- Email: [email protected]
The equipment maintenance management in manufacturing enterprises
18th IFAC Conference on Technology, Culture and International 18th IFAC Conference on Technology, Culture and International Stability 18th IFAC Conference on Technology,Available Culture and International Stability online at www.sciencedirect.com Baku, Azerbaidschan, Sept 13-15, 2018 18th Conference Sept on Technology, Stability Baku,IFAC Azerbaidschan, 13-15, 2018Culture and International Stability Baku, Azerbaidschan, Sept 13-15, 2018 Baku, Azerbaidschan, Sept 13-15, 2018
ScienceDirect
IFAC PapersOnLine 51-30 (2018) 800–802
The The equipment equipment maintenance maintenance management management in in manufacturing manufacturing enterprises enterprises The equipment maintenance management in manufacturing enterprises The equipment maintenance management in manufacturing enterprises Xh. Mehmeti*, B. Mehmeti**, Rr. Sejdiu***
Xh. Mehmeti*, B. Mehmeti**, Rr. Sejdiu*** Xh. Mehmeti*, B. Mehmeti**, Rr. Sejdiu*** Xh. Mehmeti*, Mehmeti**, Sejdiu*** IHRT *TU Wien, Institute forB. Mechanics and Rr. Mechatronics, *TU Wien, Institute for Mechanics and Mechatronics, IHRT Favoritenstrasse 9-11/E325 A6, A – 1040, Wien (e-mail:[email protected]) *TU9-11/E325 Wien, Institute Mechanics and Mechatronics, IHRT Favoritenstrasse A6, Afor – 1040, Wien (e-mail:[email protected]) *TUof Wien, Institute for Mechanics and Mechatronics, **University Applied Sciences in Ferizaj, St. Universiteti, p.n.IHRT 70000 Ferizaj, Favoritenstrasse 9-11/E325 A6, A – 1040, Wien (e-mail:[email protected]) **University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Favoritenstrasse 9-11/E325 A6, A – 1040, Wien (e-mail:[email protected]) Republic of Kosovo. (e-mail: [email protected]) **University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Republic of Kosovo. (e-mail: [email protected]) ***University ofApplied Applied Sciences inFerizaj, Ferizaj, St.Universiteti, Universiteti, p.n. p.n.70000 70000Ferizaj, Ferizaj, **University of Sciences in St. Republic of Kosovo. (e-mail: [email protected]) ***University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Republic Kosovo. (e-mail: [email protected]) Republic of of Kosovo. (e-mail: [email protected]) ***University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Republic of Kosovo. (e-mail: [email protected]) ***UniversityRepublic of Applied Sciences(e-mail: in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, of Kosovo. [email protected]) Republic of Kosovo. (e-mail: [email protected]) Abstract: With continued global market growth and increased equipments complexity, professional Abstract: With continued global market growth and increased equipments complexity, professional access to maintenance playsglobal a key role togrowth be competitive in the equipments market and increase productivity of Abstract: With continued and increased professional access to maintenance plays a keymarket role to be competitive in the market and complexity, increase productivity of production. Advanced production systems are related to the wider use of information technology in Abstract: With continued global market growth and increased equipments complexity, professional access to maintenance plays a keysystems role to are be competitive in wider the market increase productivity production. Advanced production related to the use ofand information technology of in maintenance management, staff training, professional staff engagement in maintenance, and wider use of access to maintenance plays a key role to be competitive in the market and increase productivity production. Advanced production systems are related to engagement the wider use of information in maintenance management, staff training, professional staff in maintenance, andtechnology wider use of preventive In paperprofessional will presented results use from research and on technology maintenance production. maintenance. Advanced production systems are be related to engagement the wider of information in maintenance management, staffthis training, staff maintenance, wider use of preventive maintenance. In this paper will be presented results in from research on maintenance managementmaintenance. and the importance of maintenance in manufacturing enterprises inresearch Kosovo.and maintenance management, staffthis training, professional staff engagement in maintenance, wider use of preventive In paper will be presented results from on maintenance management and the importance of maintenance in manufacturing enterprises in Kosovo. preventive maintenance. In this paper will be presented results from research on maintenance management and the importance of maintenance in manufacturing enterprises Kosovo. © 2018, IFAC (International Federation of Automatic Control) Hosting by ElsevierinLtd. All rights reserved. Keywords: maintenance management, preventive maintenance, failures management and the importance of maintenance manufacturing enterprises in Kosovo. Keywords: maintenance management, preventivein maintenance, failures Keywords: maintenance management, preventive maintenance, failures Keywords: maintenance management, preventive maintenance, failures Therefore maintenance does not only aim to keep the Therefore maintenance does not only aim to keep the 1. INTRODUCTION 1. INTRODUCTION equipment in a state ofdoes working order aim but also playsthea Therefore maintenance not only to keep equipment in a state ofdoes working order aim but also playsthea 1. INTRODUCTION Therefore maintenance not only to keep The concept of equipment maintenance is present and decisive role production goals in in a achieving state of working order butwith also optimum plays a 1. INTRODUCTION The concept of equipment maintenance is present and equipment decisive role in achieving production goals with optimum in ina achieving state of working order butwith also optimum plays a indispensable inofany production. Maintenanceisis present required and for equipment The concept equipment maintenance cost of ownership and maximum productivity. decisive role production goals indispensable in any production. Maintenance is required for cost of ownership and maximum productivity. equipment because the efficiency and quality of production is The concept of equipment maintenance is present and decisive role in achieving production goals with optimum indispensable in anythe production. required for of ownership and maximum productivity. equipment because efficiency Maintenance and quality ofisproduction is cost Maintenance reduced over time the machines may fail more often. indispensable in anyand production. Maintenance required for equipment because and quality ofisproduction is 1.1 cost of ownershipmethods and maximum productivity. 