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Cost Oriented Maintenance Management Systems for Manufacturing Processes.
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Cost Cost Oriented Oriented Maintenance Maintenance Management Management Systems Systems for for Manufacturing Manufacturing Processes. Processes. Cost Oriented Maintenance Management Systems for Manufacturing Processes. Mary Doyle Kent*. Orlagh Costello**. Sean Phelan***. Kalin Petrov****. Mary Doyle Kent*. Orlagh Costello**. Sean Phelan***. Kalin Petrov****. *Dept of Engineering Technology, Waterford Institute of Technology, Waterford, X91 KOEK, Ireland. Mary Doyle Kent*. Waterford Orlagh Costello**. Phelan***. Kalin Petrov****. *Dept of Engineering Technology, Institute ofSean Technology, Waterford, X91 KOEK, Ireland. (Tel +353 51 302058 Email [email protected]) *Dept of Engineering Technology, Waterford Institute Technology, Waterford, X91 KOEK, Ireland. (Tel +353 51 302058 [email protected]) **Bausch & Lomb Ireland, Ireland.(Email [email protected]) (Tel Waterford, +353 51 302058 Email [email protected]) **Bausch & Lomb Ireland, Waterford, Ireland.(Email [email protected]) ***Dept of**Bausch Engineering Technology, WIT, Waterford, X91 KOEK, Ireland. (Email [email protected]) & Lomb Ireland, WIT, Waterford, Ireland.(Email [email protected]) ***Dept of Engineering Technology, Waterford, X91 KOEK, Ireland. (Email [email protected]) ****Dept of Engineering Technology, WIT, Waterford, X91 KOEK, Ireland. ([email protected]) [email protected] ) ***Dept ****DeptofofEngineering EngineeringTechnology, Technology,WIT, WIT,Waterford, Waterford,X91 X91KOEK, KOEK,Ireland. Ireland.(Email (Email [email protected] ) ****Dept of Engineering Technology, WIT, Waterford,firms X91 KOEK, Ireland.knowledge (Email [email protected] Abstract: Case studies of manufacturing have shown retention in industrial ) Abstract: Case studies of manufacturing firms have shown knowledge retention in industrial settings critical. The retirement of skilledfirms technicians can cause important knowledge to drain Abstract:is studies of manufacturing have shown knowledge retention in industrial settings is Case critical. The retirement of skilled technicians can cause important knowledge to drain from the firm. Few recent case studies of cost-oriented maintenance management systems for settings critical. The retirement of skilled technicians can cause important knowledge to drain from theis firm. Few recent case studies of cost-oriented maintenance management systems for manufacturing processes have appeared in literature to date. from the firm. processes Few recent studiesinofliterature cost-oriented manufacturing havecase appeared to date.maintenance management systems for manufacturing processes have appeared in literature to date. A manufacturing facility is presented here and the skills of the maintenance technician workforce A manufacturing facility is presented here and the skills of the maintenance technician workforce analyzed. A manufacturing engineering graduate was interviewed ascertaining the relevance of an A manufacturing facility is presented here and thewas skills of the maintenance technician workforce analyzed. A manufacturing engineering graduate interviewed ascertaining the relevance of an Irish third level qualification in preparation for the workforce internationally. An investigation analyzed. manufacturing engineering graduate ascertaining theAn relevance of an Irish thirdAlevel qualification in preparation for was the interviewed workforce internationally. investigation into maintenance in software programs is made focusing on adaptability for developing Irishopen thirdsource level qualification preparation for the workforce internationally. Anfor investigation into open source maintenance software programs is made focusing on adaptability developing countries. into open source maintenance software programs is made focusing on adaptability for developing countries. countries. © 2018, IFAC (International Federation ofCost Automatic Control) Knowledge Hosting by Elsevier rights reserved. Keywords: Maintenance, Manufacturing, Effectiveness, TransferLtd. andAll Computerized Keywords: Maintenance, Manufacturing, Cost Effectiveness, Knowledge Transfer and Computerized Maintenance Management Systems Keywords: Maintenance, Manufacturing, Cost Effectiveness, Knowledge Transfer and Computerized Maintenance Management Systems Maintenance Management Systems
1. INTRODUCTION 1. INTRODUCTION 1. INTRODUCTION Cost oriented automation research has a long tradition in Cost oriented automation research has a long tradition in IFAC and has typically focused upon describing new Cost oriented a long traditionnew in IFAC and hasautomation typically research focused has upon describing automatic and semi-automatic solutions to control important IFAC andand hassemi-automatic typically focused upon describing new automatic solutions to control important processes and systems. Recent cost-oriented automation automatic and solutions to controlautomation important cost-oriented processes and semi-automatic systems. Recent papers have focused upon sophisticated production processes and systems. Recent cost-oriented automation papers have focused upon sophisticated production operations and processes upon (e.g. Kent (2016), production Groumpos papers have operations and focused processes (e.g. sophisticated Kent (2016), Groumpos (2015a), Shala et al (2015)) and the provision of new services operations andet al processes (e.g.theKent (2016), Groumpos (2015a), Shala (2015)) and provision of new services using advanced, cost-oriented robotics (e.g. Kopacek et al (2015a), Shala et al (2015)) and robotics the provision new services using advanced, cost-oriented (e.g. of Kopacek et al (2015)). International studies have long shown that in using advanced, cost-oriented (e.g. shown Kopacek al (2015)). International studies robotics have long thatet in developing countries where populations do not have access to (2015)). International studies have long that in developing countries where populations do notshown have access to well-developed, university level cross-disciplinary education developing countries where level populations do not haveeducation access to well-developed, university cross-disciplinary the problem of knowledge development, retention and well-developed, leveldevelopment, cross-disciplinary education the problem ofuniversity knowledge retention and transfer can be exacerbated and even hamper economic the problem of exacerbated knowledge and development, retention and transfer can be even hamper economic development (Arunachalam (1999)). Groumpos showed that transfer can be exacerbated and even hamper economic development (Arunachalam (1999)). Groumpos showed that a key to successful advanced engineering processes inthat an (Arunachalam (1999)). Groumpos showedin adevelopment key to successful advanced engineering processes an international stability and developing country context is the a key to successful engineering processes in the an international stability advanced and developing country context is effective control and management of systemic knowledge in international stability and developing country context is the effective control and management of systemic knowledge in the enterprise (Groumpos (2015a), (2015b)). This is effective control (Groumpos and management of systemic knowledge the enterprise (2015a), (2015b)). This in is particularly important for enhancing cost-oriented innovative the enterprise (Groumpos (2015a), (2015b)). innovative This is particularly important for enhancing cost-oriented capacity in less developed regions in manufacturing firms particularly for enhancing innovative capacity in important less developed regions cost-oriented in manufacturing firms (e.g. Shala et al (2015)). capacity developed regions in manufacturing firms (e.g. Shalainetless al (2015)). (e.g. Shala et al (2015)). This paper establishes that knowledge development, retention This paper establishes that knowledge development, retention and transfer is of critical concern in Irish high-tech This paper establishes knowledge retention and transfer is of that critical concerndevelopment, in Irish high-tech companies. It looks at the aptness of inIrish education in and transferIt islooks of at critical concernof Irish high-tech companies. the aptness Irish education in engineering and investigates some potential low-cost options companies. and It looks at the some aptness of Irish education in engineering investigates potential low-cost options for facilitating theinvestigates effective transfer of this tacit knowledge. engineering andthe some potential low-cost options for facilitating effective transfer of this tacit knowledge. for facilitating the effective transfer of this tacit knowledge. In 2014 in Waterford Institute of Technology (WIT) two final In 2014 in Waterford Institute of Technology (WIT) two final year students Kalin Petrov and Sean Phelan undertook case In 2014 in Waterford Institute Technology (WIT) twoaa final year students Kalin Petrov andofSean Phelan undertook case study as part of their final year thesis “Knowledge Transfer year students Kalin and thesis Sean Phelan undertook a case study as part of theirPetrov final year “Knowledge Transfer study as part of their final year thesis “Knowledge Transfer
