You are here

Implementing a Strategy of Reliability Centered Maintenance (RCM) in the Libyan Cement Industry

Journal Name:

Publication Year:

Abstract (2. Language): 
The substantial development of the construction industry has forced the cement industry, its major support, to focus on achieving maximum productivity to meet the growing demand for this material. This means that the reliability of a cement production system needs to be at the highest level that can be achieved by good maintenance. This paper studies the extent to which the implementation of RCM is needed as a strategy for increasing the reliability of the production systems component can be increased, thus ensuring continuous productivity. In a case study of four Libyan cement factories, 80 employees were surveyed and 12 top and middle managers interviewed. It is evident that these factories usually breakdown more often than once per month which has led to a decline in productivity. In many times they cannot achieve the minimum level of production amount. This has resulted from the poor reliability of their production systems as a result of poor or insufficient maintenance. It has been found that most of the factories’ employees misunderstand maintenance and its importance. The main cause of this problem is the lack of qualified and trained staff, but in addition it has been found that most employees are not found to be motivated as a result of a lack of management support and interest. In response to these findings, it has been suggested that the RCM strategy should be implemented in the four factories. The results show the importance of the development of maintenance strategies through the implementation of RCM in these factories. The purpose of it would be to overcome the problems that could secure the reliability of the production systems. This study could be a useful source of information for academic researchers and the industrial organizations which are still experiencing problems in maintenance practices.
FULL TEXT (PDF): 
51
60

REFERENCES

References: 