1.1 Maintenance methods reduced over time the andefficiency the machines may fail more often. Thereforeover abecause technical system that and is inquality regular for isa 1.1 Maintenance methods equipment the efficiency ofcondition production reduced time and the machines may fail more often. Therefore a technical system that is in regular condition for a There are many divisions from the aspect of strategy, policy, 1.1 Maintenance methods from the aspect of strategy, policy, long time, i.e. to function period reduced over time and theregularly machines maya longer fail more often. are many divisions Therefore technical system that is inover regular condition forof long time, ai.e. to function regularly over a longer period ofa There type and maintenance. Butaspect in most the literature, areform manyof divisions from the of of strategy, policy, time, time, it isai.e. necessary to beregularly properly maintained. (Xhemajl Therefore technical system that is inover regular condition forofa There long to function a longer period type and form of maintenance. Butaspect in most of the literature, time, it is necessary to be properly maintained. (Xhemajl There are many divisions from the of strategy, maintenance is divided as planned and unplanned which type and form of maintenance. But in most of the literature, Mehmeti, 2012). This is especially important for those long time, i.e. to function regularly a longer (Xhemajl period of maintenance is divided as planned and unplanned policy, time, it is 2012). necessary properlyover maintained. which Mehmeti, Thisto isbe especially important for those type and form of maintenance. But in most of the literature, systems that can cause failure relatively often, which disable time, it is necessary to be properly maintained. (Xhemajl particularly make its main divisions. Most of the maintenance is divided as plannedMost and ofunplanned which Mehmeti, Thisfailure is especially fordisable those maintenance systems that2012). can cause relativelyimportant often, which particularly make its main divisions. the maintenance is divided as planned and through unplanned which the regular operation of therelatively system, but which with proper Mehmeti, 2012). Thisfailure is especially important fordisable those maintenance operations in the industry are conducted preventive particularly make its main divisions. Most of the maintenance systems that can cause often, the regular operation of the system, but with proper operations in the industry are conducted through preventive maintenance methods they can be avoided, which means to systems that can cause failure relatively often, which disable particularly make its main divisions. Most of the maintenance the regular methods operationthey of can the besystem, withmeans proper methods with fixed time or corrective. in the industry are conducted through Preventive preventive maintenance avoided,but which to operations with fixed time or corrective. Preventive be repaired. toolsthey can be damaged, which can the regular Work operation of fail the and system, but with proper operations in the industry are conducted through preventive maintenance methods which means to methods maintenance tasks according to fixed intervals have fixed be repaired. Work tools cancan fail be andavoided, be damaged, which can methods with time toorfixed corrective. Preventive tasksfixed according intervals have fixed result in termination ofthey production. For these reasons, costs maintenance methods which means to maintenance be repaired. Work tools cancan fail be andavoided, be damaged, which can methods with fixed time or corrective. Preventive result in termination of production. For these reasons, costs time intervalstasks (number of to working hours, number of according fixed intervals have fixed arise due to replacement and fail repair parts andreasons, expenses due be repaired. Work tools can andofFor be damaged, whichcosts can maintenance time intervals (number of working hours, number of result in termination of production. these arise due to replacement and repair of parts and expenses due maintenance tasks according to fixed intervals have fixed kilometres past, etc.) in order to prevent the failure time intervals (number of working hours, number of to delays in the production process. result in termination of production. For these reasons, costs arise due to replacement and repair of parts and expenses due kilometres past, etc.) in order to prevent the failure of to delays in the production process. time intervals (number of working hours, number elements, subsystems and systems. Corrective maintenance is kilometres past, etc.) in order to prevent the failure of arise due in to the replacement and repair of parts and expenses due elements, subsystems and systems. Corrective maintenance of to delays production process. is Maintenance management supports enterprises maintaining kilometres past, etc.) in order to prevent the failure of Maintenance supports enterprises maintaining elements, to delays in themanagement production process. carried outsubsystems after the failures occur.Corrective Both methods have been and systems. maintenance is carried out after the failures occur. Both methods have been high asset productivity (factories, equipments, vehicles, etc.). Maintenance