Implementing total productive maintenance in Nigerian manufacturing industries

Remarkable improvements have occurred recently in the maintenance management of physical assets and productive systems, so that less wastages of energy and resources occur. The requirement for optimal preventive maintenance using, for instance, justin-time (JIT) and total quality-management (TQM) techniques has given rise to whathas been called the total productive-maintenance (TPM) approach. This study explores the ways in which Nigerian manufacturing industries can implement TPM as a strategy and culture for improving its performance and suggests self-auditing and bench-marking as desirable prerequisites before TPM implementation

Development and implementation of preventive-maintenance practices in Nigerian industries.

A methodology for the development of PM using the modern approaches of FMEA, root-cause analysis, and fault-tree analysis is presented. Applying PM leads to a cost reduction in maintenance and less overall energy expenditure. Implementation of PM is preferable to the present reactive maintenance procedures (still prevalent in Nigeria

Petrochemical industry in Nigeria: a performance appraisal

For any country, having a large indigenous petrochemical-producing industry tends to lead to raised prosperity, improved average standard-of-living for the population and the introduction of associated modern-technology locally. However, such benefits in Nigeria have as yet not been forthcoming to significant extents. This project reviews what needs to be done in the industry to achieve these desired improvements

Impact of corporate culture on plant maintenance in the Nigerian electric-power industry

Comparisons have been made of modern maintenance-practices, i.e. in the more developed economies, with what occurs in Nigeria. Significant differences arise due to variations in corporate culture, pertinent learning opportunities and effectiveness of strategic planning. The managerial implications of these divergences are discussed. A systematic, total productive-maintenance (TPM) approach needs to be adopted to allow corporate changes to be implemented at a rate commensurate with each organization's evolving culture. This paper advocates that maintenance should be managed better, in each organization, so as to cultivate a sense of ownership in the operators. Also autonomous maintenance-teams, consisting of operators, engineers and managers, should be set up with the aims of improving personnel competence and equipment performance

Reducing the cost of preventive maintenance (PM) through adopting a proactive reliability-focused culture.

The economic and political realities of the 1990s forced managers to reverse long-standing organizational cultures in order to reduce costs and energy expenditures in their organisations. For instance, these can be achieved, with respect to maintenance, by replacing a reactive repair-focused attitude by a proactive reliability-focused culture. Thereby far less (i) human effort is expended and (ii) energy would be wasted, both of which lead to increased profitability

Reliability of the Afam electric power generating station, Nigeria

Today’s economic climate requires that each industry aim at achieving maximum production capability while minimizing capital investment e.g. in the maintenance function. This means finding ways to maximize equipment reliability and up-time and extend plant and equipment life through cost effective maintenance. This paper surveys the performance of gas turbine plants in Afam Thermal Power Station. The findings show that the impact of lost generation (through non-availability) exceeded within a few years, the initial purchase price of the power plants and associated equipments

OPTIMUM PREVENTIVE MAINTENANCE REPLACEMENT TIME FOR THE AFAM THERMAL POWER STATION

Maintenance experts agree that replacing component/equipment before ¡t fails may, under certain circumstances, make better economic sense than replacing the component/equipment when if fails. The key is to determine whether the preventive maintenance replacement of specific component/equipment ¡s appropriate and if so, to identify the best time to replace it. Generally, maintenance is the area where sound management principles are still largely ignored in Afam Power Station, hence maintenance productivity is very low and the associated costs of repair/replacement as a percentage of total cost continue to increase. Therefore, power plants/auxiliaries in the station are facing big repair/replacement cost challenges. In order to improve the PM activities, an optimum replacement time of plants/equipment was conducted. A net present value was used in order to determine the optimum time of pump replacement as a case study. Based on this study, several actions and strategies are suggested to reduce complex problems and implications, one of which is to use proactive maintenance strategy for long-term strategy

Strategic maintenance-management in Nigerian industries

A developing society needs to adapt to change and foster creativity. In the pursuit of continual improvement (e.g., reducing fossil-fuel consumption and waste, better service performance, greater availability and improved reliability), implementing wise maintenance-schedules is essential for contemporary organisations. Several studies of a wide range of Nigerian industries indicate that indigenous low availability and low productivity are endemic. The resulting closure of some of these industries has triggered off a realisation of the strategic challenges in maintenance management. In addition, the increasingly-competitive business environment in Nigeria has raised the strategic importance of maintenance functions, especially in organisations with significant investments in physical assets. Five strategic aspects of maintenance management have been identified, namely: maintenance methodology; support processes; organisation and work structuring; comparable culture; and general management policy. Three factors that permeate these dimensions are wise leadership, excellent communications and an understanding of the human factors involved.Strategy Maintenance Nigerian electric-power stations