A Costing Analysis For Decision Making Grid Model In Failure-Based Maintenance

In current economic downturn, industries have to set good control on production cost, to maintain their profit margin. Maintenance department as an imperative unit in industries should attain all maintenance data, process information instantaneously, and subsequently transform it into a useful decision. Then act on the alternative to reduce production cost. Decision Making Grid model is used to identify strategies for maintenance decision. However, the model has limitation as it consider two factors only, that is, downtime and frequency of failures. We consider third factor, cost, in this study for failure-based maintenance. The objective of this paper is to introduce the formulae to estimate maintenance cost. Methods. Fish bone analysis conducted with Ishikawa model and Decision Making Grid methods are used in this study to reveal some underlying risk factors that delay failure-based maintenance. The goal of the study is to estimate the risk factor that is, repair cost to fit in the Decision Making Grid model. Decision Making grid model consider two variables, frequency of failure and downtime in the analysis. This paper introduces third variable, repair cost for Decision Making Grid model. This approaches give better result to categorize the machines, reduce cost, and boost the earning for the manufacturing plant. Results. We collected data from one of the food processing factories in Malaysia. From our empirical result, Machine C, Machine D, Machine F, and Machine I must be in the Decision Making Grid model even though their frequency of failures and downtime are less than Machine B and Machine N, based on the costing analysis. The case study and experimental results show that the cost analysis in Decision Making Grid model gives more promising strategies in failure-based maintenance. Conclusions. The improvement of Decision Making Grid model for decision analysis with costing analysis is our contribution in this paper for computerized maintenance management system

DECISION SUPPORT MODEL IN FAILURE-BASED COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM FOR SMALL AND MEDIUM INDUSTRIES

Maintenance decision support system is crucial to ensure maintainability and reliability of equipments in production lines. This thesis investigates a few decision support models to aid maintenance management activities in small and medium industries. In order to improve the reliability of resources in production lines, this study introduces a conceptual framework to be used in failure-based maintenance. Maintenance strategies are identified using the Decision-Making Grid model, based on two important factors, including the machines’ downtimes and their frequency of failures. The machines are categorized into three downtime criterions and frequency of failures, which are high, medium and low. This research derived a formula based on maintenance cost, to re-position the machines prior to Decision-Making Grid analysis. Subsequently, the formula on clustering analysis in the Decision-Making Grid model is improved to solve multiple-criteria problem. This research work also introduced a formula to estimate contractor’s response and repair time. The estimates are used as input parameters in the Analytical Hierarchy Process model. The decisions were synthesized using models based on the contractors’ technical skills such as experience in maintenance, skill to diagnose machines and ability to take prompt action during troubleshooting activities. Another important criteria considered in the Analytical Hierarchy Process is the business principles of the contractors, which includes the maintenance quality, tools, equipments and enthusiasm in problem-solving. The raw data collected through observation, interviews and surveys in the case studies to understand some risk factors in small and medium food processing industries. The risk factors are analysed with the Ishikawa Fishbone diagram to reveal delay time in machinery maintenance. The experimental studies are conducted using maintenance records in food processing industries. The Decision Making Grid model can detect the top ten worst production machines on the production lines. The Analytical Hierarchy Process model is used to rank the contractors and their best maintenance practice. This research recommends displaying the results on the production’s indicator boards and implements the strategies on the production shop floor. The proposed models can be used by decision makers to identify maintenance strategies and enhance competitiveness among contractors in failure-based maintenance. The models can be programmed as decision support sub-procedures in computerized maintenance management systems

A Survey on Economic-driven Evaluations of Information Technology

The economic-driven evaluation of information technology (IT) has become an important instrument in the management of IT projects. Numerous approaches have been developed to quantify the costs of an IT investment and its assumed profit, to evaluate its impact on business process performance, and to analyze the role of IT regarding the achievement of enterprise objectives. This paper discusses approaches for evaluating IT from an economic-driven perspective. Our comparison is based on a framework distinguishing between classification criteria and evaluation criteria. The former allow for the categorization of evaluation approaches based on their similarities and differences. The latter, by contrast, represent attributes that allow to evaluate the discussed approaches. Finally, we give an example of a typical economic-driven IT evaluation

Life cycle cost modelling as an aircraft design decision support tool

This report summarizes the work that has been carried out as part of the FLAVIIR project, a 5 year research program looking at technologies for future unmanned air vehicles. A novel classification of aircraft product definition is utilised and a framework to estimate the life cycle cost of aircraft using the product definition is presented. The architecture to estimate the life cycle cost and the associated models are described.The acquisition costs are estimated using a hierarchical structure and a discrete simulation model is used to estimate the maintenance and operation costs. The acquisition cost model uses an object oriented approach with libraries of materials and processes integrated into the cost model. Risk analysis is performed to identify the important design parameters and uncertainty in the model. The acquisition cost model developed has the capability to estimate the costs of aircraft structures manufactured using metal-based materials as well as non-metal-based materials.The discrete event simulation model estimates the operation and maintenance costs of a fleet of aircraft using the mission characteristics, aircraft performance and the logistics data as input. The aircraft performance parameters are calculated by using aerodynamic analysis along with performance analysis models and the simulation model utilises a novel methodology to link aircraft performance with survivability analysis for estimating the maintenance costs.A framework is presented in which the cost models developed can be integrated into the conceptual design process to facilitate the comparison between different configurations. The usage of the life cycle cost framework as a decision support tool is outlined and three case studies are presented which include composites vs metals trade-off analysis, optimisation studies and web deployment for real time cost estimation. The novel contributions of this research are outlined and interesting avenues for future research that can be pursued are identified

An Economic Analysis and Cost Sharing Assessment for Dryland Salinity Management: A case study of the Lower Eyre Peninsula in South Australia