management supports enterprises maintaining elements, subsystems andtosystems. Corrective maintenance is high asset productivity (factories, equipments, vehicles, etc.). shown to be costly due reduced productivity, quality and carried out after the failures occur. Both methods have been Maintenance management supports enterprises maintaining shown to beafter costly due to reduced productivity, quality and high asset productivity (factories, equipments, vehicles, etc.). carried out the failures occur. Both methods have been Unfortunately, in comparison with the vehicles, manufacturing becausetothe of storing parts is high, andquality so on. and So, shown becost costly due to spare reduced productivity, high asset productivity (factories, equipments, etc.). Unfortunately, in comparison with the manufacturing because the cost of storing spare parts is high, andquality so on. and So, shown to be costly due to reduced productivity, problems which have awakened a great interest of researchers the high implementation of maintenance means additional because the cost of storing of spare parts is high, and so on. So, Unfortunately, in comparison with interest the manufacturing problems which have awakened a great of researchers the high implementation maintenance means additional Unfortunately, inmaintenance comparisonhas with thesmaller manufacturing the cost and of storing parts is high, and so on. So, and practitioners, a much attention; because costs, resources, loss ofspare productivity. high implementation maintenance means additional problems which have awakenedhas a great interest of researchers and practitioners, maintenance a much smaller attention; the costs, resources, and loss ofof productivity. problems which have awakened a great interest of researchers the high implementation of maintenance means additional this is one of the factors that have a lower efficiency of costs, resources, and loss of productivity. and practitioners, maintenance has ahad much smaller attention; this one of the factors that have a lower efficiency of costs, and is practitioners, maintenance has ahad much smaller attention; In recent years the of the maintenance strategy is to resources, andpurpose loss of productivity. maintenance. As Mobley (2002) said, one third of the this is one of the factors that have had a lower efficiency of In recent years the purpose of the maintenance strategy is to maintenance. As factors Mobley (2002) said, one third of the this is one of the that have had a lower efficiency of calculate the maintenance needs before the equipment failure. In recent years the purpose of the maintenance strategy is to maintenance costs as unnecessary or because maintenance. As result Mobley (2002) said,expenses one third of the calculate the maintenance needs before the equipment failure. maintenance costs result as unnecessary expenses or because In recent years themaintenance purposeneeds of the maintenance strategy is to maintenance. As Mobley (2002) said, one third of the For these reasons is used because of condition, calculate the maintenance before the equipment failure. of inadequatecosts maintenance activities. According to because studies, For these reasons maintenance is used because of condition, maintenance result as unnecessary expenses or of inadequate maintenance activities. According to studies, calculate the maintenance the equipment failure. maintenance costs result ascan unnecessary expenses or is carried out on theneeds basisbefore ofused continuous monitoring of For these reasons maintenance because of condition, the inadequate cost of maintenance reach 15-40% of the product of maintenance activities. According to because studies, which which is carried out on the basisis ofused continuous monitoring of the cost of maintenance can reach 15-40% of the product For these reasons maintenance is because of condition, of inadequate maintenance activities. According to studies, the condition of the systems (Ravnå, monitoring 2016). is carried outequipment on the basis of continuous of cost, depending on the manufacturing industry (Tran Van which the cost of maintenance can reach 15-40% of the product the condition of the equipment systems (Ravnå, 2016). cost,cost depending on the manufacturing industry (Tran Van which is carried out on the basis of continuous monitoring of the of maintenance can reach 15-40% of the product the condition of the equipment systems (Ravnå, 2016). Tung,depending 2009). cost, on the manufacturing industry (Tran Van the condition of the equipment systems (Ravnå, 2016). Tung, 2009). cost, on the manufacturing industry (Tran Van Tung,depending 2009). Tung, 2009).
2405-8963 © IFAC (International Federation of Automatic Control) Copyright © 2018, 2018 IFAC 800Hosting by Elsevier Ltd. All rights reserved. Copyright 2018 responsibility IFAC 800Control. Peer review©under of International Federation of Automatic Copyright © 2018 IFAC 800 10.1016/j.ifacol.2018.11.192 Copyright © 2018 IFAC 800
IFAC TECIS 2018 Baku, Azerbaidschan, Sept 13-15, 2018
Xh. Mehmeti et al. / IFAC PapersOnLine 51-30 (2018) 800–802
In order to assess the state of the technical system, conditionbased maintenance mainly uses destructive tests, visual controls and data from system performance (power, torque, acceleration, etc.). This replaces maintenance actions at fixed time intervals with maintenance actions that are attained when it is best suited to the condition of the equipment. Actions that are carried out within the condition-based maintenance should be properly understood and should be determined based on the state of the system. Also based on the state of the system is set the frequency of maintenance tasks. Since people are not constantly observant or sensitive to small changes and cannot access small areas, especially when equipments are during the process of work, it is necessary to monitor the condition of the systems being realized by the sensors that will monitor equipment work and will transmit the information all the time (Sethiya, 2008).