(KT) through Computerised Maintenance Management (KT) through Computerised Maintenance Management Systems (CMMS). An in-depth investigation into the (KT) through Computerised Maintenance Management Systems (CMMS). An in-depth investigation into the transfer of knowledge within the maintenance sector.” This Systems of(CMMS). in-depth investigation into This the transfer knowledge An within the maintenance sector.” looked at the requirements of a large high-tech company, transfer atof the knowledge withinofthea maintenance sector.” This large high-tech company, looked requirements analysing the knowledge and skills maintenance technicians looked at the the knowledge requirements a large high-techtechnicians company, analysing andofskills maintenance were required to have for the successful running of the plant. analysing the knowledge and skills maintenance technicians were required to have for the successful running of the plant. The company realized that to maintain the vital know-how were company required to have for thetosuccessful the plant. The realized that maintain running the vitalofknow-how they had to assess current staff, highlight deficits and plan for The had company realized that to maintain vitaland know-how they to assess current staff, highlight the deficits plan for the future. The company was considering hiring they had to assess staff, highlight deficits and plan for the future. Thecurrent company was considering hiring manufacturing engineering graduates. It seemed that they the future. The company was It considering hiringaa manufacturing engineering graduates. seemed that they more eclectic range of knowledge and skills due to thethey type manufacturing engineering graduates. seemed more eclectic range of knowledge and Itskills due that to the typea of education received in an Irish Institute, rather than the more eclectic received range of in knowledge skills rather due to than the type of education an Irish and Institute, the more traditional craft approach. of education received in an Irish Institute, rather than the more traditional craft approach. more traditional craft approach. The second element of this paper is an account of an The second element of this paper is an account of an engineering undergraduate’s educational experience. How The second undergraduate’s element of this educational paper is anexperience. account ofHow an engineering did a manufacturing engineering degree, offered by an IOT engineering undergraduate’s educational experience. did a manufacturing engineering degree, offered by an How IOT (Institute of Technology) in the south east of Ireland, prepare did a manufacturing engineering degree, by prepare an IOT (Institute of Technology) in the south east offered of Ireland, him to work in the manufacturing industry internationally? (Institute of Technology) in the south east internationally? of Ireland, prepare him to work in the manufacturing industry him work in thesection manufacturing The toconcluding focuses industry on low internationally? cost open source The concluding section focuses on low cost open source CMMS. These systems can be an option for developing The concluding section focuses low cost source CMMS. These systems can be on an option foropen developing industrial communities. An analysis of software packages has CMMS. These systemsAncan be anofoption forpackages developing industrial communities. analysis software has been made, and recommendations are outlined on the industrial communities. An analysis of software packages been made, and recommendations are outlined on has the feasibility of using these packages in differing economies. been made, and these recommendations are outlined on the feasibility of using packages in differing economies. feasibility of using these packages in differing economies. Three research questions are posed: Three research questions are posed: Three research questions arean posed: Q1. Using a case study in Irish manufacturing company Q1. Using a case study in an Irish manufacturing company can the knowledge and skills of the maintenance technicians Q1. the Using a case study in anofIrish company can knowledge and skills the manufacturing maintenance technicians be measured and deficits evaluated? canmeasured the knowledge and skills of the maintenance technicians be and deficits evaluated? be measured and deficits evaluated?
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Q2. Can education in an Irish third level Institute bring the required skills to individuals to equip them for a career in manufacturing on an international platform?
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company will prove to be an important trend in the future (Rothwell, (2014)), especially the tacit knowledge, not explicitly outlined in manuals and other official documentation. This knowledge is difficult to capture even prior to retirement. Company policies and procedures should allow for such knowledge to be captured as part of the normal work recording procedures, for example using the CMMS to record the knowledge used on all jobs. As technology develops it is vital for all companies to introduce a culture of continuous improvement.
Q3. Can low cost maintenance software programs be used to manage maintenance requirements internationally? 2. RESEARCH APPROACH Following an approach by the manufacturing manager of a high-tech industrial facility to form a collaboration in maintenance knowledge transfer, it was agreed that a student led project would investigate if a methodical solution could be found to minimise the negative effects of the current aging maintenance technician workforce retiring within the plant. Data was gathered using a mixed model research methodology including questionnaires, interviews and technical assessment. This data was used to gain an understanding of knowledge deficits and pointed to potential solutions. In section 3.1 a summary of some of the data is presented, whilst protecting anonymity of the firm.
Knowledge management (KM) should be achieved through an integrated and comprehensive company strategy, including policies implementation, monitoring and evaluation. Knowledge must be available when and where it is needed from both external and internal sources. As a deliverable of the project a low-cost bespoke model of the company’s skills profile was developed. The company’s maintenance technician’s skills matrix in figure 1 was used to itemise the skills required.
In Section 3.2 one of the co-authors from Bulgaria, has, in an interview, explained how an engineering education in Ireland has helped him to fulfil a lifelong aspiration in manufacturing. He was one of the students on the original maintenance project. It becomes clear from this interview that an appropriate education can fill the gaps in a high-tech company and open doors internationally. To investigate low cost solutions of CMMS systems one of the co-authors, who has extensive experience in high-tech maintenance management systems, undertook a literature review. It was noted that a range of solutions are available now and can be low cost and adapted to the requirements of the firm. A summary of the findings is presented in section 3.3.
Fig. 1 Skills Requirement Matrix A customized, date-driven inventory and schedule of skills and knowledge was developed. It defined the role of workers, the resources available and test questions needed to confirm the right knowledge that had to be transferred. This led the authors to develop a “Bespoke Company Matrix”, where the employee names where placed across the X-axis and the chosen subject matter down the Y-axis. The employees were simply scored on each subject depending on their abilities. Figure 2 is a sample of the matrix layout.
3. FINDINGS 3.1 Maintenance Needs of an Irish High-Tech Industry. A final year project undertaken by Kalin Petrov and Sean Phelan firstly investigated the extent to which narrow technical fields of expertise were a challenge in the maintenance sector in a high-tech Irish manufacturing firm. Secondly, the case explored how to transfer, at low cost, maintenance knowledge in a high technology manufacturing plant with an aging work force many of whom are close to retirement.
As an additional part of the project, the international footprint of the Irish vocational training of maintenance technicians was assessed. They were given access to the European VocTrainMaint exam which has been developed for people with an electrical, mechanical or maintenance background. The goal of the exam was to improve efficiency, quality and safety in a modern industrial production unit. The complete program consists of individual subjects that can be taken on a full time or modular basis. Each module will in turn be rewarded credits under the European Credit Transfer and Accumulation Program for the European Credit and Transfer Accumulation System (ECTS).