Report to Primary Industry and Resources SA. This report has 2 components. Firstly, it discusses issues relating to cost sharing for dryland salinity management. Secondly, it presents an economic analysis and cost sharing assessment of six dryland salinity management options for the Lower Eyre Peninsula in South Australia. The report includes a benefit-cost analysis of revegetation to control salinity.Australia;dryland;salinity;economic analysis;cost sharing;revegetation

Flat-plate solar array project. Volume 8: Project analysis and integration

Project Analysis and Integration (PA&I) performed planning and integration activities to support management of the various Flat-Plate Solar Array (FSA) Project R&D activities. Technical and economic goals were established by PA&I for each R&D task within the project to coordinate the thrust toward the National Photovoltaic Program goals. A sophisticated computer modeling capability was developed to assess technical progress toward meeting the economic goals. These models included a manufacturing facility simulation, a photovoltaic power station simulation and a decision aid model incorporating uncertainty. This family of analysis tools was used to track the progress of the technology and to explore the effects of alternative technical paths. Numerous studies conducted by PA&I signaled the achievement of milestones or were the foundation of major FSA project and national program decisions. The most important PA&I activities during the project history are summarized. The PA&I planning function is discussed and how it relates to project direction and important analytical models developed by PA&I for its analytical and assessment activities are reviewed

Including design in e-manufacturing

This paper reviews major issues in the implementation of e-manufacturing, particularly the design aspects. It will examine recent progress, drawing out particular issues that are being addressed. Use will be made of the work by the author and colleagues to devise rule-based design and Internet-based control of machines to illustrate how these developments affect the integrated e-manufacturing environment. A dynamic Simulink model of the way e-manufacture is affected by overall design delays is used to evaluate general solutions for partial and complete e-based companies. These models show how changing to improved designs reduces WI

An investigation into the collection, measurement and use of quality costs within a high volume production environment

The thesis describes an investigation into the collection and measurement of quality costs. It goes on to explain the manner in which this information was presented and used as an integral part of a specific (high volume manufacturing) company's total quality drive. Finally, it demonstrates how the cost of quality can help to identify and direct efforts to improve quality. Guidelines are given for the collection and analysis of quality cost data within the packaging industry. A comprehensive literature survey covering issues directly related to the objectives of the research, and peripheral issues of importance, was carried out. Literature on case studies for the promotion of quality were also included 'in the survey. The survey was confined to English language publications, using a list of keywords relating to money (i.e. cost, profit, economic, etc.) and topics ranging from the use of "quality improvement" as a business strategy to the quality-related costs associated with specific manufacturing operations. The search was primarily confined to quality related literature. This literature was reviewed and discussed in the light of the research experience, some gaps in the literature and information available were identified. These are discussed as a part of the development of a dedicated methodology, within the final chapter. A three stage, action research methodology was adopted. Action research encompasses direct involvement in organisational change whilst providing an increase in the knowledge base for a specific topic. This was the best possible option as the project specification relates to a practical problem with theoretical relevance. The main advantage of action research is that it is carried out in real-time and produces a concrete result, putting something of real practical worth back into an organisation. Four practical costing models were identified: (i) Prevention, Appraisal, Failure Model; (ii) Process Cost Model; (iii) Economic Balance of Quality (Optimum Quality Cost) Model; and (iv) Total Loss to Society (Quadratic Loss Function) Model. A host firm was used to test (i) and (ii). These two models were chosen because they exhibited certain characteristics. They both form part of British Standard - BS 6143, have had some publicity in the form of articles within professional journals, and have been utilised within both manufacturing and service industries to provide quality costing data. The British Standard (BS) 6143: Parts 1 (1991) and 2 (1990) was used as the primary guide. A detailed analysis of the applicability of both models was carried out, with necessary modifications being made to suit the host firms' particular industry (plastic injection moulding). This analysis is reported and discussed at length. Among the key conclusions are that quality costing can have a, very positive effect upon an organisations' quality improvement drive, and that the careful development of a specific cost model (in this instance the P.A.F. model) and a methodology for employing it, within a larger framework, should be considered essential. Further conclusions are that all organisations are at various stages in the use of formal measurement systems. As such, the identification of what stage an organisation has progressed to, and the determination of how they should proceed, is important for forward progress in the use of quality measurement systems. A conceptual framework has been designed for this purpose. A set of guidelines for quality cost collection and analysis within the packaging industry (high volume manufacturing) was created. As was a matrix to show an organisations' current place and potential development within certain key parameters, for example: i) company awareness, ii) costing models used, iii) measurement systems in place. The methodology developed for the host company is being used within other companies from the same corporate group. This is allowing refinement of the original model to take place. Other recommendations for further study are proposed in order to establish the validity of the above measurement system framework. This research has contributed to the existing knowledge base by trailing and modifying existing models within a specific environment, and through the development of a conceptual framework for assessing an organisations quality measurement system development. The direct contribution to the host company, in terms of practical and theoretical assistance has been considerable. This is fully detailed within the thesis

Process Evaluation of Community Energy Development Programme Projects

This report sets out the findings, conclusions and recommendations of a Process Evaluation, conducted between January and March 2015, of the Community Energy Development Programme (CEDP) projects as part of the Malawi Renewable Energy Acceleration Programme (MREAP). It was commissioned by the Scottish Government (SG) as a product of the Institutional Support Programme Component (ISP) of MREAP. Its main purpose is to assess what has been delivered, how this has been achieved and to compile learning from the process for policy and future projects. The agreed scope for the process evaluation was the portfolio of 46 CEDP projects implemented across the 3 regions of Malawi and the relevant processes and systems in place to design, implement and manage these projects. Due consideration was also given to framing the scope of the evaluation through the choice of evaluation questions and the feasibility of what was possible