Purpose The purpose of this paper is to provide comprehensive information on preventive maintenance (PM) planning and methods used in the industry in order to achieve an effective maintenance system. Design/methodology/approach The literature review is organized in a way that provides the general overview of the researches done in the PM. This paper discusses the literatures that had been reviewed on four main topics, which are the holistic view of maintenance policies, PM planning, PM planning concept and PM planning-based in developing optimal planning in executing PM actions. Findings PM policy is one of the original proactive techniques that has been used since the start of researches on maintenance system. Review of the methods presented in this paper shows that most researches analyse effectiveness using artificial intelligence, simulation, mathematical formulation, matrix formation, critical analysis and multi-criteria method. While in practice, PM activities were either planned based on cost, time or failure. Research trends on planning and methods for PM show that the variation of approaches used over the year from early 1990s until today. Practical implications Research about PM is known to be extensively conducted and majority of companies applied the policy in their production line. However, most analysis and method suggested in published literatures were done based on mathematical computation rather than focussing on solution to real problems in the industry. This normally would lead to the problems in understanding by the practitioner. Therefore, this paper presented researches on PM planning and suggested on the methods that are practical, simple and effective for application in the real industry. Originality/value The originality of this paper comes from its detail analysis of PM planning in term of its research focus and also direction for application. Extensive reviews on the methods adopted in relation to PM planning based on the planning-based such as cost-based, time-based and failure-based were also provided.

Purpose – This paper reviews the literature on opportunistic maintenance (OM) as new advance maintenance approach and policy. The purpose of this paper is to conceptually identify common principle and thereby provide absolute definition, concept and characteristics of this policy. Design/methodology/approach – A conceptual analysis was conducted on various literatures to clarify a number of principle and concepts as a method for understanding information on OM. The analysis involves the process of separating the compound terms used in the literatures into a few parts, analyse them and then recombining them to have more clear understanding of the policy. Findings – The paper discussed the maintenance approach, genealogy, principle, concept and applications of OM both in numerical analysis and real industry. OM policy is developed based on combination of age replacement policy and block replacement policy and in practical; OM is applied as the combination of corrective maintenance which is applied when any failure occurred, with preventive maintenance (PM) – a planned and scheduled maintenance approach to prevent failure to happen. Any machine shutdown or stoppages due to failure is the “opportunity” to conduct PM even though it is not as planned. The characterization of OM was provided in order to present its theoretical novelty for researchers and practical significance for industries. Practical implications – To date, there is no publication that reviews the OM in-depth and provides clear understanding on the topic. Therefore, this paper aims to show lineage of OM and the current trend in researches. This discussion will pave the way of new research areas on this optimal maintenance policy. Clear definition and principle of OM provided in this paper will trigger interest in its practicality as well as aid industries to understand and conduct OM in operation plant. Originality/value – This paper discussed the available literature about OM in various perspectives and scopes for further understanding of the topic by maintenance management professionals and researchers. Therefore, OM can be widely studied and applied in real industry as it is an effective and optimal maintenance policy.

Energy efficiency program is used to reduce energy cost that leads to a reduction in production or overhead cost. Energy saving can be obtained by application of energy-efficient technologies, operational improvement, and effective maintenance. However, maintenance and energy efficiency is usually researched separately. The purpose of this paper is to investigate the role of maintenance in energy saving and available maintenance approaches for energy consumption reduction. Various literatures and publication on the research areas were reviewed and summarized to show the importance on maintenance and approached commonly used for energy efficiency.

Maintenance is an important process in a manufacturing system. Thus it should be conducted and measured effectively to ensure performance efficiency. A variety of studies have been conducted on maintenance as affected by factors such as productivity, cost, employee skills, resource utilisation, equipment, processes, and maintenance task planning and scheduling [1,2]. According to Coetzee [3], equipment is the most significant factor affecting maintenance performance because it is directly influenced by maintenance activities. This paper proposes an equipment performance and reliability (EPR) model for measuring maintenance performance based on machine effectiveness. The model is developed in four phases, using Pareto analysis for machine selection, and failure mode and effect analysis (FMEA) for failure analysis processes. Machine effectiveness is measured using the integration of overall equipment effectiveness and the reliability principle. The result is interpreted in terms of maintenance effectiveness, using five health index levels as bases. The model is implemented in a semiconductor company, and the outcomes confirm the practicality of the EPR model as it helps companies to measure maintenance effectiveness.

Maintenance is an important issue that needs to be addressed during the design and manufacturing or building of a system. Both Total Productive Maintenance (TPM) and Reliability Centered Maintenance (RCM) have its own concepts and principles as a maintenance strategy to give impact to the performance and reliability of the system. Therefore, in this research, the TPM will be studied with RCM to show their relationship. Based on the conceptual analysis, the author will analyze publications from journals, books, and articles to find all related information, such as genealogy, definition, concepts, and principle, and implementation of both strategy. The conceptual method used is Näsi’s four elements of conceptual analysis and a questionnaire survey method which has been answered electronically to study the current maintenance strategies in the real industries and to relate it to TPM and RCM. The result of the study shows that TPM had started in 1970 while RCM started in the 1960s, but the foundation of TPM and RCM was started in 1950s with Breakdown Maintenance (BM). TPM is basically about elimination of faults through day-today activities involving the entire force work while the concept of RCM is to improve equipment reliability. The objective of TPM is to achieve zero breakdowns, zero defects, and zero accidents while TPM is to preserve the functions. Although both are using different tools but both are linked together through the Lean Tool and can increase product quality, equipment reliability, increase safety, and increase profit. From the survey result, most of the respondent comes from the companies that implementing traditional maintenance (PM and CM) rather than TPM and RCM. TPM mostly can be implemented in big plant industries while RCM can be applied in small or medium size plant.