In the study, it was established that many vocationally educated technicians such as fitters and electricians have been trained to be experts in narrow fields of expertise. A system to highlight current skill profiles of the workforce, help identify knowledge gaps and set out the programs needed to fill the gaps in a timely manner had to be developed. The study highlighted the need for ambitious and broadminded team members keen to develop their own skillsets while supporting other team members also develop their own new skillsets. Managing the retiree pool of a 49
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Fig. 3. Results of the VocTrainMaint exam. A number of Electricians, Fitters and Students from a level 7 Institute of Technology Engineering course took the VocTrainMaint exam and the results were plotted and analysed. A summary of the results can be seen in Figure 3. It was noted that the students demonstrated a relatively good level of maintenance knowledge as compared to the Maintenance Technicians. They had no work experience when tested. These results were considered by the company management and will be considered in the future, when seeking to hire technicians with a more eclectic range of knowledge and skills. 3.2 An interview of a manufacturing engineering student. Kopacek et al in 2006 stated that “it is evident that there is a need to focus upon higher education as a pre-requisite for sustainable growth and stability, and, in particular, a focus upon emerging disciplines in the field of high technology. This is very important in developing a skill-base for potential, future inward investment.” (Kopacek et al (2015)) Ireland welcomes all nationalities and is often chosen by students looking for an English language European education. In WIT we have a long history of visiting Erasmus and International students. WIT has developed many interinstitutional Erasmus links and in 2017-18 it had 110 agreements in place. International students came from 28 countries worldwide to study on various programmes in the Institute. During the academic year 2017-18 #189 Erasmus students and #50 International students studied in WIT. These figures were provided by WITs International office.
Fig. 2 Bespoke Knowledge Transfer Matrix This software was conceptualised under the banner of the EFNMS (European Federation of Nation Maintenance Societies) and was funded by the European Union’s lifelong learning program. On completion of the exam participants who pass will receive a cert recognised and accepted across Europe for expertise in Maintenance. He/she can in turn use this qualification to progress along the European Qualification Framework (EQF) at their own pace. Those who fail the exam will highlight deficiencies in their own knowledge base to improve on.
Engineering courses, and especially in mechanical and manufacturing, prove to be particularly sought after. As stated by Kopacek et al. “research articles clearly demonstrated the need for a coherent theoretical approach to the development of engineering education curricula which enables undergraduates develop the necessary professional competences to perform their work on graduation.” (Kopacek et Al (2006)). WIT currently offers 36 courses that are accredited with Engineers Ireland (EI), including the BEng in Manufacturing Engineering. EI is the Irish professional body, and a registered professional title from EI provides peer reviewed and international formal recognition of professional competence. (EngineersIreland.ie, (2018)). Categories of Registered Professional Titles: Fellow (CEng FIEI), Chartered Engineer (CEng MIEI), Associate Engineer (AEng
According the European Federation of National Maintenance Societies (EFNMS) the benefits in completing the VTM program are; independent verification of professional maintenance skills, competitive advantage in the sale of maintenance services, ability to identify knowledge gaps within the maintenance area and support for continued skills development in maintenance (Efnms.eu. (2018)).
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MIEI), Engineering Technician (EngTech MIEI). The skills offered in these courses are highly valued internationally. Students also understand the importance of these skills.
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employing time served craftsmen in different roles. Much depends, therefore, on union agreements and the relationship between union members and the employer.
Following is an interview of a co-author of this paper - an international student who completed a degree in manufacturing engineering in WIT. This testimony illustrates the versatility and usefulness of an accredited engineering education.
3.3 Investigation of Open Source Maintenance Software’s. The CMMS has long been the backbone of the maintenance department and is the main knowledge transfer system used in most organisations, primarily functioning as a database, storing information for later retrieval or for transferring essential information. For example, a maintenance plan is often the first thing one might think of in relation to the CMMS - originally, the systems were used to produce regular jobs and activities at specified frequencies.
Kalin Petrov was a manufacturing engineering graduate in 2014 from WIT. He had left Bulgaria and travelled to Ireland to earn money and improve his quality of life, with a view to returning to his native country after several years. Ireland was unknown to him, but an agency organised his move here because of his English language proficiency. Kalin had, from an early age, a passion for problem solving so this led him to work in an engineering company on arrival in Ireland. He realised quickly that to progress and move up the career ladder he would have to upskill and decided to follow his dream of becoming an engineer. Initially he studied in WIT as an evening/part time student but completed his course in a full-time capacity. His experience was very positive. His communication and language skills improved significantly in this period. Technically he said “since joining WIT in 2009 I have learned a lot of engineering practical and theoretical skills which have helped me achieve my career goal. I knew that if I wanted to go back to my home country someday, all the engineering education and expertise would help me there. During the course I studied mechatronics, robotics, quality, statistical process control, product and process design, maths and other modules. Projects were very important. My project partner was Sean Phelan. Team projects helped me to develop team work skills, communication & presentation skills, technical report writing & time management expertise. Software packages learned included MS-Office, Labview, AutoCAD, SolidWorks, and programming software’s for PLC’s.”
Fig. 4. CMMS (Computerised Maintenance Mgt. System) The CMMS expanded to record work such as breakdowns, improvements and other interventions that would not be included in an equipment plan. This is where the real knowledge transfer can happen. Technicians and engineers record what problem they found, what steps they took to correct it and any other information that they think is relevant. The quality and quantity of information recorded varies, but personnel can review previous reports to find similar problems, speeding up the repair process. The CMMS can therefore be a method of storing and retaining tacit knowledge, not otherwise captured in official documentation. As CMMS software packages developed, these basic functions were expanded to advanced reporting functions, spares programs and links to financial programs. The cost of such systems can prove prohibitive for developing economies. For a standalone system with the potential to be integrated with other onsite systems, with 200+ users, the cost can be approx. €100,000 for installation, training and licence fees. This does not include any internal business process changes required or other software or hardware requirements. In developing economies, this price tag can be too high, with the internal change needed adding another layer of complexity and cost to the equation.
Kalin explains that on graduating, he encountered difficulty in trying to get a graduate engineering position in Ireland. He did find employment as an operator/technician, which then led to a graduate engineering position. Kalin went on to save the medical device company he was working for €1.3 million. His experience in this and in a later company, opened a fantastic opportunity in his native Bulgaria where he is currently a project manager for a multinational company. It is possible to use engineering graduates to fill gaps in the maintenance sector of manufacturing companies. With the skills learned as part of their degrees, they are valuable additions to the maintenance function. However, many trade union agreements enforce strict division of labour requirements on the employer. Where such policies are in place, it is not usually possible to employ graduates as technicians. However, these agreements are not unilateral. There is at least one medical devices company in the west of Ireland where this is not the case. The plant is unionised, but also employs engineering graduates as technicians, while also
However, it is possible to run a CMMS at its basic function level of a database, using spreadsheets. It requires reasonable use of formulae, a clear understanding of what the CMMS is required to do and a format that is easily accessible to technicians and engineers. An effective system can be established using open-source software such as Google Sheets (Google.com a, (2018)), Apache OpenOffice (Openoffice.org, (2018)) or LibreOffice (Libreoffice.org, (2018)). Systems such as DropBox (DropBox, (2018)) or Google Drive (Google.com b, (2018)) can allow multiple 51
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users to edit such documents while still maintaining version integrity. Regular users need only know which sheets to access and what information to store in each sheet. If such a plan is not sufficient, either due to regulatory requirements or an inability to facilitate the spreadsheet option, there are simpler alternative options available. Online collaboration tools such as Trello (Trello, (2018)) or TargetProcess (TargetProcess, (2018)) can, with some adjustments, be used to control and store information important to the maintenance process. These systems are set up as tools for teams working on projects and could be said to facilitate easier communication between team members than more traditional systems. These online options are designed for a certain amount of local customisation as well as coming with mobile friendly apps, making interactions more intuitive than the traditional CMMS. Most of the online/ app based project management solutions include chat options for ready communication between members, easily accessible noticeboard-type areas for announcements and other project management tools that can be extremely useful in managing maintenance activities.
these apps on cross cultural collaboration and communication has not been investigated and could be a topic for future studies. 4. DISCUSSION Ultimately, successful implementation of a cost-oriented KM system depends upon a combination of personnel skills and knowledge, organisational processes and structures. Having a KM system capable of responding to the specific needs of the organisation in a timely, cost-oriented fashion is vital for the long-term success of the business. Using a case study in an Irish manufacturing company the knowledge and skills of the maintenance technicians were measured using a mixed research model. They were evaluated using a European tool and deficits measured. It was noted that if the company did not have trade unions then the gaps in the vocationally trained younger technicians could be enhanced by recruiting manufacturing engineering graduates. Engineering graduates are seen as more willing to embrace new knowledge and learning and to be more willing to store and disseminate such knowledge where needed. A clear understanding of what knowledge and skills are needed is vital to such an enterprise and activities leading to such understanding could represent a considerable investment. In the modern technological environment, a narrow spectrum of skills and knowledge is no longer sufficient to support the company.
