iv. **Maintenance Control**

Maintenance control refers to coordination and allocation of the set of maintenance resources, activities, tools, and procedures utilized to achieve the objectives of the maintenance system. For the successful accomplishment of planned maintenance, it is necessary to establish the mechanism by which each planned maintenance input and output activities are controlled. Maintenance is controlled based on the following major input and output; these are:

• Scheduling of planned and prioritized work

*DOI: http://dx.doi.org/10.5772/intechopen.93007*

• Scrutinization of manpower; performance to be measured, and any questionable use of labor being justified by maintenance supervision

*Implementation of Computerized Maintenance and Management System in Wine Factory…*

man-hours required is necessary to make use of optimum available human resources and implement it accordingly. To increase availability of production machine, use priority order as mentioned above under work order priority analysis. **Stock control:** stock policies are considered as prior role to reduce the downtime over the selection of materials and parts. Planned maintenance activities are used to enable the giving orders of spare and consumable parts. Having the economic reorder quantities can minimize the inventory, labor cost, and also, plant downtime based upon the usage of the materials. Stock control based on fast moving items and slow moving items in the factory maintenance section is essential under mainte-

nance schedule analysis as discussed in the sub-topic spare part supply.

include the activities as follows:

to give promotions and incentives.

**2. Maintenance program/cycle**

**319**

ciency of the organization.

**Performance control:** performance control can be seen from the technical personnel assigned to conduct the maintenance activities and the equipment maintained point of view. Therefore, it is essential to evaluate the whole system which includes the productivity and service quality of every technician and entire workshop. Moreover, the maintenance management department must consider and

**Maintenance costs**: the maintenance cost is inversely proportional to the effi-

The overall performance of the organization has been evaluated by cumulating of all mentioned parameters so that the productivity and quality can act accordingly

**Quality and process control:** the quality of the product has a direct link to the maintenance. Accordingly, effective maintenance gives minimal scrap and also increases the process capabilities. Scrap and repeated jobs are required to record and repot by monthly basis to enable for determining the quality of the machines. The corrective action will be taking place after identifying the repaired machines. **Reporting and feedback system**: maintenance activities need follow-up, reviewing, monitoring, and streamlining of practice (corrective actions) and making continuous improvement to become a genuine part of organizational culture. Maintenance report should be produced every week by maintenance supervisor. The maintenance activities within a week or a couple of weeks should be evaluated by a committee of maintenance workers, maintenance foreman, planners, and production foreman and give solution to the problems and feedback goes to the planner for improvement. It encourages everyone involved in the maintenance process to be responsible for their performance efforts and accomplishments.

**Yearly down time:** the efficiency is reduced when the downtime increases.

**Service life**: if the service life increases, efficiency is also increases.

Maintenance program/cycle is the maintenance type taking place in

chronological order. In other words, maintenance cycle is the period between two

**Work control:** deals with monitoring the work status and the accomplished work to investigate if the work is done according to standards (quality and time). To do so, supervisors take responsibility for auditing the maintenance works either the routine maintenance or break down maintenance. To achieve this type of control, it is assumed that the maintenance control system includes standards that are assigned in advance of performing actual maintenance work. Proper planning of


**Cost controlling:** the most neglected part in maintenance activities conducted in AWF is the cost incurred due to improper maintenance management. Operation department does not stop the work for preventive maintenance purpose for the sake of time saving and short-term profit, respectively. Routine maintenance is not emphasized in the department rather break down maintenance is done. These problems resulted in complex maintenance work, high machine down time, and increased maintenance costs. Maintenance costs to be controlled include:

direct maintenance cost: labor cost and material cost and indirect maintenance costs: down time cost and overhead costs (**Figure 3**).