[1] B. Al-Najjar, “Cost-Effective & Continuous Improvement of Production Process and Company’s Business when using Total Quality Maintenance (TQMain)”, International Conference on Maintenance Engineering, vol. 1, pp. 1-11, 15-18, Oct. 2006.
[2] H, K. Alfares, “Aircraft maintenance workforce scheduling”, Journal of Quality in Maintenance Engineering, Vol. 5, No. 2, pp. 78-88, 1999.
[3] N.V. Bhat, “The determinants of maintenance expenditures in chemical companies”, Journal of Quality in Maintenance Engineering, Vol. 6, No. 2, pp. 106-112, 2000.
[4] R. Yam, P. Tse, L. Ling, and F. Fung, “Enhancement of maintenance management through benchmarking”, Journal of Quality in Maintenance Engineering, Vol. 6, No. 4,pp. 224-240, 2000.
[5] J. Momme, and H. Hvolby, “An outsourcing framework: action research in the heavy industry sector”, European Journal of Purchasing & Supply Management, Vol. 8, No. 4, pp. 185-196, 2002.
[6] S.I. Mostafa, “Implementation of proactive maintenance in the Egyptian glass company”, Journal of Quality in Maintenance Engineering, Vol. 10, No. 2, pp. 107-122,2004.
[7] W. Chen, “Scheduling with different maintenance policies in a textile company”, Journal of Quality in Maintenance Engineering, Vol. 11 No. 1, pp. 43-52, 2005.
[8] I. Alsyouf, “Measuring maintenance performance using a balanced scorecard approach”, Journal of Quality in Maintenance Engineering, Vol. 12 No. 2, pp. 133-149,2006.
[9] M. Aoudia, and O. Belmokhtar, “Economic impact of maintenance management ineffectiveness of an oil and gas company”, Journal of Quality in Maintenance Engineering, Vol. 14, No. 3, pp. 237-261, 2008.
[10] I.P.S. Ahuja, and P. Kumar, “A case study of total productive maintenance implementation at precision tube mills”, Journal of Quality in Maintenance Engineering, Vol. 15, No. 3, pp. 241-258, 2009.
[11] E. Vassilakis, “An application of TQM tools at a maintenance division of a large aerospace company”, Journal of Quality in Maintenance Engineering, Vol. 15, No. 1,pp. 31-46, 2009.
[12] H. Shafeek, "Continuous improvement of maintenance process for the cement industry – a case study", Journal of Quality in Maintenance Engineering, Vol. 20, No.4 pp. 333 – 376, 2014.
[13] H. Bin Jabar, “Plant Maintenance Strategy: Key for Enhancing. Profitability”, 2003, Maintenance Resources.com (http://www.maintenanceresources.com/referencelibrary/ezine/chemclean.htm) (21 March 2015).
[14] R. C. Mishra, and K. Pathak, Maintenance Engineering and Management, 2nd ed. Newdilhi: PHI Learning, 2012.
[15] D. Telang, and A. Telang, Comprehensive Maintenance Management, New Delhi: PHI Learning Pvt. Ltd, 2010.
[16] BBC History, “Why the Industrial Revolution happened in Britain”, 2013, BBC History (http://www.bbc.co.uk/history/0/20979973) (Accessed 14 January 2013)
[17] British Standards Institution, BS EN 13306:2001. Maintenance, maintenance terminology, London: BSI. , 2001.
[18] C. J. Robinson, and A. Gander, Implementing TPM: The North American Experience, Portland: Taylor & Francis, 1995.
[19] A. Garg, & S. Deshmukh, “Maintenance management: literature review and directions”, Journal of Quality in Maintenance Engineering, Vol.12, No.3, pp.205 – 238, 2006.
[20] R. K. Sharma, D. Kumar, and P. Kumar, “Manufacturing excellence through TPM implementation: a practical analysis”, Industrial Management and Data Systems.Vol.106, No. 2, pp. 256-280, 2006.
[21] I.P.S. Ahuja, and J.S.Khamba, “Total productive maintenance: literature review and directions”, International Journal of Quality & Reliability Management, Vol. 25, No. 7, pp.709- 756, 2008.
[22] J. Hansson, F. Backlund, and L. Lycke, “Managing commitment: increasing the odds for successful implementation of TQM, TPM or RCM”, International Journal of Quality & Reliability Management, Vol. 20, No. 9, pp. 993-1008, 2003.
[23] F. L. Cooke, “Plant maintenance strategy: evidence from four British manufacturing firms." Journal of Quality in Maintenance Engineering, Vol. 9, No. 3, pp. 239 -249, 2003.
[24] European Committee for Standardization, EN13306:2001, Maintenance Terminology, the European Committee for Standardization. Brussels: CEN., 2006.
[25] I. Alsyouf, “The role of maintenance in improving companies' productivity and profitability International”, Journal of Production Economics, Vol.105, No.1, pp.70-78, 2007.
[26] D. Baglee, and M. Knowles, “Maintenance strategy development in the UK food and drink industry”, International Journal of Strategic Engineering Asset Management, Vol.1, No. 3, pp. 289-300, 2013.
[27] T. Ömür; and K. Orhan, “Preventive Maintenance Optimization under Deterioration”, University Journal of Economics & Administrative, Vol. 23, No.4, pp.125-134, 2009.
[28] M. Kans, and A. Ingwald, “Common database for cost-effective improvement of maintenance performance”, International Journal of Production Economics, Vol.113, No. 2, pp.734-747, 2008.
[29] L. Swanson, “Linking maintenance strategies to performance”, International Journal of Production Economics, Vol 70, No. 3, pp.237-244, 200.