PROJECT
REPORTING FUNCTION
RESOURCE BALANCING
OPTIONS FOR LARGE TEAMS
OPTIONS FOR SMALLER TEAMS
X
X
X
X
X
X
X
Y
X
X
X
X
X
SPARES
X
COST TRACKING
X
CORRCTIVE MAINTENANCE
SAP PEMAC TRELLO TARGET PROCESS MACHINE SENTRY
PLANNED MAINATINANCE
CMMS
COST OF SYSTEM
Table 1. Comparison of options for CMMS and alternatives.
HIGH
X
X
X
X
HIGH
X
X
X
X
LOW
Y
X
X
LOW
Y
X
X
X
MID
X
X
X
X
Engineering education in an Irish third level Institute brings the required skills to individuals to equip them for a career in manufacturing on an international platform and the interview with a co-author illustrates this strongly. Engineers Ireland registered professional titles are internationally recognised, supporting the view that an Irish engineering education supports the needs of engineering on an international platform. It is recognised that trade union agreements can sometimes prevent the use of engineering graduates in technician roles, but this is not universally the case.
Given the above, it seems unlikely that any organisation would not choose to move to the web-based options. There are downsides to these options however. A validated version of the collaborative apps has not been seen yet, for use in regulated environments. Some of the reporting functions possible with traditional options do not appear, as yet, in the project management apps. Some fear the communication aspects of such apps could lead to less rather than more effective communication in the workplace.
The CMMS can serve as a repository for much knowledge and information, but traditionally has been expensive and time consuming to implement and manage. Newer systems offer lower cost alternatives, albeit not including all features of traditional systems. These options can allow the knowledge to be captured and accessed by multiple persons, while maintaining data integrity.
AVT Reliability, Cork (AVT Reliability.com, 2018) have developed an app and system that fulfils the basic requirements of a CMMS, allows for the easy recording and access of information the online apps offer, but comes at a more reasonable cost than the traditional CMMS options. The app is developed for both iOS and Android devices, allows a technician or engineer to create new equipment records and task records on the spot and is heavily invested in predictive maintenance techniques. It could be a potential effective solution for knowledge transfer while maintaining costs at a lower level than a traditional option.
5. CONCLUSIONS A well educated workforce is vital for ensuring the knowledge management and development necessary for success in modern industry. It is possible that engineering graduates could be used to fill a gap in maintenance populations, but this would depend on trade union agreements, among other factors. A systematic, considered approach in assessing and determining knowledge and skills requirements is important to ensure the best outcomes – such approaches are available, for example the European VocTrainMaint exam. To capture tacit knowledge, and prevent the loss of knowledge due to retirement or other
Low cost CMMS options exist. They play a vital role in the overall viability and efficiency of the plant. New technology is emerging with useful functions that could be used in developing or developed countries. However, the impact of 52
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types of attrition from the company, it is important to have a systemic, procedural approach to knowledge management, such that recording knowledge and information becomes part of daily life, rather than a unique event prior to an employee’s departure.
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Efnms.eu. (2018). EFNMS – European Certification Cmte. URL: http://www.efnms.eu/committees/europeancertification-committee/ [Acc. 26 May 2018]. Engineersireland.ie. (2018). EI - Registered Prof Titles. URL: http://engineersireland.ie/Membership/RegisteredTitles.aspx [Acc. 23 May 2018]. Google.com. (2018a). Google Drive URL: https://www.google.com/drive/ [Acc. 30 May 2018]. Google.com. (2018b). Google Sheets URL: https://www.google.com/sheets/about/ [Acc. 30/5/2018]. E. Hajrizi, L. Stapleton, P. Kopacek (2009). “Knowledge and Tech Transfer in Dev Countries: Cases Study of UBT”, Proceedings of the 5th ETAI Int. Con. on App Automatic Systems (AAS-ETAI-09) and the 6th IFAC Int. Workshop on Knowledge and Tech. Transfer in/to Dev. Countries (DECOM-IFAC-09), Ohrid, Macedonia. P. Kopacek, M. Ceccharelli, E. Hajrizi & L. Stapleton (2006). Mechatronics Education and International Stability: The Development of University-Level Education Programmes in Advanced Engineering in Kosovo. In Improving Stability in Developing Nations through Automation 2006 (pp. 1-7). P. Kopacek, J. Bauer, I. Dorna & Krauter, L. (2015). “Cost Oriented (humanoid) Robots”, Proceedings of the IFAC Int. Con. in International Stability and Systems Engineering (TECIS 2015), September 2015 Sozopol, North Holland: Elsevier. Libreoffice.org. (2018). Home | LibreOffice - Free Office Suite - Fun Project - Fantastic People. URL https://www.libreoffice.org/ [Acc. 30/5/ 2018]. Openoffice.org. (2018). Apache OpenOffice - Official Site The Free and Open Productivity Suite. [URL https://www.openoffice.org/ [Acc. 30/5/2018]. Rothwell, Ph.D., SPHR, Y. W.. (2018). Dev leadership. URL: http://docplayer.net/162508-Developingleadership-talent-a-guide-to-succession-planning-andleadership-development.html. [Acc. 1/6/ 2018]. M. Shala, E. Hajrizi and L. Stapleton (2015). “Cost-Oriented Agile Innovation for Mechatronics Management in Less Developed Regions”, Pro. of the IFAC Int. Con. in Int. Stability and Systems Engineering (TECIS 2015), September 2015 Sozopol, North Holland: Elsevier. M. Shala, V. Hoxha, I. Bula, E. Hajrizi & L. Stapleton (2016 Cost-Oriented Innovation Methods and Education in Developing Countries: Re-eng. Ind. Production Systems. IFAC-PapersOnLine, 49(29), pp.48-51. L. Stapleton, Smith, D. & Murphy, F. (2005). ‘A Human-Centred Systems approach to the Management of Tacit Knowledge,’ AI and Society, 19(2), pp. 159-179. L. Stapleton, P. Kopacek, E. Hajrizi (2009). “Reflections on Third Level Accred. In Post-Crisis Dev. Countries”, Pro. of the IFAC Con. on Suppl. Ways of Improving Int. Stability (SWIIS 2009), North Holland: Elsevier. Targetprocess.com (2018) Target Process. [online] Ava at: https://www.targetprocess.com/ [acc 30 May 2018]. Trello.com. (2018). Trello. [online] URL: https://trello.com/ [acc 30/5/2018].