Successful cost reduction program requires:


**Figure 3.**

*Implementation of Computerized Maintenance and Management System in Wine Factory… DOI: http://dx.doi.org/10.5772/intechopen.93007*

• Scheduling of planned and prioritized work

iv. **Maintenance Control**

• Cost incurred

• Work control

• Stock control

• Performance

• Safety required

• Quality and process control

• Reporting and feedback system

• Prioritized planned work

**Figure 3.**

**318**

costs: down time cost and overhead costs (**Figure 3**). Successful cost reduction program requires:

*Cost category in service and/or production sector (cost center based).*

• Approval of maintenance work before it is performed

the following major input and output; these are:

*Operations Management - Emerging Trend in the Digital Era*

Maintenance control refers to coordination and allocation of the set of maintenance resources, activities, tools, and procedures utilized to achieve the objectives of the maintenance system. For the successful accomplishment of planned maintenance, it is necessary to establish the mechanism by which each planned maintenance input and output activities are controlled. Maintenance is controlled based on

**Cost controlling:** the most neglected part in maintenance activities conducted in AWF is the cost incurred due to improper maintenance management. Operation department does not stop the work for preventive maintenance purpose for the sake of time saving and short-term profit, respectively. Routine maintenance is not emphasized in the department rather break down maintenance is done. These problems resulted in complex maintenance work, high machine down time, and increased maintenance costs. Maintenance costs to be controlled include:

direct maintenance cost: labor cost and material cost and indirect maintenance

• Planning of maintenance work according to its scope, criticality, cost, etc.

• Scrutinization of manpower; performance to be measured, and any questionable use of labor being justified by maintenance supervision

**Work control:** deals with monitoring the work status and the accomplished work to investigate if the work is done according to standards (quality and time). To do so, supervisors take responsibility for auditing the maintenance works either the routine maintenance or break down maintenance. To achieve this type of control, it is assumed that the maintenance control system includes standards that are assigned in advance of performing actual maintenance work. Proper planning of man-hours required is necessary to make use of optimum available human resources and implement it accordingly. To increase availability of production machine, use priority order as mentioned above under work order priority analysis.

**Stock control:** stock policies are considered as prior role to reduce the downtime over the selection of materials and parts. Planned maintenance activities are used to enable the giving orders of spare and consumable parts. Having the economic reorder quantities can minimize the inventory, labor cost, and also, plant downtime based upon the usage of the materials. Stock control based on fast moving items and slow moving items in the factory maintenance section is essential under maintenance schedule analysis as discussed in the sub-topic spare part supply.

**Performance control:** performance control can be seen from the technical personnel assigned to conduct the maintenance activities and the equipment maintained point of view. Therefore, it is essential to evaluate the whole system which includes the productivity and service quality of every technician and entire workshop. Moreover, the maintenance management department must consider and include the activities as follows:

**Maintenance costs**: the maintenance cost is inversely proportional to the efficiency of the organization.

**Yearly down time:** the efficiency is reduced when the downtime increases. **Service life**: if the service life increases, efficiency is also increases.

The overall performance of the organization has been evaluated by cumulating of all mentioned parameters so that the productivity and quality can act accordingly to give promotions and incentives.

**Quality and process control:** the quality of the product has a direct link to the maintenance. Accordingly, effective maintenance gives minimal scrap and also increases the process capabilities. Scrap and repeated jobs are required to record and repot by monthly basis to enable for determining the quality of the machines. The corrective action will be taking place after identifying the repaired machines.

**Reporting and feedback system**: maintenance activities need follow-up, reviewing, monitoring, and streamlining of practice (corrective actions) and making continuous improvement to become a genuine part of organizational culture. Maintenance report should be produced every week by maintenance supervisor. The maintenance activities within a week or a couple of weeks should be evaluated by a committee of maintenance workers, maintenance foreman, planners, and production foreman and give solution to the problems and feedback goes to the planner for improvement. It encourages everyone involved in the maintenance process to be responsible for their performance efforts and accomplishments.

