Maintenance Strategy Selection For Continuously Operated Beverage Industry Utility Machines A Case Study

This research paper focuses on a case company where downtimes from set of utility machines arerna major setback to the main production lines due to extensive breakdowns. Nailing down thernmanagement to focus on firefighting, the downtimes had an effect on the departments KPIs andrnthe company’s profitability. rnOnwards, the research sets on finding the right maintenance strategy for each set of utility subsystem.rnThisrnwasrnaccomplishedrnbyrnfirstrnfilteringrntherninformationrngainedrnfromrntherncompany’srnERPrnrnsystemrnbyrnanrnaidrnofrnAHPrnandrnParetorntoolsrntornselectrntherndowntimerncausesrnthatrncanrnberncontrolledrnandrnrncriticallyrnaffectsrnthernoutputrndeliveryrnofrnthernmachines.rnThereafter,rntherndatarngainedrnwasrnusedrnasrnanrnrninputrnforrnarnprovedrnmaintenancernstrategyrnselectionrntoolrnofrnDMGrntornselectrnarnmaintenancernstrategyrnrnforrneachrnsetrnofrnmachinesrninrnthernutilityrnsystem.rnFrom the analysis, the most machines contributing to the downtimes were identified, and arnmaintenance strategy as well as maintenance policy was suggested. A Design out Maintenancernwas proposed from the DMG tool for the electric supply system and the HP compressor that mainlyrncontributed for most of the downtime accounting for a total of 71%. rnThough the integration of AHP and DMG tool is new in the selection of maintenance strategy forrncontinuous operating utility set of machines, it matched the current situation with the managementrndecisions on modifying the design of the two mentioned systems, showing it can also be useful inrnmaintenance strategy selection of such continuous operating equipment. rnThe strategies selected for each sub plant and a continued use of this tool is expected to save 39rnmillion birr and 26,106,000 bottles worth of production time. This estimate is considered to bringrnthe new downtime rate of the department to an acceptable level of 0.92%, which is below therncompany standard of 2.5%. In addition, following a maintenance strategy aids management to getrnrid of firefighting mentality to focus on proactive maintenance.

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