An Irish third level engineering education provides the skills necessary for employment on an international platform. Both the popularity of Ireland as a destination for Erasmus students and the interview with a former student in WIT show that the skills and knowledge gained in an Irish accredited engineering program are valued and popular among students and employers. While an immediate position as an engineering graduate may not always be possible on graduation (as was the case for the interviewee), employment as a technician is possible where trade union agreements allow it. CMMS systems can be used to fill the knowledge gaps often found in manufacturing companies, in particular, the tacit knowledge used in any correction or maintenance activity. The key elements of these systems have been established and investigated in this paper – work and knowledge recording should be routine and not unique events, the system should be suited to the work culture, in particular be suitable in terms of cost. There are low cost options available, where the large sums required for traditional options are not viable. An area for future research would include how the collaborative tools mentioned would operate in cross cultural environments. In terms of future research there is wide scope to establish a case study in a developing country to see how international collaborations could establish an improvement in management systems. 8. REFERENCES Arunachalam, S. (1999). "Information and knowledge in the age of electronic communication: a developing country perspective." J. of information science 25, 6, 465-476. Avtreliability.com. (2018). Machine Sentry | AVT Reliability. URL https://www.avtreliability.com/products/machinesentry [Acc. 30 May 2018]. J. Bauer, Durakbasa, N, Bas, G, Guciu, E. (2015). “Telepresence in Education”, Proceedings of the IFAC Int. Con. in Int. Stability and Systems Eng (TECIS 2015), September 2015 Sozopol, North Holland: Elsevier. Dropbox. (2018). Dropbox. [online] Avail. at: https://www.dropbox.com/ [Accessed 30 May 2018]. P. Groumpos, P.P., (2015a). Modelling business and mgt systems using fuzzy cognitive maps: a critical overview. IFAC-PapersOnLine, 48(24), pp.207-212. P. Groumpos, P.P., (2015b). Overview of the triangle of knowledge: a driving force for sustainable growth in less developed nations. AI & society, 31(3), pp.305-318. M.Doyle-Kent, Curtis, H., Darcy, R., Stapleton, L. and Norton, S., 2016. Effs. Through the Automatic Control of Age-Profiled Manuf. Machines: A Case Study of Cost-Saving in an Irish Production Facility. IFACPapersOnLine, 49(29), pp.42-47.
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Cost Cost Oriented Oriented Maintenance Maintenance Management Management Systems Systems for for Manufacturing Manufacturing Processes. Processes. Cost Oriented Maintenance Management Systems for Manufacturing Processes. Mary Doyle Kent*. Orlagh Costello**. Sean Phelan***. Kalin Petrov****. Mary Doyle Kent*. Orlagh Costello**. Sean Phelan***. Kalin Petrov****. *Dept of Engineering Technology, Waterford Institute of Technology, Waterford, X91 KOEK, Ireland. Mary Doyle Kent*. Waterford Orlagh Costello**. Phelan***. Kalin Petrov****. *Dept of Engineering Technology, Institute ofSean Technology, Waterford, X91 KOEK, Ireland. (Tel +353 51 302058 Email [email protected]) *Dept of Engineering Technology, Waterford Institute Technology, Waterford, X91 KOEK, Ireland. (Tel +353 51 302058 [email protected]) **Bausch & Lomb Ireland, Ireland.(Email [email protected]) (Tel Waterford, +353 51 302058 Email [email protected]) **Bausch & Lomb Ireland, Waterford, Ireland.(Email [email protected]) ***Dept of**Bausch Engineering Technology, WIT, Waterford, X91 KOEK, Ireland. (Email [email protected]) & Lomb Ireland, WIT, Waterford, Ireland.(Email [email protected]) ***Dept of Engineering Technology, Waterford, X91 KOEK, Ireland. (Email [email protected]) ****Dept of Engineering Technology, WIT, Waterford, X91 KOEK, Ireland. ([email protected]) [email protected] ) ***Dept ****DeptofofEngineering EngineeringTechnology, Technology,WIT, WIT,Waterford, Waterford,X91 X91KOEK, KOEK,Ireland. Ireland.(Email (Email [email protected] ) ****Dept of Engineering Technology, WIT, Waterford,firms X91 KOEK, Ireland.knowledge (Email [email protected] Abstract: Case studies of manufacturing have shown retention in industrial ) Abstract: Case studies of manufacturing firms have shown knowledge retention in industrial settings critical. The retirement of skilledfirms technicians can cause important knowledge to drain Abstract:is studies of manufacturing have shown knowledge retention in industrial settings is Case critical. The retirement of skilled technicians can cause important knowledge to drain from the firm. Few recent case studies of cost-oriented maintenance management systems for settings critical. The retirement of skilled technicians can cause important knowledge to drain from theis firm. Few recent case studies of cost-oriented maintenance management systems for manufacturing processes have appeared in literature to date. from the firm. processes Few recent studiesinofliterature cost-oriented manufacturing havecase appeared to date.maintenance management systems for manufacturing processes have appeared in literature to date. A manufacturing facility is presented here and the skills of the maintenance technician workforce A manufacturing facility is presented here and the skills of the maintenance technician workforce analyzed. A manufacturing engineering graduate was interviewed ascertaining the relevance of an A manufacturing facility is presented here and thewas skills of the maintenance technician workforce analyzed. A manufacturing engineering graduate interviewed ascertaining the relevance of an Irish third level qualification in preparation for the workforce internationally. An investigation analyzed. manufacturing engineering graduate ascertaining theAn relevance of an Irish thirdAlevel qualification in preparation for was the interviewed workforce internationally. investigation into maintenance in software programs is made focusing on adaptability for developing Irishopen thirdsource level qualification preparation for the workforce internationally. Anfor investigation into open source maintenance software programs is made focusing on adaptability developing countries. into open source maintenance software programs is made focusing on adaptability for developing countries. countries. © 2018, IFAC (International Federation ofCost Automatic Control) Knowledge Hosting by Elsevier rights reserved. Keywords: Maintenance, Manufacturing, Effectiveness, TransferLtd. andAll Computerized Keywords: Maintenance, Manufacturing, Cost Effectiveness, Knowledge Transfer and Computerized Maintenance Management Systems Keywords: Maintenance, Manufacturing, Cost Effectiveness, Knowledge Transfer and Computerized Maintenance Management Systems Maintenance Management Systems
1. INTRODUCTION 1. INTRODUCTION 1. INTRODUCTION Cost oriented automation research has a long tradition in Cost oriented automation research has a long tradition in IFAC and has typically focused upon describing new Cost oriented a long traditionnew in IFAC and hasautomation typically research focused has upon describing automatic and semi-automatic solutions to control important IFAC andand hassemi-automatic typically focused upon describing new automatic solutions to control important processes and systems. Recent cost-oriented automation automatic and solutions to controlautomation important cost-oriented processes and semi-automatic systems. Recent papers have focused upon sophisticated production processes and systems. Recent cost-oriented automation papers have focused upon sophisticated production operations and processes upon (e.g. Kent (2016), production Groumpos papers have operations and focused processes (e.g. sophisticated Kent (2016), Groumpos (2015a), Shala et al (2015)) and the provision of new services operations andet al processes (e.g.theKent (2016), Groumpos (2015a), Shala (2015)) and provision of new services using advanced, cost-oriented robotics (e.g. Kopacek et al (2015a), Shala et al (2015)) and robotics the provision new services using advanced, cost-oriented (e.g. of Kopacek et al (2015)). International studies have long shown that in using advanced, cost-oriented (e.g. shown Kopacek al (2015)). International studies robotics have long thatet in developing countries where populations do not have access to (2015)). International studies have long that in developing countries where populations do notshown have access to well-developed, university level cross-disciplinary education developing countries where level populations do not haveeducation access to well-developed, university cross-disciplinary the problem of knowledge development, retention and well-developed, leveldevelopment, cross-disciplinary education the problem ofuniversity knowledge retention and transfer can be exacerbated and even hamper economic the problem of exacerbated knowledge and development, retention and transfer can be even hamper economic development (Arunachalam (1999)). Groumpos showed that transfer can be exacerbated and even hamper economic development (Arunachalam (1999)). Groumpos showed that a key to successful advanced engineering processes inthat an (Arunachalam (1999)). Groumpos showedin adevelopment key to successful advanced engineering processes an international stability and developing country context is the a key to successful engineering processes in the an international stability advanced and developing country context is effective control and management of systemic knowledge in international stability and developing country context is the effective control and management of systemic knowledge in the enterprise (Groumpos (2015a), (2015b)). This is effective control (Groumpos and management of systemic knowledge the enterprise (2015a), (2015b)). This in is