100%
801
81%
80% 60% 40%
19%
20% 0% Preventive maintenance Corrective maintenance
Fig. 1. Planning maintenance (planned and unplanned) The quality of production does not depend directly on the age of the machines but machine failure depends on the age of the machine. Fig. 2 is shown that the age of machine in manufacturing enterprises, 77% of machines are less than 10 years old.
Applying maintenance management software to modern production systems is a necessity. A computerized maintenance management system is software that helps the team record all the assets, programs, and maintenance tasks, and record the performance history of the equipment.
50%
Percent
40%
20%
10%
Many maintenance teams are looking after assets that are 10, 20 or even 30 years old; these machines have a long history of repairs. When there is a problem with the equipment functioning, it is very important to look at how it was solved in the past. In maintenance management software, when repairs are made, they are recorded in the history of the machine and can be viewed again by the workers. The combination of condition-based maintenance with software maintenance management gives the software more information to realize a more accurate maintenance plan (Ravnå, 2016).
43%
30% 24%
10%
19%
5%
0% less than 1
1 to less 5
5 to less 10 10 to less 15 15 or above
Age of machines Fig. 2 The age of machines in manufacturing enterprises Since the age of machines in the industry is largely new, the staff training for machine use and maintenance is a necessity. According to the research, 44% of manufacturing enterprises have trained employees and 56% haven’t done. One of the key factors in maintenance management is data from the history of failures. The research shows that 81% manufacturing enterprises keep track of machine failure, while 19% do not record failure data. According to various studies, and also according to the research it is noticed that the enterprises that keep the data on the history of the failures it is easier to maintain and repair the machines because in many cases occurs after approximately the same time period and their repair is easier when there are notes about the history of the failure.
Condition-based maintenance cannot completely eliminate traditional maintenance (correction or preventive maintenance by fixed intervals), but can reduce the number of unexpected failures and provide more reliable tools for maintenance tasks by fixed intervals (Mobley, 2002). 2. DATA ANALYSIS Based on the research was found that in manufacturing enterprises mainly carried out planned equipment maintenance is 81% while corrective maintenance 19% (Fig. 1). The planned maintenance is mainly dominated by fixed interval maintenance.
As it is known, machines are advanced mechatronic systems and it is very important to know which machine systems occur the failures more frequently. Fig. 3 shows the failures. According to the research, in the manufacturing enterprises the most frequent failures are in electrical and electronic systems with 69%, with 26% mechanical and 5% hydraulic and pneumatic. Thus, the greatest need for expert and staff training is in maintain electrical and electronic systems.
801
IFAC TECIS 2018 802 Baku, Azerbaidschan, Sept 13-15, 2018
80% 70% 60% 50% 40% 30% 20% 10% 0%
Xh. Mehmeti et al. / IFAC PapersOnLine 51-30 (2018) 800–802
Failures in industrial equipments result not only in productivity loss but also in delays of customer service and can also cause security and environmental problems. According to the research conducted, it is noticed that most of the maintenance operations are corrective action or preventive maintenance by fixed intervals, but there is a tendency to advance from the traditional maintenance to condition-based maintenance. As seen from the research most of the machines are less than 10 years old, and the most frequent failure occur in electrical and electronic systems, this means that the staff dealing with their maintenance need to be trained more in the field of electronic systems.
68%
27% 5% Mechanical
Electrical and Electronic
Hydraulic and Pneumatic
Fig 3 Failures by systems
REFERENCES
The main machine failure is the improper current supply, which is 44%, age of machines is 22%, carelessness of workers 17%, heavy load 13%, and other factors 4 %.
Mobley, R. K. (2002). AN INTRODUCTION TO PREDICTIVE MAINTENANCE. Ravnå, R. (2016). Industry 4.0 and Maintenance. Norwegian Maintenance Society. Sethiya, S. (2008). Condition Based Maintenance (CBM). Secy. to CME/WCR/JBP. Tran Van Tung, B.-S. Y. (2009). Machine Fault Diagnosis and Prognosis: The State of The Art. International Journal of Fluid Machinery and Systems, 61-70. Xhemajl Mehmeti, N. L. (2012). Preventive Maintenance of Passengers Cars Driving in the Territory of the Republic of Kosovo. David Publishing, 197-202.
