Quality Function Deployment in Maintenance Work Planning

1
Quality Function Deployment in Maintenance
WorkPlanning

• by
• S.O.Duffuaa, A.H.Al-Ghamdi, A.Al-Amer

2
Presentation Plan

• Introduction
• Literature review
• Paper objectives
• Problem statement
• Approach for the problem Quality
  Function Deployment
• Application of QFD in planning maintenance
  work
• Planning Conclusion and further research

3
Introduction

• Maintenance systems contribute to organizations
  objectives, Specifically maintenance contributes
  through
• reducing cost
• minimizing equipment down time
• improving quality
• Increasing equipment reliability
• Improving safety

4
Quality of Maintenance

• Quality of maintenance work has been controlled
  by the following factors in the past
• Lining up the best qualified crafts
• and trades.
• Inspection of performed jobs
• Continuous training of maintenance
• personnel

5
Literature

• Ben Daya and Duffuaa, 1995 proposed several
  ways to link quality and Maintenance.
• Duffuaa and Ben Daya, 1995 has shown how the
  seven quality tools can be used to improve
  maintenance work .
• Kelly, 1989 has outlined means and ways to
  treat and manage maintenance as a business
  function

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Literature

• Treating maintenance as a business function has
  directed the attention to maintenance planning
  and the effective utilization of resources.
• Kutucuoglu et al, 2001 utilized the matrix
  structure of QFD to develop performance
  measurement systems in maintenance
• QFD has been used in designing manufacturing and
  production areas.
• QFD has been applied for curriculum design and
  other areas

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Problem Statement

• Planning critical jobs has a tremendous impact
  on plant availability.
• Planning reduces downtime and improves quality
  of maintenance.
• Planning improves crafts utilization.
• Planning improves safety.
• Therefore it is essential to develop a standard
  plan for critical jobs.

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Objectives

• Enhance the process for planning critical
  maintenance jobs.
• To meet Operations requirements
• To meet maintenance technical staff requirements

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Approach

• Customize and use the methodology of quality
  function deployment (QFD) to design and plan
  critical maintenance jobs.
• QFD is a planning technique that is born in Japan
  as a strategy for assuring that quality is built
  into new processes. It helps organization to take
  the voice of the customer and factor their wants
  and needs into organization product and process
  planning

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Quality Function Deployment

• QFD is a TQM tool. It is a planning technique
  that was borne in Japan as a strategy for
  assuring that quality is built into new
  processes.
• The QFD process uses matrices (sometimes called
  quality tables) to help organizations to satisfy
  their customer requirements, e.g. HOQ.
• These matrices are developed to generate design
  concepts, evaluate them and propose process
  parameters to deliver or produce the best design
  concept that meets customer requirements

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QFD Process Analysis
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Job, External and Internal Customers

• Valve overhaul.
• Valves are important, they controls the flow of
  fluids --- block flow, throttle flow.
• Operations Engineers are the external customer.
• Maintenance crafts as internal customers.

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External Customer requirements

• The requirements identified by the operations
  engineers (external customers) are
• Quick response to the job.
• Reliability of the valve for the process.
• Good flow rate of the valve.
• Timely overhaul (least duration).
• Durability of the overhauled valve.
• Minimal shut down.
• Resistance to corrosion.

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Internal Customers Requirements

• The requirements identified by the
• maintenance staff (internal customers) are
• Availability of spare parts
• Availability of support equipment
• Proper job standards

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Technical Requirements

• The technical requirements for the maintenance
  job given by the maintenance technical staff are
• Priority
• Skill Level
• Material quality
• Inspection
• Support Equipment
• Kit availability

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Technical Requirements Level

• Priority Two level 1 ( jobs are attended
  immediately) and 2. (jobs can be delayed up to
  two days).
• Manpower Skill level Three skill levels,
  specialist, foreman and craft.
• Material type Three levels depending on
  manufactures and composition

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Technical Requirements Level

• Inspection Three levels depending on the
  inspector. These are specialist, foreman and
  craft.
• Support equipment Two levels depending on
  availability.
• Kit availability Two levels depending if kit is
  available or not.

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QFD Process Analysis
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Design Concepts

• A design concept is a selection of a level from
  the technical requirements to come up with a
  design that best satisfies operation and
  maintenance staffs requirements. As an example,
  a design concept 2 assigns level 1 priority,
  level 2 manpower, level 1 material, level 2
  inspection, level 1 support equipment and level 1
  for kit availability.

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Summary of Design Concepts
Table 2 Course Design Concepts
Numbers in the cells represent the level of each
requirement. Numbers in first row are the design
concept number. concept 7 represent current
practice.
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Table 3 Design Concept Evaluation
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Results

• The results indicate a room for improvement
  exist. Design concepts 1, 2 and 6 are better than
  the current practice.
• Design concept 1 is the best but could be
  infeasible.
• Design concept 2 is recommended

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Conclusion and Further Research

• QFD is an effective tool for improving
  maintenance jobs planning
• It matches customer requirements with technical
  requirements.
• The use of QFD provides a better understanding of
  the planning process.
• The job design will be more effective.

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Conclusion and Further Research

• More work could be done to identify more design
  concepts for evaluation.
• AHP or a more sophisticated evaluation process
  can be used to evaluate resulting design
  concepts.
• An awareness program must be launched before
  applying QFD in process, product or service
  design.

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Acknowledgement

• The authors acknowledge the support provided by
  the Department of Systems Engineering, King Fahd
  University of Petroleum and Minerals, Dhahran,
  Saudi Arabia for conducting this research. The
  efforts of Sarah Duffuaa in typing this paper is
  highly appreciated.

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Thank you. Any Questions or Comments?