particularly important for enhancing cost-oriented innovative the enterprise (Groumpos (2015a), (2015b)). innovative This is particularly important for enhancing cost-oriented capacity in less developed regions in manufacturing firms particularly for enhancing innovative capacity in important less developed regions cost-oriented in manufacturing firms (e.g. Shala et al (2015)). capacity developed regions in manufacturing firms (e.g. Shalainetless al (2015)). (e.g. Shala et al (2015)). This paper establishes that knowledge development, retention This paper establishes that knowledge development, retention and transfer is of critical concern in Irish high-tech This paper establishes knowledge retention and transfer is of that critical concerndevelopment, in Irish high-tech companies. It looks at the aptness of inIrish education in and transferIt islooks of at critical concernof Irish high-tech companies. the aptness Irish education in engineering and investigates some potential low-cost options companies. and It looks at the some aptness of Irish education in engineering investigates potential low-cost options for facilitating theinvestigates effective transfer of this tacit knowledge. engineering andthe some potential low-cost options for facilitating effective transfer of this tacit knowledge. for facilitating the effective transfer of this tacit knowledge. In 2014 in Waterford Institute of Technology (WIT) two final In 2014 in Waterford Institute of Technology (WIT) two final year students Kalin Petrov and Sean Phelan undertook case In 2014 in Waterford Institute Technology (WIT) twoaa final year students Kalin Petrov andofSean Phelan undertook case study as part of their final year thesis “Knowledge Transfer year students Kalin and thesis Sean Phelan undertook a case study as part of theirPetrov final year “Knowledge Transfer study as part of their final year thesis “Knowledge Transfer
(KT) through Computerised Maintenance Management (KT) through Computerised Maintenance Management Systems (CMMS). An in-depth investigation into the (KT) through Computerised Maintenance Management Systems (CMMS). An in-depth investigation into the transfer of knowledge within the maintenance sector.” This Systems of(CMMS). in-depth investigation into This the transfer knowledge An within the maintenance sector.” looked at the requirements of a large high-tech company, transfer atof the knowledge withinofthea maintenance sector.” This large high-tech company, looked requirements analysing the knowledge and skills maintenance technicians looked at the the knowledge requirements a large high-techtechnicians company, analysing andofskills maintenance were required to have for the successful running of the plant. analysing the knowledge and skills maintenance technicians were required to have for the successful running of the plant. The company realized that to maintain the vital know-how were company required to have for thetosuccessful the plant. The realized that maintain running the vitalofknow-how they had to assess current staff, highlight deficits and plan for The had company realized that to maintain vitaland know-how they to assess current staff, highlight the deficits plan for the future. The company was considering hiring they had to assess staff, highlight deficits and plan for the future. Thecurrent company was considering hiring manufacturing engineering graduates. It seemed that they the future. The company was It considering hiringaa manufacturing engineering graduates. seemed that they more eclectic range of knowledge and skills due to thethey type manufacturing engineering graduates. seemed more eclectic range of knowledge and Itskills due that to the typea of education received in an Irish Institute, rather than the more eclectic received range of in knowledge skills rather due to than the type of education an Irish and Institute, the more traditional craft approach. of education received in an Irish Institute, rather than the more traditional craft approach. more traditional craft approach. The second element of this paper is an account of an The second element of this paper is an account of an engineering undergraduate’s educational experience. How The second undergraduate’s element of this educational paper is anexperience. account ofHow an engineering did a manufacturing engineering degree, offered by an IOT engineering undergraduate’s educational experience. did a manufacturing engineering degree, offered by an How IOT (Institute of Technology) in the south east of Ireland, prepare did a manufacturing engineering degree, by prepare an IOT (Institute of Technology) in the south east offered of Ireland, him to work in the manufacturing industry internationally? (Institute of Technology) in the south east internationally? of Ireland, prepare him to work in the manufacturing industry him work in thesection manufacturing The toconcluding focuses industry on low internationally? cost open source The concluding section focuses on low cost open source CMMS. These systems can be an option for developing The concluding section focuses low cost source CMMS. These systems can be on an option foropen developing industrial communities. An analysis of software packages has CMMS. These systemsAncan be anofoption forpackages developing industrial communities. analysis software has been made, and recommendations are outlined on the industrial communities. An analysis of software packages been made, and recommendations are outlined on has the feasibility of using these packages in differing economies. been made, and these recommendations are outlined on the feasibility of using packages in differing economies. feasibility of using these packages in differing economies. Three research questions are posed: Three research questions are posed: Three research questions arean posed: Q1. Using a case study in Irish manufacturing company Q1. Using a case study in an Irish manufacturing company can the knowledge and skills of the maintenance technicians Q1. the Using a case study in anofIrish company can knowledge and skills the manufacturing maintenance technicians be measured and deficits evaluated? canmeasured the knowledge and skills of the maintenance technicians be and deficits evaluated? be measured and deficits evaluated?
Copyright © 2018 IFAC 48 Copyright © 2018, 2018 IFAC 48 Hosting by Elsevier Ltd. All rights reserved. 2405-8963 © IFAC (International Federation of Automatic Control) Copyright 2018 responsibility IFAC 48 Control. Peer review©under of International Federation of Automatic 10.1016/j.ifacol.2018.11.244
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Q2. Can education in an Irish third level Institute bring the required skills to individuals to equip them for a career in manufacturing on an international platform?
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company will prove to be an important trend in the future (Rothwell, (2014)), especially the tacit knowledge, not explicitly outlined in manuals and other official documentation. This knowledge is difficult to capture even prior to retirement. Company policies and procedures should allow for such knowledge to be captured as part of the normal work recording procedures, for example using the CMMS to record the knowledge used on all jobs. As technology develops it is vital for all companies to introduce a culture of continuous improvement.
Q3. Can low cost maintenance software programs be used to manage maintenance requirements internationally? 2. RESEARCH APPROACH Following an approach by the manufacturing manager of a high-tech industrial facility to form a collaboration in maintenance knowledge transfer, it was agreed that a student led project would investigate if a methodical solution could be found to minimise the negative effects of the current aging maintenance technician workforce retiring within the plant. Data was gathered using a mixed model research methodology including questionnaires, interviews and technical assessment. This data was used to gain an understanding of knowledge deficits and pointed to potential solutions. In section 3.1 a summary of some of the data is presented, whilst protecting anonymity of the firm.
Knowledge management (KM) should be achieved through an integrated and comprehensive company strategy, including policies implementation, monitoring and evaluation. Knowledge must be available when and where it is needed from both external and internal sources. As a deliverable of the project a low-cost bespoke model of the company’s skills profile was developed. The company’s maintenance technician’s skills matrix in figure 1 was used to itemise the skills required.
In Section 3.2 one of the co-authors from Bulgaria, has, in an interview, explained how an engineering education in Ireland has helped him to fulfil a lifelong aspiration in manufacturing. He was one of the students on the original maintenance project. It becomes clear from this interview that an appropriate education can fill the gaps in a high-tech company and open doors internationally. To investigate low cost solutions of CMMS systems one of the co-authors, who has extensive experience in high-tech maintenance management systems, undertook a literature review. It was noted that a range of solutions are available now and can be low cost and adapted to the requirements of the firm. A summary of the findings is presented in section 3.3.
Fig. 1 Skills Requirement Matrix A customized, date-driven inventory and schedule of skills and knowledge was developed. It defined the role of workers, the resources available and test questions needed to confirm the right knowledge that had to be transferred. This led the authors to develop a “Bespoke Company Matrix”, where the employee names where placed across the X-axis and the chosen subject matter down the Y-axis. The employees were simply scored on each subject depending on their abilities. Figure 2 is a sample of the matrix layout.
