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IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 02 | August 2016

ISSN (online): 2349-784X

Selection of an Optimum Maintenance Strategy


for Improving the Production Efficiency in a
Casting Unit
Jacob Joshua
PG Scholar
Department of Industrial Engineering & Management
Mangalam college of Engineering Ettumanoor

Subin George Mathew


Assistant Professor
Department of Mechanical Engineering
Mangalam college of Engineering Ettumanoor

Harikrishnan A. R
Assistant Professor
Department of Mechanical Engineering
Mangalam college of Engineering Ettumanoor

Abstract
The aim of this paper is to select an appropriate maintenance strategy for improving the production efficiency in a casting
industry. It is identified that there is a decreasing trend in production due to annual maintenance. The conflicting objectives and
constraints are considered simultaneously to evaluate alternative maintenance strategies. The choice of maintenance strategies is
a typical Multiple Criteria Decision-Making (MCDM) problem with differing goals. Appraising the criteria and sub criteria, it is
found that there are complicated tasks due to various objectives. To contend with this problem Analytic Network Process (ANP)
is considered for finding the dependency among criteria and sub-criteria. The model presented in this paper gives a clear view of
maintenance strategy selection involving four main factors of cost, safety, strategic and time requirements. Considering the
relations between these factors a network with many criteria and sub-criteria, a pair wise comparison is proposed. In the further
step group Analytic Network Process (ANP) method was followed to prioritize these criteria and determine the optimum
maintenance strategy.
Keywords: Analytical network process (ANP), multi-criteria decision making (MCDM), pair-wise comparison
_______________________________________________________________________________________________________
I.

INTRODUCTION

Maintenance is defined as the practice of preserving a condition or situation or the state of being well-kept. Almost every
industry has some sort of maintenance programme for its physical assets. The starting point for the selection of the maintenance
tasks for equipment is the maintenance classification and the related requirement specification assigned to the related Equipment
location. The objective of the maintenance tasks is to secure the operability of equipment, detect faults and/ or prevent functional
failures. In maintenance management, evaluating criterias and selecting best among them are complicated tasks due to the fact
that various criterias and sub criterias such as cost, safety, strategic and time requirements must be considered in the decision
making process.
II. NEED FOR USING ANP
The ANP technique is an improved form of AHP method and it is more accurate with many complicated models in which many
criteria feedback and interrelations among criteria are used.
The ANP is fabricated on the AHP; By allowing for dependence, the ANP goes beyond the AHP by including independence
and hence also the AHP as a special case;
The ANP deals with dependence within a set of elements (inner dependence), and among different sets of elements (outer
dependence). The looser network structure of the ANP makes possible the representation of any decision problem without
concern for what comes first and what comes next as in a hierarchy; The ANP prioritizes not just element but also groups or
clusters of elements as is often necessary in the real world. Here in this paper it determines the appropriate maintenance strategy
for the company provided by the criteria identified in the Casting Unit.
III. PROBLEM IDENTIFICATION AND PROBLEM STATEMENT
The work was studied in a casting unit. Industry. Production rate is lowered during these times due to lack of a maintenance
strategy. Company is currently using an annual maintenance strategy Due to this the profit earned is being fluctuated per year.

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138

Selection of an Optimum Maintenance Strategy for Improving the Production Efficiency in a Casting Unit
(IJSTE/ Volume 3 / Issue 02 / 021)

The problem statement is The absence of an optimum maintenance strategy for improving the production efficiency for better
quality and quantity of products.
IV. PROBLEM DEFINITION
The major problem faced by the company is decreasing trend in production due to annual maintenance.
Table 1
Production (In Metric Tonnes)
Year
Planned Production Actual Production
2012-2013
5148.62
4373.851
2013-2014
5267.21
3928.124
2014-2015
5414.215
3835.723

The table shows the performance analysis of the company. The diminishing trend in production is due to increased equipment
downtime.
V. PROCEDURE
1) Stage 1: The data collection is done by survey approach through questionnaires from a group of experts and workers of the
casting industry. It includes goal, determinants, criteria, sub criteria, alternatives
Table 2

Table 2

Best
strategy
optimization
BestMaintenance
Maintenance strategy
optimization

Overall maintenance weighted score


RISK

MARKET DEMAND

Time requirement

Cost requirement

1. Production shift

1. Repair cost

2. Spare parts
availability

2. Annual
maintenance cost

3. Man power

3. Spares inventory

4. Operating
condition

4. Power
consumption

Scheduled
maintenance

Reactive
maintenance

MARKET COMPETITIVENESS

safety requirement

1. Personnel safety
2. Facility
3. Machine security

strategic requirement

1. Workers and
union acceptance
2. Dispatch plan3.
Training for
employees
4. Quality

Predictive
maintenance

Corrective
maintenance

2) Stage 2: The ANP approach allows for complex interrelationships among decision levels and attributes calculating priorities
among elements in order to make a comparison
The consistency index of a matrix is given by C.I. = (max n)/(n1).
CR= CI/RI
Max eig value, max= 3.0536 ; n=3 ; RI = .58
C.I. = (max n)/(n1). = (3.0536-3)/2 = .0268
CR = CI/RI ; CR= .0268/.58 = .04620