#### **2. Maintenance program/cycle**

Maintenance program/cycle is the maintenance type taking place in chronological order. In other words, maintenance cycle is the period between two successive major overhauls. Each preventive maintenance program conducted on each machine/equipment comprises maintenance cycles of the machine/equipment. Maintenance programs are inputs for preparation of maintenance plan. Maintenance program is the set of maintenance activities that are planned to be accomplished in a definite interval based on the following factors:


The maintenance program/cycle for the washing machine is illustrated as follows: Type of machine: **BONY Washer Machine**. Machine made: **Turkey**. Machine model: **Mbt0213**. Purchased date: **May 2013**. Monthly running/operating hour: 8000 hours. Total hours to be covered before the first overhaul: 288,000 (5 years). Preventive maintenance interval: 6000 hours.

Interval of preventive maintenance conducted in month **=** *Interval of Preventiv Maintenance Monthly running hour*

> <sup>¼</sup> <sup>6000</sup> <sup>8000</sup> <sup>¼</sup> <sup>0</sup>*:*75*month* <sup>¼</sup> <sup>23</sup>*days*

Number of maintenance program/cycle = *total hour in a complet cycle Preventive Maintenance Interval* <sup>¼</sup> 288, 000 6, 000 ¼ 48*:*

Thus, the 48 preventive maintenance programs/cycles for the washer machine to its first overhaul time is **MP1-MP2-MP1-MP2-MP1-MP2-MP1-MP3-MP1-MP2- MP1-MP2-MP1-MP2-MP1**-**MP3-MP1-MP2-MP1-MP2-MP1-MP2-MP1-MP4- MP1-MP2-MP1-MP2 MP1-MP2-MP1-MP3-MP1-MP2-MP1-MP2-MP1-MP2- MP1-MP3-MP1-MP2-MP1-MP2-MP1-MP2-MP1-MP5.**

The common activities to be performed on each maintenance program (PMn) are listed in **Table 2**.

The 1 year preventive maintenance program proposed to the washer machine operates for *6200 hours and the last maintenance type performed is MP1 at the first position in the cycle as on April 30/2019* is discussed below (**Table 3**).

Determination of maintenance programs, maintenance cycles, and maintenance schedules for each machine or equipment simplify the task of maintenance planning. Maintenance planning can easily be determined (derived) from maintenance programs and maintenance cycles.

Maintenance program for other machineries and equipment is left to the main-

*Annual maintenance schedule for the washer machine with PMI 6000 hours.*

**Types of maintenance activities Period**

*Implementation of Computerized Maintenance and Management System in Wine Factory…*

Every 6000 hour or 3 weeks whichever comes first

12,000 hour or 1 and half months whichever comes first

Every 144,000 hour or 2 and half years whichever comes

Every 48,000 hour or 10 months whichever comes

288,000 hour or 5 year whichever comes first

first

first

MP1 Clean parts, inspection parts, lubricate necessary parts, clean burner chamber, etc.

`MP3 Perform all activities in MP2, check and repair:

MP4 Perform all activities in MP3, check and change: bearings, mechanical seals, bushings

MP5 Perform PM4, check and change the main chain,

electric control panels, etc.

motors

*DOI: http://dx.doi.org/10.5772/intechopen.93007*

*Maintenance activities in a maintenance program.*

MP2 Perform all activities in MP1, check and adjust pump

drive belts, inspect and adjust the main chain, etc.

carriers, roller rails, pipes, pump impellers, electric

check and change the injector, check and change the

**PM conducting date Running hours PM program Position/cycle** May 23, 2019 12,000 MP2 2 June 16, 2019 18,000 MP1 3 July 9, 2019 24,000 MP2 4 August 2, 2019 30,000 MP1 5 September 25, 2019 36,000 MP2 6 October 18, 2019 42,000 MP1 7 November 11, 2019 48,000 MP3 8 December 4, 2019 54,000 MP1 9 December 27, 2019 60,000 MP2 10 January 20, 2020 66,000 MP1 11 February 13, 2020 72,000 MP2 12 March 6, 2020 78,000 MP1 13 March 29, 2020 84,000 MP2 14 April 22, 2020 90,000 MP1 15 May 15, 2020 96,000 MP3 16

The success of maintenance organization relays highly on workflow system. For successful accomplishment of maintenance activities, it is necessary to develop and implement a well understood workflow system. This simplifies the task of maintenance and enhances productivity. Thus, for the case company, the suitable work

tenance staffs of the factory.