3. FINDINGS 3.1 Maintenance Needs of an Irish High-Tech Industry. A final year project undertaken by Kalin Petrov and Sean Phelan firstly investigated the extent to which narrow technical fields of expertise were a challenge in the maintenance sector in a high-tech Irish manufacturing firm. Secondly, the case explored how to transfer, at low cost, maintenance knowledge in a high technology manufacturing plant with an aging work force many of whom are close to retirement.
As an additional part of the project, the international footprint of the Irish vocational training of maintenance technicians was assessed. They were given access to the European VocTrainMaint exam which has been developed for people with an electrical, mechanical or maintenance background. The goal of the exam was to improve efficiency, quality and safety in a modern industrial production unit. The complete program consists of individual subjects that can be taken on a full time or modular basis. Each module will in turn be rewarded credits under the European Credit Transfer and Accumulation Program for the European Credit and Transfer Accumulation System (ECTS).
In the study, it was established that many vocationally educated technicians such as fitters and electricians have been trained to be experts in narrow fields of expertise. A system to highlight current skill profiles of the workforce, help identify knowledge gaps and set out the programs needed to fill the gaps in a timely manner had to be developed. The study highlighted the need for ambitious and broadminded team members keen to develop their own skillsets while supporting other team members also develop their own new skillsets. Managing the retiree pool of a 49
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Fig. 3. Results of the VocTrainMaint exam. A number of Electricians, Fitters and Students from a level 7 Institute of Technology Engineering course took the VocTrainMaint exam and the results were plotted and analysed. A summary of the results can be seen in Figure 3. It was noted that the students demonstrated a relatively good level of maintenance knowledge as compared to the Maintenance Technicians. They had no work experience when tested. These results were considered by the company management and will be considered in the future, when seeking to hire technicians with a more eclectic range of knowledge and skills. 3.2 An interview of a manufacturing engineering student. Kopacek et al in 2006 stated that “it is evident that there is a need to focus upon higher education as a pre-requisite for sustainable growth and stability, and, in particular, a focus upon emerging disciplines in the field of high technology. This is very important in developing a skill-base for potential, future inward investment.” (Kopacek et al (2015)) Ireland welcomes all nationalities and is often chosen by students looking for an English language European education. In WIT we have a long history of visiting Erasmus and International students. WIT has developed many interinstitutional Erasmus links and in 2017-18 it had 110 agreements in place. International students came from 28 countries worldwide to study on various programmes in the Institute. During the academic year 2017-18 #189 Erasmus students and #50 International students studied in WIT. These figures were provided by WITs International office.
Fig. 2 Bespoke Knowledge Transfer Matrix This software was conceptualised under the banner of the EFNMS (European Federation of Nation Maintenance Societies) and was funded by the European Union’s lifelong learning program. On completion of the exam participants who pass will receive a cert recognised and accepted across Europe for expertise in Maintenance. He/she can in turn use this qualification to progress along the European Qualification Framework (EQF) at their own pace. Those who fail the exam will highlight deficiencies in their own knowledge base to improve on.
Engineering courses, and especially in mechanical and manufacturing, prove to be particularly sought after. As stated by Kopacek et al. “research articles clearly demonstrated the need for a coherent theoretical approach to the development of engineering education curricula which enables undergraduates develop the necessary professional competences to perform their work on graduation.” (Kopacek et Al (2006)). WIT currently offers 36 courses that are accredited with Engineers Ireland (EI), including the BEng in Manufacturing Engineering. EI is the Irish professional body, and a registered professional title from EI provides peer reviewed and international formal recognition of professional competence. (EngineersIreland.ie, (2018)). Categories of Registered Professional Titles: Fellow (CEng FIEI), Chartered Engineer (CEng MIEI), Associate Engineer (AEng
According the European Federation of National Maintenance Societies (EFNMS) the benefits in completing the VTM program are; independent verification of professional maintenance skills, competitive advantage in the sale of maintenance services, ability to identify knowledge gaps within the maintenance area and support for continued skills development in maintenance (Efnms.eu. (2018)).
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MIEI), Engineering Technician (EngTech MIEI). The skills offered in these courses are highly valued internationally. Students also understand the importance of these skills.
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employing time served craftsmen in different roles. Much depends, therefore, on union agreements and the relationship between union members and the employer.
Following is an interview of a co-author of this paper - an international student who completed a degree in manufacturing engineering in WIT. This testimony illustrates the versatility and usefulness of an accredited engineering education.
3.3 Investigation of Open Source Maintenance Software’s. The CMMS has long been the backbone of the maintenance department and is the main knowledge transfer system used in most organisations, primarily functioning as a database, storing information for later retrieval or for transferring essential information. For example, a maintenance plan is often the first thing one might think of in relation to the CMMS - originally, the systems were used to produce regular jobs and activities at specified frequencies.
Kalin Petrov was a manufacturing engineering graduate in 2014 from WIT. He had left Bulgaria and travelled to Ireland to earn money and improve his quality of life, with a view to returning to his native country after several years. Ireland was unknown to him, but an agency organised his move here because of his English language proficiency. Kalin had, from an early age, a passion for problem solving so this led him to work in an engineering company on arrival in Ireland. He realised quickly that to progress and move up the career ladder he would have to upskill and decided to follow his dream of becoming an engineer. Initially he studied in WIT as an evening/part time student but completed his course in a full-time capacity. His experience was very positive. His communication and language skills improved significantly in this period. Technically he said “since joining WIT in 2009 I have learned a lot of engineering practical and theoretical skills which have helped me achieve my career goal. I knew that if I wanted to go back to my home country someday, all the engineering education and expertise would help me there. During the course I studied mechatronics, robotics, quality, statistical process control, product and process design, maths and other modules. Projects were very important. My project partner was Sean Phelan. Team projects helped me to develop team work skills, communication & presentation skills, technical report writing & time management expertise. Software packages learned included MS-Office, Labview, AutoCAD, SolidWorks, and programming software’s for PLC’s.”
Fig. 4. CMMS (Computerised Maintenance Mgt. System) The CMMS expanded to record work such as breakdowns, improvements and other interventions that would not be included in an equipment plan. This is where the real knowledge transfer can happen. Technicians and engineers record what problem they found, what steps they took to correct it and any other information that they think is relevant. The quality and quantity of information recorded varies, but personnel can review previous reports to find similar problems, speeding up the repair process. The CMMS can therefore be a method of storing and retaining tacit knowledge, not otherwise captured in official documentation. As CMMS software packages developed, these basic functions were expanded to advanced reporting functions, spares programs and links to financial programs. The cost of such systems can prove prohibitive for developing economies. For a standalone system with the potential to be integrated with other onsite systems, with 200+ users, the cost can be approx. €100,000 for installation, training and licence fees. This does not include any internal business process changes required or other software or hardware requirements. In developing economies, this price tag can be too high, with the internal change needed adding another layer of complexity and cost to the equation.