One of the main factors influencing good maintenance management is the use of maintenance management software. Enterprises in Kosovo does not have any special software for maintenance management but in most cases they use the same asset management software. Approximately 81% of enterprises use asset management software, whereas 19% do not use asset management software. According to studies it is seen that enterprises do not apply any standard for maintenance management and most of them (90%) are not certified by any standard for management systems (ISO 9001, ISO 55000, etc.).
6. CONCLUSIONS 802
ScienceDirect
IFAC PapersOnLine 51-30 (2018) 800–802
The The equipment equipment maintenance maintenance management management in in manufacturing manufacturing enterprises enterprises The equipment maintenance management in manufacturing enterprises The equipment maintenance management in manufacturing enterprises Xh. Mehmeti*, B. Mehmeti**, Rr. Sejdiu***
Xh. Mehmeti*, B. Mehmeti**, Rr. Sejdiu*** Xh. Mehmeti*, B. Mehmeti**, Rr. Sejdiu*** Xh. Mehmeti*, Mehmeti**, Sejdiu*** IHRT *TU Wien, Institute forB. Mechanics and Rr. Mechatronics, *TU Wien, Institute for Mechanics and Mechatronics, IHRT Favoritenstrasse 9-11/E325 A6, A – 1040, Wien (e-mail:[email protected]) *TU9-11/E325 Wien, Institute Mechanics and Mechatronics, IHRT Favoritenstrasse A6, Afor – 1040, Wien (e-mail:[email protected]) *TUof Wien, Institute for Mechanics and Mechatronics, **University Applied Sciences in Ferizaj, St. Universiteti, p.n.IHRT 70000 Ferizaj, Favoritenstrasse 9-11/E325 A6, A – 1040, Wien (e-mail:[email protected]) **University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Favoritenstrasse 9-11/E325 A6, A – 1040, Wien (e-mail:[email protected]) Republic of Kosovo. (e-mail: [email protected]) **University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Republic of Kosovo. (e-mail: [email protected]) ***University ofApplied Applied Sciences inFerizaj, Ferizaj, St.Universiteti, Universiteti, p.n. p.n.70000 70000Ferizaj, Ferizaj, **University of Sciences in St. Republic of Kosovo. (e-mail: [email protected]) ***University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Republic Kosovo. (e-mail: [email protected]) Republic of of Kosovo. (e-mail: [email protected]) ***University of Applied Sciences in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, Republic of Kosovo. (e-mail: [email protected]) ***UniversityRepublic of Applied Sciences(e-mail: in Ferizaj, St. Universiteti, p.n. 70000 Ferizaj, of Kosovo. [email protected]) Republic of Kosovo. (e-mail: [email protected]) Abstract: With continued global market growth and increased equipments complexity, professional Abstract: With continued global market growth and increased equipments complexity, professional access to maintenance playsglobal a key role togrowth be competitive in the equipments market and increase productivity of Abstract: With continued and increased professional access to maintenance plays a keymarket role to be competitive in the market and complexity, increase productivity of production. Advanced production systems are related to the wider use of information technology in Abstract: With continued global market growth and increased equipments complexity, professional access to maintenance plays a keysystems role to are be competitive in wider the market increase productivity production. Advanced production related to the use ofand information technology of in maintenance management, staff training, professional staff engagement in maintenance, and wider use of access to maintenance plays a key role to be competitive in the market and increase productivity production. Advanced production systems are related to engagement the wider use of information in maintenance management, staff training, professional staff in maintenance, andtechnology wider use of preventive In paperprofessional will presented results use from research and on technology maintenance production. maintenance. Advanced production systems are be related to engagement the wider of information in maintenance management, staffthis training, staff maintenance, wider use of preventive maintenance. In this paper will be presented results in from research on maintenance managementmaintenance. and the importance of maintenance in manufacturing enterprises inresearch Kosovo.and maintenance management, staffthis training, professional staff engagement in maintenance, wider use of preventive In paper will be presented results from on maintenance management and the importance of maintenance in manufacturing enterprises in Kosovo. preventive maintenance. In this paper will be presented results from research on maintenance management and the importance of maintenance in manufacturing enterprises Kosovo. © 2018, IFAC (International Federation of Automatic Control) Hosting by ElsevierinLtd. All rights reserved. Keywords: maintenance management, preventive maintenance, failures management and the importance of maintenance manufacturing enterprises in Kosovo. Keywords: maintenance management, preventivein maintenance, failures Keywords: maintenance management, preventive maintenance, failures Keywords: maintenance management, preventive maintenance, failures Therefore maintenance does not only aim to keep the Therefore maintenance does not only aim to keep the 1. INTRODUCTION 1. INTRODUCTION equipment in a state ofdoes working order aim but also playsthea Therefore maintenance not only to keep equipment in a state ofdoes working order aim but also playsthea 1. INTRODUCTION Therefore maintenance not only to keep The concept of equipment maintenance is present and decisive role production goals in in a achieving state of working order butwith also optimum plays a 1. INTRODUCTION The concept of equipment maintenance is present and equipment decisive role in achieving production goals with optimum in ina achieving state of working order butwith also optimum plays a indispensable inofany production. Maintenanceisis present required and for equipment The concept equipment maintenance cost of ownership and maximum productivity. decisive role production goals indispensable in any production. Maintenance is required for cost of ownership and maximum productivity. equipment because the efficiency and quality of production is The concept of equipment maintenance is present and decisive role in achieving production goals with optimum indispensable in anythe production. required for of ownership and maximum productivity. equipment because efficiency Maintenance and quality ofisproduction is cost Maintenance reduced over time the machines may fail more often. indispensable in anyand production. Maintenance required for equipment because and quality ofisproduction is 1.1 cost of ownershipmethods and maximum productivity. 