[30] J. Bateman, “Preventive Maintenance: Stand Alone Manufacturing Compared With Cellular Manufacturing”, Industrial Management, Vol 37 No1, pp. 19-21, 1995.
[31] M. Rausand, “Reliability Centred Maintenance”, Reliability Engineering and System Safety, Vol 60, No. 2, pp. 12 -132, 1998.
[32] International Atomic Energy Agency (IAEA), “Application of Reliability Centred Maintenance to Optimize Operation and Maintenance in Nuclear Power Plants”, 2007, International Atomic Energy Agency, IAEA report (http://www-pub.iaea.org/MTCD/publications/PDF/te_1590_web.pdf) (May 2007)
[33] National Aeronautics and Space Administration (NASA), RCM Reliability Centred Maintenance Guide for Facilities and Collateral Equipment”, 2008, National Aeronautics and Space Administration, NASA Report, (http://www.hq.nasa.gov/office/codej/codejx/Assets/Docs/ NASARCM Guide.pdf) (September 2008)
[34] K. Holmberg, A. Adgar, A. Arnaiz, S. Mekid, J. Mascolo, and E. Jantunen, “E-maintenance”, London: Springer. 2010.
[35] World Business Council for Sustainable Development, “The cement sustainability initiative”, 2002, World Business Council for Sustainable Development (wbcsd) (http://www.wbcsd.org/ home.aspx) (02 April 2014).
[36] T. Tourki, “Implementation of Lean within the Cement Industry”, PhD thesis, De Montfort University, 2010
[37] USGS, “Cement Statistics and Information”, 2014, USGS science for a changing world: Minerals Information. (http://minerals.usgs.gov/minerals/pubs/commodity/cement/ ) (15April 20140)
[38] Portland Cement Association, “Report on Sustainable Manufacturing Tracks Advances in Environmental Performance Portland”, 2008, PAC. Executive Report (http://www2.cement. org/ exec2 /04-28-08.htm) (April 28, 2008)
[39] A. S. Ngab, “Libya – The Construction Industry – An Overview”, 2005, CBM-CI International Workshop, Karachi Pakistan
International Journal of Science and Engineering Investigations, Volume 4, Issue 42, July 2015 60
www.IJSEI.com Paper ID: 44215-07
ISSN: 2251-8843
(http://enpub.fulton.asu.edu/cement/cbm_CI/CBMI_Separate Articles/Article%2021.pdf) (01 April 2014)
[40] P. Edwards, “North African cement focus”, 2013, Global cement (http://www.globalcement. com/magazine/articles/816-north-african-cement-focus ) (09 April 20140)
[41] CemNet.com,Global, “Cement Report. Libya”, 2014, CemNet.com (http://www.cemnet. Com /gcr/country/Libya ) (10 April 2014)
[42] R. A. Hokoma, M. K. Khan, and K. Hussain, “The Current Status of MRPIl Implementation in Some Key Manufacturing Industries within Libya: A Survey Investigation”. In: Proceedings of the 22nd International Conference on CAD CAM, Robotics and Factories of the Future, India, pp. 483-490, 2006.
[43] M. Graisa, “An Investigation into the Need and Implementation of Total Productive Maintenance (TPM) in Libyan Cement Industry”, PhD thesis, Nottingham Trent University, 2011
[44] Alahlia Cement Company, “Company profile”, 2014, (http:// http://www.ahliacement.ly/) (01 April 2013)
[45] H. Essmui, M. Berma, F. Shahadan, and S. Ramlee, “Technical Efficiency of Manufacturing Enterprises in Libya: A Stochastic Frontier Analysis”, International Journal of Management & Information Technology, Vol. 5, No. 2, pp. 528-535, 2013.
[46] M., Rana, M. AzizulBaten, S. Das, and M. Abdul Khaleque, “Technical Efficiency of Some Selected Manufacturing Industries in Bangladesh: A Stochastic Frontier Analysis” The Lahore Journal of Economics, Vol. 11, No. 2, pp. 23-41, 2006.
[47] R. Hokoma, M. Khan, and K. Hussain, “Investigation into the implementation stages of manufacturing and quality techniques and philosophies within the Libyan cement industry”, Journal of Manufacturing Technology Management, Vol.19, No.7, pp. 893- 907, 2008.
[48] M. Elmagri, “The reduction of the causal factors of interpersonal conflict (IPC) in the Libyan cement industry”, PhD thesis, University of Salford, 2013
[49] World Report, “Libya Back on the World Stage, Trade and investment benefits set to flow, Ancient Heritage”, 2004, World Report International Ltd (http://www.worldreport-ind.com/libya/interview12. htm.) (25 September 2004)
[50] M. Graisa, and A. Al-Habaibeh, “An investigation into current production challenges facing the Libyan cement industry and the need for innovative total productive maintenance (TPM) strategy” Journal of Manufacturing Technology Management, Vol. 22, No. 4, pp. 541-58, 2010.
[51] C. R. Cassady, W. P. Cassady and E. A. Pohl, “Selective maintenance for support equipment involving multiple maintenance actions”, European Journal of Operational Research, Vol. 129, No. 2, pp.252-258, 2001.
[52] M. Al-Muhaisen,and N. Santarisi, “Auditing of the maintenance system of Fuhais plant/ Jordan Cement Co.”, Journal of Quality in Maintenance Engineering, Vol. 8, No.1, pp.62-76, 2002.
[53] M. C. Ogajl, and S. D. Probert, “Development and implementation of preventive-maintenance practices in Nigerian industries”, Applied Energy, Vol. 83, No.10, pp.1163-1179, 2006

Thank you for copying data from http://www.arastirmax.com