Kalin explains that on graduating, he encountered difficulty in trying to get a graduate engineering position in Ireland. He did find employment as an operator/technician, which then led to a graduate engineering position. Kalin went on to save the medical device company he was working for €1.3 million. His experience in this and in a later company, opened a fantastic opportunity in his native Bulgaria where he is currently a project manager for a multinational company. It is possible to use engineering graduates to fill gaps in the maintenance sector of manufacturing companies. With the skills learned as part of their degrees, they are valuable additions to the maintenance function. However, many trade union agreements enforce strict division of labour requirements on the employer. Where such policies are in place, it is not usually possible to employ graduates as technicians. However, these agreements are not unilateral. There is at least one medical devices company in the west of Ireland where this is not the case. The plant is unionised, but also employs engineering graduates as technicians, while also
However, it is possible to run a CMMS at its basic function level of a database, using spreadsheets. It requires reasonable use of formulae, a clear understanding of what the CMMS is required to do and a format that is easily accessible to technicians and engineers. An effective system can be established using open-source software such as Google Sheets (Google.com a, (2018)), Apache OpenOffice (Openoffice.org, (2018)) or LibreOffice (Libreoffice.org, (2018)). Systems such as DropBox (DropBox, (2018)) or Google Drive (Google.com b, (2018)) can allow multiple 51
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users to edit such documents while still maintaining version integrity. Regular users need only know which sheets to access and what information to store in each sheet. If such a plan is not sufficient, either due to regulatory requirements or an inability to facilitate the spreadsheet option, there are simpler alternative options available. Online collaboration tools such as Trello (Trello, (2018)) or TargetProcess (TargetProcess, (2018)) can, with some adjustments, be used to control and store information important to the maintenance process. These systems are set up as tools for teams working on projects and could be said to facilitate easier communication between team members than more traditional systems. These online options are designed for a certain amount of local customisation as well as coming with mobile friendly apps, making interactions more intuitive than the traditional CMMS. Most of the online/ app based project management solutions include chat options for ready communication between members, easily accessible noticeboard-type areas for announcements and other project management tools that can be extremely useful in managing maintenance activities.
these apps on cross cultural collaboration and communication has not been investigated and could be a topic for future studies. 4. DISCUSSION Ultimately, successful implementation of a cost-oriented KM system depends upon a combination of personnel skills and knowledge, organisational processes and structures. Having a KM system capable of responding to the specific needs of the organisation in a timely, cost-oriented fashion is vital for the long-term success of the business. Using a case study in an Irish manufacturing company the knowledge and skills of the maintenance technicians were measured using a mixed research model. They were evaluated using a European tool and deficits measured. It was noted that if the company did not have trade unions then the gaps in the vocationally trained younger technicians could be enhanced by recruiting manufacturing engineering graduates. Engineering graduates are seen as more willing to embrace new knowledge and learning and to be more willing to store and disseminate such knowledge where needed. A clear understanding of what knowledge and skills are needed is vital to such an enterprise and activities leading to such understanding could represent a considerable investment. In the modern technological environment, a narrow spectrum of skills and knowledge is no longer sufficient to support the company.
PROJECT
REPORTING FUNCTION
RESOURCE BALANCING
OPTIONS FOR LARGE TEAMS
OPTIONS FOR SMALLER TEAMS
X
X
X
X
X
X
X
Y
X
X
X
X
X
SPARES
X
COST TRACKING
X
CORRCTIVE MAINTENANCE
SAP PEMAC TRELLO TARGET PROCESS MACHINE SENTRY
PLANNED MAINATINANCE
CMMS
COST OF SYSTEM
Table 1. Comparison of options for CMMS and alternatives.
HIGH
X
X
X
X
HIGH
X
X
X
X
LOW
Y
X
X
LOW
Y
X
X
X
MID
X
X
X
X
Engineering education in an Irish third level Institute brings the required skills to individuals to equip them for a career in manufacturing on an international platform and the interview with a co-author illustrates this strongly. Engineers Ireland registered professional titles are internationally recognised, supporting the view that an Irish engineering education supports the needs of engineering on an international platform. It is recognised that trade union agreements can sometimes prevent the use of engineering graduates in technician roles, but this is not universally the case.
Given the above, it seems unlikely that any organisation would not choose to move to the web-based options. There are downsides to these options however. A validated version of the collaborative apps has not been seen yet, for use in regulated environments. Some of the reporting functions possible with traditional options do not appear, as yet, in the project management apps. Some fear the communication aspects of such apps could lead to less rather than more effective communication in the workplace.
The CMMS can serve as a repository for much knowledge and information, but traditionally has been expensive and time consuming to implement and manage. Newer systems offer lower cost alternatives, albeit not including all features of traditional systems. These options can allow the knowledge to be captured and accessed by multiple persons, while maintaining data integrity.
AVT Reliability, Cork (AVT Reliability.com, 2018) have developed an app and system that fulfils the basic requirements of a CMMS, allows for the easy recording and access of information the online apps offer, but comes at a more reasonable cost than the traditional CMMS options. The app is developed for both iOS and Android devices, allows a technician or engineer to create new equipment records and task records on the spot and is heavily invested in predictive maintenance techniques. It could be a potential effective solution for knowledge transfer while maintaining costs at a lower level than a traditional option.
5. CONCLUSIONS A well educated workforce is vital for ensuring the knowledge management and development necessary for success in modern industry. It is possible that engineering graduates could be used to fill a gap in maintenance populations, but this would depend on trade union agreements, among other factors. A systematic, considered approach in assessing and determining knowledge and skills requirements is important to ensure the best outcomes – such approaches are available, for example the European VocTrainMaint exam. To capture tacit knowledge, and prevent the loss of knowledge due to retirement or other
Low cost CMMS options exist. They play a vital role in the overall viability and efficiency of the plant. New technology is emerging with useful functions that could be used in developing or developed countries. However, the impact of 52
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types of attrition from the company, it is important to have a systemic, procedural approach to knowledge management, such that recording knowledge and information becomes part of daily life, rather than a unique event prior to an employee’s departure.
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An Irish third level engineering education provides the skills necessary for employment on an international platform. Both the popularity of Ireland as a destination for Erasmus students and the interview with a former student in WIT show that the skills and knowledge gained in an Irish accredited engineering program are valued and popular among students and employers. While an immediate position as an engineering graduate may not always be possible on graduation (as was the case for the interviewee), employment as a technician is possible where trade union agreements allow it. CMMS systems can be used to fill the knowledge gaps often found in manufacturing companies, in particular, the tacit knowledge used in any correction or maintenance activity. The key elements of these systems have been established and investigated in this paper – work and knowledge recording should be routine and not unique events, the system should be suited to the work culture, in particular be suitable in terms of cost. There are low cost options available, where the large sums required for traditional options are not viable. An area for future research would include how the collaborative tools mentioned would operate in cross cultural environments. In terms of future research there is wide scope to establish a case study in a developing country to see how international collaborations could establish an improvement in management systems. 8. REFERENCES Arunachalam, S. (1999). "Information and knowledge in the age of electronic communication: a developing country perspective." J. of information science 25, 6, 465-476. Avtreliability.com. (2018). Machine Sentry | AVT Reliability. URL https://www.avtreliability.com/products/machinesentry [Acc. 30 May 2018]. J. Bauer, Durakbasa, N, Bas, G, Guciu, E. (2015). “Telepresence in Education”, Proceedings of the IFAC Int. Con. in Int. Stability and Systems Eng (TECIS 2015), September 2015 Sozopol, North Holland: Elsevier. Dropbox. (2018). Dropbox. [online] Avail. at: https://www.dropbox.com/ [Accessed 30 May 2018]. P. Groumpos, P.P., (2015a). Modelling business and mgt systems using fuzzy cognitive maps: a critical overview. IFAC-PapersOnLine, 48(24), pp.207-212. P. Groumpos, P.P., (2015b). Overview of the triangle of knowledge: a driving force for sustainable growth in less developed nations. AI & society, 31(3), pp.305-318. M.Doyle-Kent, Curtis, H., Darcy, R., Stapleton, L. and Norton, S., 2016. Effs. Through the Automatic Control of Age-Profiled Manuf. Machines: A Case Study of Cost-Saving in an Irish Production Facility. IFACPapersOnLine, 49(29), pp.42-47.
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