1.1 Maintenance methods reduced over time the andefficiency the machines may fail more often. Thereforeover abecause technical system that and is inquality regular for isa 1.1 Maintenance methods equipment the efficiency ofcondition production reduced time and the machines may fail more often. Therefore a technical system that is in regular condition for a There are many divisions from the aspect of strategy, policy, 1.1 Maintenance methods from the aspect of strategy, policy, long time, i.e. to function period reduced over time and theregularly machines maya longer fail more often. are many divisions Therefore technical system that is inover regular condition forof long time, ai.e. to function regularly over a longer period ofa There type and maintenance. Butaspect in most the literature, areform manyof divisions from the of of strategy, policy, time, time, it isai.e. necessary to beregularly properly maintained. (Xhemajl Therefore technical system that is inover regular condition forofa There long to function a longer period type and form of maintenance. Butaspect in most of the literature, time, it is necessary to be properly maintained. (Xhemajl There are many divisions from the of strategy, maintenance is divided as planned and unplanned which type and form of maintenance. But in most of the literature, Mehmeti, 2012). This is especially important for those long time, i.e. to function regularly a longer (Xhemajl period of maintenance is divided as planned and unplanned policy, time, it is 2012). necessary properlyover maintained. which Mehmeti, Thisto isbe especially important for those type and form of maintenance. But in most of the literature, systems that can cause failure relatively often, which disable time, it is necessary to be properly maintained. (Xhemajl particularly make its main divisions. Most of the maintenance is divided as plannedMost and ofunplanned which Mehmeti, Thisfailure is especially fordisable those maintenance systems that2012). can cause relativelyimportant often, which particularly make its main divisions. the maintenance is divided as planned and through unplanned which the regular operation of therelatively system, but which with proper Mehmeti, 2012). Thisfailure is especially important fordisable those maintenance operations in the industry are conducted preventive particularly make its main divisions. Most of the maintenance systems that can cause often, the regular operation of the system, but with proper operations in the industry are conducted through preventive maintenance methods they can be avoided, which means to systems that can cause failure relatively often, which disable particularly make its main divisions. Most of the maintenance the regular methods operationthey of can the besystem, withmeans proper methods with fixed time or corrective. in the industry are conducted through Preventive preventive maintenance avoided,but which to operations with fixed time or corrective. Preventive be repaired. toolsthey can be damaged, which can the regular Work operation of fail the and system, but with proper operations in the industry are conducted through preventive maintenance methods which means to methods maintenance tasks according to fixed intervals have fixed be repaired. Work tools cancan fail be andavoided, be damaged, which can methods with time toorfixed corrective. Preventive tasksfixed according intervals have fixed result in termination ofthey production. For these reasons, costs maintenance methods which means to maintenance be repaired. Work tools cancan fail be andavoided, be damaged, which can methods with fixed time or corrective. Preventive result in termination of production. For these reasons, costs time intervalstasks (number of to working hours, number of according fixed intervals have fixed arise due to replacement and fail repair parts andreasons, expenses due be repaired. Work tools can andofFor be damaged, whichcosts can maintenance time intervals (number of working hours, number of result in termination of production. these arise due to replacement and repair of parts and expenses due maintenance tasks according to fixed intervals have fixed kilometres past, etc.) in order to prevent the failure time intervals (number of working hours, number of to delays in the production process. result in termination of production. For these reasons, costs arise due to replacement and repair of parts and expenses due kilometres past, etc.) in order to prevent the failure of to delays in the production process. time intervals (number of working hours, number elements, subsystems and systems. Corrective maintenance is kilometres past, etc.) in order to prevent the failure of arise due in to the replacement and repair of parts and expenses due elements, subsystems and systems. Corrective maintenance of to delays production process. is Maintenance management supports enterprises maintaining kilometres past, etc.) in order to prevent the failure of Maintenance supports enterprises maintaining elements, to delays in themanagement production process. carried outsubsystems after the failures occur.Corrective Both methods have been and systems. maintenance is carried out after the failures occur. Both methods have been high asset productivity (factories, equipments, vehicles, etc.). Maintenance