RISK
MARKET COMPETITIVENESS
MARKET DEMAND

RISK
1
1
4

Table 3
Pairwise Comparison of matrix
MARKET COMPETITIVENESS MARKET DEMAND
1
1/4
1
1/2
2
1

EIGEN VECTOR
.184
.232
.584

RANK
3
2
1

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139

Selection of an Optimum Maintenance Strategy for Improving the Production Efficiency in a Casting Unit
(IJSTE/ Volume 3 / Issue 02 / 021)

The final set of pair-wise comparisons was pursued for the relative impact of each of the alternatives on the enablers in
influencing the determinants.
There are 16 enablers for each of the determinants, which lead to 48 such pair-wise matrices.
3) Stage 3: Once the weight of all criteria are obtained through MATLAB we can use ANP.
Steps in ANP are:
Calculate the Decision matrix.
Normalize the Decision matrix.
Calculate the weighted normalized decision matrix.
The desirability index, Dia, for the alternative i and the determinant a is defined as
Dia = Pja*ADkja* AI kja*SIkja
where Pja is the relative importance weight of dimension of company maintenance strategy selection network j on the
determinant of network, a ADkja is the relative importance weight for network attribute enabler k of dimension of network j in
the determinant of control hierarchy network, a
m140
PDS
SP
MP
OC
RC
AMC
SI
PC
PES
FS
MS
PLS
WA
DP
TE
QT

Pds
.136
.164
.089
.149
0
0
0
0
0
0
0
0
0
0
0
0

sp
.136
.164
.089
.149
0
0
0
0
0
0
0
0
0
0
0
0

mp
.136
.164
.089
.149
0
0
0
0
0
0
0
0
0
0
0
0

oc
.136
.164
.089
.149
0
0
0
0
0
0
0
0
0
0
0
0

Table 4
Weighted Matrix of Total desirability index
Rc
Amc
SI
PC PES
FS
MS
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
.027 .027 .027 .027
0
0
0
.015 .015 .015 .015
0
0
0
.036 .036 .036 .036
0
0
0
.011 .011 .011 .011
0
0
0
0
0
0
0
.020 .020 .020
0
0
0
0
.016 .016 .016
0
0
0
0
.043 .043 .043
0
0
0
0
.038 .038 .038
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PLS
0
0
0
0
0
0
0
0
.020
.016
.043
.038
0
0
0
0

WA
0
0
0
0
0
0
0
0
0
0
0
0
.113
.176
.103
.183

DP
0
0
0
0
0
0
0
0
0
0
0
0
.113
.176
.103
.183

TE
0
0
0
0
0
0
0
0
0
0
0
0
.113
.176
.103
.183

QT
0
0
0
0
0
0
0
0
0
0
0
0
.113
.176
.103
.183

Over all weighted Score index(OWSI)=Sum of(Alternatives(Dia)*Weighted scores(Ca))


OWSI i = DiaCa
OWSI SM = [(.184*.10834) +(.232*.1331) +(.584*.04392)]
= .07604
Alternatives
Weights
SM
RM
CM
PM

Risk
.184
.10834
.03571
.04691
.03427

Table 5
Normalized Values
Market competitiveness Market Demand
.232
.584
.13319
.04392
.03622
.01856
.05078
.017080
.04726
.01244

OWSI

Normalized Values for OWSI

.07604
.02581
.03038
.02452

.4851
.1646
.1938
.1564

4) Stage 4: The ANP values can be coded in MATLAB, so that any unit can use this method to find the best maintenance
strategy. Also since the number of criterias are to be entered by the user, this method can be applied to find the best among
any number of determinants.
VI. RESULT
The ANP method is very well suited to find the suitable multiple alternatives by prioritizing the values. When comparing the
existing method that gives more weight-age for ISO certified criterias, the proposed ANP method takes into consideration
various criteria and helps in choosing the right strategy with right time.
VII. CONCLUSION
Main purpose of this paper is to determine the optimum maintenance strategy for improving the production efficiency. By ANP
tool the best strategy is selected ,so that the quality and quantity of the products can be improved,thus the company can meet
demands and a increased profit rate can be attained accordingly.

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Selection of an Optimum Maintenance Strategy for Improving the Production Efficiency in a Casting Unit
(IJSTE/ Volume 3 / Issue 02 / 021)

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