**Table 3.**

**321**

**Maintenance program**

**Table 2.**

**2.1 Maintenance work flow**

Maintenance planning may be prepared for the life of the machine/equipment or working budget year. Annual maintenance plan is recommended to Awash Wine Factory. The annual maintenance plan has to be broken down to quarterly, monthly, weekly, and daily maintenance works to be done. The above maintenance planning samples help the maintenance department to prepare and adopt their annual preventive maintenance plan for other machineries/equipment and instruments according to the criteria already discussed.

*Implementation of Computerized Maintenance and Management System in Wine Factory… DOI: http://dx.doi.org/10.5772/intechopen.93007*


#### **Table 2.**

successive major overhauls. Each preventive maintenance program conducted on each machine/equipment comprises maintenance cycles of the machine/equipment. Maintenance programs are inputs for preparation of maintenance plan. Maintenance program is the set of maintenance activities that are planned to be accomplished in a definite interval based on the following factors:

• Age of the machinery/equipment/service life of major components

The maintenance program/cycle for the washing machine is illustrated as follows:

<sup>8000</sup> <sup>¼</sup> <sup>0</sup>*:*75*month* <sup>¼</sup> <sup>23</sup>*days*

Thus, the 48 preventive maintenance programs/cycles for the washer machine to its first overhaul time is **MP1-MP2-MP1-MP2-MP1-MP2-MP1-MP3-MP1-MP2- MP1-MP2-MP1-MP2-MP1**-**MP3-MP1-MP2-MP1-MP2-MP1-MP2-MP1-MP4- MP1-MP2-MP1-MP2 MP1-MP2-MP1-MP3-MP1-MP2-MP1-MP2-MP1-MP2-**

The common activities to be performed on each maintenance program (PMn)

The 1 year preventive maintenance program proposed to the washer machine operates for *6200 hours and the last maintenance type performed is MP1 at the first*

Determination of maintenance programs, maintenance cycles, and maintenance schedules for each machine or equipment simplify the task of maintenance planning. Maintenance planning can easily be determined (derived) from maintenance

Maintenance planning may be prepared for the life of the machine/equipment or working budget year. Annual maintenance plan is recommended to Awash Wine Factory. The annual maintenance plan has to be broken down to quarterly,

monthly, weekly, and daily maintenance works to be done. The above maintenance planning samples help the maintenance department to prepare and adopt their annual preventive maintenance plan for other machineries/equipment and instru-

*Preventive Maintenance Interval* <sup>¼</sup> 288, 000

6, 000 ¼ 48*:*

Total hours to be covered before the first overhaul: 288,000 (5 years).

• Manufacture recommendations

• Criticality of the machine or equipment

*Operations Management - Emerging Trend in the Digital Era*

Type of machine: **BONY Washer Machine**.

Monthly running/operating hour: 8000 hours.

Preventive maintenance interval: 6000 hours.

Interval of preventive maintenance conducted in month **=**

<sup>¼</sup> <sup>6000</sup>

**MP1-MP3-MP1-MP2-MP1-MP2-MP1-MP2-MP1-MP5.**

Number of maintenance program/cycle = *total hour in a complet cycle*

*position in the cycle as on April 30/2019* is discussed below (**Table 3**).

• Maintenance history of the machine or reported data

• Operation conditions

Machine made: **Turkey**. Machine model: **Mbt0213**. Purchased date: **May 2013**.

*Interval of Preventiv Maintenance Monthly running hour*

are listed in **Table 2**.