management supports enterprises maintaining elements, subsystems andtosystems. Corrective maintenance is high asset productivity (factories, equipments, vehicles, etc.). shown to be costly due reduced productivity, quality and carried out after the failures occur. Both methods have been Maintenance management supports enterprises maintaining shown to beafter costly due to reduced productivity, quality and high asset productivity (factories, equipments, vehicles, etc.). carried out the failures occur. Both methods have been Unfortunately, in comparison with the vehicles, manufacturing becausetothe of storing parts is high, andquality so on. and So, shown becost costly due to spare reduced productivity, high asset productivity (factories, equipments, etc.). Unfortunately, in comparison with the manufacturing because the cost of storing spare parts is high, andquality so on. and So, shown to be costly due to reduced productivity, problems which have awakened a great interest of researchers the high implementation of maintenance means additional because the cost of storing of spare parts is high, and so on. So, Unfortunately, in comparison with interest the manufacturing problems which have awakened a great of researchers the high implementation maintenance means additional Unfortunately, inmaintenance comparisonhas with thesmaller manufacturing the cost and of storing parts is high, and so on. So, and practitioners, a much attention; because costs, resources, loss ofspare productivity. high implementation maintenance means additional problems which have awakenedhas a great interest of researchers and practitioners, maintenance a much smaller attention; the costs, resources, and loss ofof productivity. problems which have awakened a great interest of researchers the high implementation of maintenance means additional this is one of the factors that have a lower efficiency of costs, resources, and loss of productivity. and practitioners, maintenance has ahad much smaller attention; this one of the factors that have a lower efficiency of costs, and is practitioners, maintenance has ahad much smaller attention; In recent years the of the maintenance strategy is to resources, andpurpose loss of productivity. maintenance. As Mobley (2002) said, one third of the this is one of the factors that have had a lower efficiency of In recent years the purpose of the maintenance strategy is to maintenance. As factors Mobley (2002) said, one third of the this is one of the that have had a lower efficiency of calculate the maintenance needs before the equipment failure. In recent years the purpose of the maintenance strategy is to maintenance costs as unnecessary or because maintenance. As result Mobley (2002) said,expenses one third of the calculate the maintenance needs before the equipment failure. maintenance costs result as unnecessary expenses or because In recent years themaintenance purposeneeds of the maintenance strategy is to maintenance. As Mobley (2002) said, one third of the For these reasons is used because of condition, calculate the maintenance before the equipment failure. of inadequatecosts maintenance activities. According to because studies, For these reasons maintenance is used because of condition, maintenance result as unnecessary expenses or of inadequate maintenance activities. According to studies, calculate the maintenance the equipment failure. maintenance costs result ascan unnecessary expenses or is carried out on theneeds basisbefore ofused continuous monitoring of For these reasons maintenance because of condition, the inadequate cost of maintenance reach 15-40% of the product of maintenance activities. According to because studies, which which is carried out on the basisis ofused continuous monitoring of the cost of maintenance can reach 15-40% of the product For these reasons maintenance is because of condition, of inadequate maintenance activities. According to studies, the condition of the systems (Ravnå, monitoring 2016). is carried outequipment on the basis of continuous of cost, depending on the manufacturing industry (Tran Van which the cost of maintenance can reach 15-40% of the product the condition of the equipment systems (Ravnå, 2016). cost,cost depending on the manufacturing industry (Tran Van which is carried out on the basis of continuous monitoring of the of maintenance can reach 15-40% of the product the condition of the equipment systems (Ravnå, 2016). Tung,depending 2009). cost, on the manufacturing industry (Tran Van the condition of the equipment systems (Ravnå, 2016). Tung, 2009). cost, on the manufacturing industry (Tran Van Tung,depending 2009). Tung, 2009).
2405-8963 © IFAC (International Federation of Automatic Control) Copyright © 2018, 2018 IFAC 800Hosting by Elsevier Ltd. All rights reserved. Copyright 2018 responsibility IFAC 800Control. Peer review©under of International Federation of Automatic Copyright © 2018 IFAC 800 10.1016/j.ifacol.2018.11.192 Copyright © 2018 IFAC 800
IFAC TECIS 2018 Baku, Azerbaidschan, Sept 13-15, 2018
Xh. Mehmeti et al. / IFAC PapersOnLine 51-30 (2018) 800–802
In order to assess the state of the technical system, conditionbased maintenance mainly uses destructive tests, visual controls and data from system performance (power, torque, acceleration, etc.). This replaces maintenance actions at fixed time intervals with maintenance actions that are attained when it is best suited to the condition of the equipment. Actions that are carried out within the condition-based maintenance should be properly understood and should be determined based on the state of the system. Also based on the state of the system is set the frequency of maintenance tasks. Since people are not constantly observant or sensitive to small changes and cannot access small areas, especially when equipments are during the process of work, it is necessary to monitor the condition of the systems being realized by the sensors that will monitor equipment work and will transmit the information all the time (Sethiya, 2008).
