenance management the process industries focus on. The second multiple case study presents production planning at tactical level in process industries. The final multiple case study presents the levels of production planner consideration of maintenance in their planning processes.

This research shows that only one out of three of the process industries analysed used a holistic view of their maintenance management. The maintenance management frameworks used by the companies are either too detailed or complicated to use, or too loosely formulated. This research also shows that these process industries are fairly flexible in their production planning.

The factors which influenced the integration of maintenance and production most were summarised as a list of the five most important. The first integrating factor is top managements interest in maintenance management, followed by transparency within departments. The third factor is the importance of understanding other departments' needs in order to perform well and using Computerised Maintenance Management Systems (CMMS) properly. The final integrating factor is working with the production assets in systems rather than as components and using cross‐functional knowledge in teamwork. The further development of the maintenance management framework also indicated the importance of leadership and organisational issues, as well as the application of CMMS and work with Safety, Health and Environment (SHE) which the Crespo Márquez (2007) maintenance management framework did not include, even though this is vital to success.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2012. , 66 p.
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1567
National Category
Economics and Business
Identifiers
URN: urn:nbn:se:liu:diva-86185Local ID: LiU-TEK-UC 2012:51ISBN: 9789175197180 (print)OAI: oai:DiVA.org:liu-86185DiVA: diva2:575489
Presentation
2012-12-20, ACAS, A-huset, Campus Valla, Linköpings universitet, Linköping, 10:15 (Swedish)
Opponent
Supervisors
Available from: 2012-12-10 Created: 2012-12-10 Last updated: 2017-12-08Bibliographically approved
List of papers
1. Maintenance management in process industries:mapping current practices
Open this publication in new window or tab >>Maintenance management in process industries:mapping current practices
2010 (English)In: Proceedings of the 17th EurOMA conference, 2010, 2010Conference paper, Published paper (Other academic)
Abstract [en]

The overall purpose of this research is to map the maintenance management in three companies in the process industry sector and to analyse whether these companies apply a holistic perspective on their maintenance management. We have mapped our cases using the framework developed by Crespo Márquez et al. (2009) and our results show that even though maintenance is of utmost importance in the process industry, few companies have a strategic and holistic perspective on maintenance management.

Keyword
Maintenance, Framework, Case study
National Category
Production Engineering, Human Work Science and Ergonomics Business Administration
Identifiers
urn:nbn:se:liu:diva-78137 (URN)
Conference
EurOMA 2010, 4-5 June, Catholic University of Portugal (CUP), Porto, Portugal
Available from: 2012-06-07 Created: 2012-06-07 Last updated: 2012-12-10
2. Production planning in process industries
Open this publication in new window or tab >>Production planning in process industries
2012 (English)Report (Other academic)
Abstract [en]

Purpose of this paper

The purpose is to map the production planning process in process industries and analyze how it is related to their specific planning conditions and relevant current literature. Further on the research aims at detecting similarities and differences in production planning at tactical level.

Design/methodology/approach

The research methodology has a holistic multi-case design with focus on planning processes involving several entities within the companies. Information sources are documentation and interviews.

Findings

Process industries with different structures and conditions plan production differently. For instance a difference has been found between how material dominated companies plan compared to capacity dominated ones.

Research limitations/implications

Focus in this research has been on production planning at tactical level and therefore the strategic and operational level has mainly been left out of the study.

What is original/value of paper

The research gives insights in production planning processes for process industries and presents ideas on why the different production planning processes are designed as they are according some specific conditions.

Publisher
19 p.
Series
LIU-IEI-WP, 2012:2
Keyword
Process Industries, Production Planning, Tactical Planning, Supply Chain Planning, Multiple Case Study
National Category
Engineering and Technology Business Administration Transport Systems and Logistics
Identifiers
urn:nbn:se:liu:diva-84980 (URN)
Note

An earlier version of this paper was presented at NOFOMA 2011, 9-10 June, Harstad, Norway.

Available from: 2012-10-29 Created: 2012-10-29 Last updated: 2014-03-25Bibliographically approved
3. How do production planners take maintenance into consideration in process industries?
Open this publication in new window or tab >>How do production planners take maintenance into consideration in process industries?
(English)Manuscript (preprint) (Other academic)
Abstract [en]

Asset utilisation and maximising output in the long run is typically of utmost importance in the process industry environment as considerable capital is often tied up in fixed assets. In spite of this, the degree to which production planners in these industries take maintenance into consideration when planning production varies. In order to shed light on this issue, a multiple case study has been conducted with the purpose of analysing how production planners take maintenance management into consideration. Furthermore, this research investigates the motivation behind different degrees of coordination between maintenance and production planning, and what can be gained by tighter coordination of the two. The research results show that the majority of production planners within the process industries analysed do not take maintenance into consideration to any great extent. This research shows that the companies that plan production over multiple plants do not take maintenance management into consideration. It is also observable that production planners who earlier worked within the maintenance department take maintenance into consideration to some extent.

Keyword
Process industries, Maintenance planning, Production planning, Integrated planning, case study
National Category
Economics and Business
Identifiers
urn:nbn:se:liu:diva-86184 (URN)
Available from: 2012-12-10 Created: 2012-12-10 Last updated: 2012-12-10

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