**320**

programs and maintenance cycles.

ments according to the criteria already discussed.

*Maintenance activities in a maintenance program.*


#### **Table 3.**

*Annual maintenance schedule for the washer machine with PMI 6000 hours.*

Maintenance program for other machineries and equipment is left to the maintenance staffs of the factory.

#### **2.1 Maintenance work flow**

The success of maintenance organization relays highly on workflow system. For successful accomplishment of maintenance activities, it is necessary to develop and implement a well understood workflow system. This simplifies the task of maintenance and enhances productivity. Thus, for the case company, the suitable work

flow system that should be followed by maintenance planner is proposed in **Figure 4** beneath.

Work orders raised from different departments will be filled on formal work order request form and approved by department manager and submitted to maintenance planner. Therefore, the planner will organize work order from its request formats. Based on the demand, works can move quickly in terms of allocating manpower, arrangement of spare parts to complete the given task effectively. Next work orders released to executers during execution maintenance planners has to follow the progress and quality of work. After completion, the maintenance work should be validated or confirmed for successfulness. This can measure by reworks and/or number of defects. Record keeping is the last stage. It helps to keep histories of machine, measuring performance, and prop up decision making. The

recommended workflow model has considered all the requirements of an effective

*Implementation of Computerized Maintenance and Management System in Wine Factory…*

Awash wine factory uses breakdown maintenance strategy with fixed time preventive maintenance management system. That means the machines are maintained according to the maintenance program planned once in a year. But these types of maintenance system is not efficient for such batch production type process, thus preventive maintenance strategy with condition-based maintenance policy is advisable for such industries. The recommended work flow model consists both preventive and reactive work flow system, for the following basic reasons: (1) it is ideal to make an accident free production system, (2) it is difficult to make a complete paradigm shifting of the existing maintenance culture of the plant from breakdown to preventive once, thus breakdown maintenance should be incorporated in the recommended

system and gradually changed into pure preventive strategy.

Regularly, preventive maintenance activities have been planned and implemented to each and every machine and equipment in the organization. As a result, the condition of the machine or equipment could be found and hence, the maintenance is decided whether it should be small, medium or high and even some times the maintenance is not required. Accordingly, the feedback is considered to make a plan to work out on good and repaired machineries together. The selection of a part and quantity of the spare parts are to be ordered concurrently to minimize the time to wait for spare parts. Finally, the observations and feedback has been analyzed for the future maintenance and stored safely. The model consists of basic activities to be performed so as to reduce the breakdown time and

**Preventive maintenance:** at the beginning of every fiscal year, preventive maintenance plans are prepared by maintenance planner discussing with maintenance supervisor, and finally approved by engineering and maintenance manager. Based on the annual plan, preventive maintenance is initiated by assigning an expert/technician. The assigned maintenance crew conducts PM activity on machineries/equipment and identifies the necessary services to be undertaken. Based on the assessment of the assigned maintenance crew, engineering and maintenance manager decides whether internal capacity exists or not. If internal capacity exists for the periodical service, then the assigned maintenance crew will service the machine. If internal capacity does not exist, then engineering and maintenance

Verification is conducted to ensure that the maintenance job is done to prevent the occurrence of potential failures. Maintenance report is prepared indicating the type of service undertaken and the responsibilities allocated at various maintenance stages. **Corrective maintenance:** Assigned expert/technician conducts inspection on the machine/equipment requested for maintenance and records the findings including:

• Resources needed to undertake the maintenance if internal capability exists

manager/commercial department head will outsource the service.

• Availability of spare parts in store and in the market

• If there is a need for modification and other related activates

& efficient recent workflow system.

*DOI: http://dx.doi.org/10.5772/intechopen.93007*

**2.2 Description**

maintenance cost.

• The nature of failure

• In-house capability

**323**

**Figure 4.** *Recommended maintenance work flow algorithm.*

recommended workflow model has considered all the requirements of an effective & efficient recent workflow system.