100%
801
81%
80% 60% 40%
19%
20% 0% Preventive maintenance Corrective maintenance
Fig. 1. Planning maintenance (planned and unplanned) The quality of production does not depend directly on the age of the machines but machine failure depends on the age of the machine. Fig. 2 is shown that the age of machine in manufacturing enterprises, 77% of machines are less than 10 years old.
Applying maintenance management software to modern production systems is a necessity. A computerized maintenance management system is software that helps the team record all the assets, programs, and maintenance tasks, and record the performance history of the equipment.
50%
Percent
40%
20%
10%
Many maintenance teams are looking after assets that are 10, 20 or even 30 years old; these machines have a long history of repairs. When there is a problem with the equipment functioning, it is very important to look at how it was solved in the past. In maintenance management software, when repairs are made, they are recorded in the history of the machine and can be viewed again by the workers. The combination of condition-based maintenance with software maintenance management gives the software more information to realize a more accurate maintenance plan (Ravnå, 2016).
43%
30% 24%
10%
19%
5%
0% less than 1
1 to less 5
5 to less 10 10 to less 15 15 or above
Age of machines Fig. 2 The age of machines in manufacturing enterprises Since the age of machines in the industry is largely new, the staff training for machine use and maintenance is a necessity. According to the research, 44% of manufacturing enterprises have trained employees and 56% haven’t done. One of the key factors in maintenance management is data from the history of failures. The research shows that 81% manufacturing enterprises keep track of machine failure, while 19% do not record failure data. According to various studies, and also according to the research it is noticed that the enterprises that keep the data on the history of the failures it is easier to maintain and repair the machines because in many cases occurs after approximately the same time period and their repair is easier when there are notes about the history of the failure.
Condition-based maintenance cannot completely eliminate traditional maintenance (correction or preventive maintenance by fixed intervals), but can reduce the number of unexpected failures and provide more reliable tools for maintenance tasks by fixed intervals (Mobley, 2002). 2. DATA ANALYSIS Based on the research was found that in manufacturing enterprises mainly carried out planned equipment maintenance is 81% while corrective maintenance 19% (Fig. 1). The planned maintenance is mainly dominated by fixed interval maintenance.
As it is known, machines are advanced mechatronic systems and it is very important to know which machine systems occur the failures more frequently. Fig. 3 shows the failures. According to the research, in the manufacturing enterprises the most frequent failures are in electrical and electronic systems with 69%, with 26% mechanical and 5% hydraulic and pneumatic. Thus, the greatest need for expert and staff training is in maintain electrical and electronic systems.
801
IFAC TECIS 2018 802 Baku, Azerbaidschan, Sept 13-15, 2018
80% 70% 60% 50% 40% 30% 20% 10% 0%
Xh. Mehmeti et al. / IFAC PapersOnLine 51-30 (2018) 800–802
Failures in industrial equipments result not only in productivity loss but also in delays of customer service and can also cause security and environmental problems. According to the research conducted, it is noticed that most of the maintenance operations are corrective action or preventive maintenance by fixed intervals, but there is a tendency to advance from the traditional maintenance to condition-based maintenance. As seen from the research most of the machines are less than 10 years old, and the most frequent failure occur in electrical and electronic systems, this means that the staff dealing with their maintenance need to be trained more in the field of electronic systems.
68%
27% 5% Mechanical
Electrical and Electronic
Hydraulic and Pneumatic
Fig 3 Failures by systems
REFERENCES
The main machine failure is the improper current supply, which is 44%, age of machines is 22%, carelessness of workers 17%, heavy load 13%, and other factors 4 %.
Mobley, R. K. (2002). AN INTRODUCTION TO PREDICTIVE MAINTENANCE. Ravnå, R. (2016). Industry 4.0 and Maintenance. Norwegian Maintenance Society. Sethiya, S. (2008). Condition Based Maintenance (CBM). Secy. to CME/WCR/JBP. Tran Van Tung, B.-S. Y. (2009). Machine Fault Diagnosis and Prognosis: The State of The Art. International Journal of Fluid Machinery and Systems, 61-70. Xhemajl Mehmeti, N. L. (2012). Preventive Maintenance of Passengers Cars Driving in the Territory of the Republic of Kosovo. David Publishing, 197-202.
One of the main factors influencing good maintenance management is the use of maintenance management software. Enterprises in Kosovo does not have any special software for maintenance management but in most cases they use the same asset management software. Approximately 81% of enterprises use asset management software, whereas 19% do not use asset management software. According to studies it is seen that enterprises do not apply any standard for maintenance management and most of them (90%) are not certified by any standard for management systems (ISO 9001, ISO 55000, etc.).
6. CONCLUSIONS 802