The aim of this research was to develop a maintenance performance measurement model, based on three main steps, these being: (1) identify and screen factors affecting maintenance performance, (2) identify relevant key indicators for the measurement of maintenance performance, and (3) apply those key indicators developed as part of a manufacturing company case study. Using three reference models -the Cost of Poor Maintenance Model, the Malcolm Baldrige National Quality Award and the Context-Input-Process-Product assessment model, the first step was to identify a number of factors relevant to maintenance performance, as taken from previous research. The resulting 105 factors were a mixture of quantitative and qualitative factors, and were categorized according to the four perspectives within the Balances Scorecard, these being learning and growth, internal process, customer, and finance. A questionnaire used to screen those factors affecting maintenance performance was then distributed to stakeholders and maintenance staff at the case study manufacturer, which produces aircraft galleys and associated equipment. An analysis was conducted using descriptive statistics, and according to the study results, 20 factors were found to most affect maintenance performance. Once the factors had been identified, a second step was carried out -to identify the key maintenance performance measurement indicators, of which 6 were financial, 6 were customer related, 5 were related to the internal process and 3 indicators were linked to learning and growth. The final step was to employ the indicators obtained as part of a study of the case study manufacturer, in order to evaluate maintenance performance there. The results of the evaluation, once obtained, helped develop a framework that could be used to improve the maintenance system.
The objective of this research is to apply the Cleaner Technology (CT) and Design of Experiment (DOE) concepts in the hard disk drive arm coil assembly process, in order to reduce chemical substance (i.e. epoxy and Isopropyl Alcohol (IPA)) consumption. In the production process, epoxy is used to fix the arms and coils, whereas IPA is used to clean the arms before they are delivered to the production process. These chemicals are toxic and cause irritation to workers if they are not careful. Furthermore, the ineffective use of these chemicals adversely affects production costs. The research methodology was divided into two main parts. The first part employed the CT concept to analyze the loss during production, as well as the causes of loss. Opportunities to reduce those losses could then be recommended. The next step was to further analyze and evaluate a particular CT opportunity using DOE. In this second part of the research, DOE was used to reduce the chemicals used in the process by finding the optimum amount of chemicals used which does not affect the quality of the product. Full factorial experiment 2 k , with two replicates was used for screening the four factors, these being: IPA, work-piece curing, epoxy usage and air pressure. The response variable was the arm coil bonding force. The analysis of variance (ANOVA) was conducted. The results of the study show that the optimal operating conditions are: 1) to clean the arms without using IPA, 2) to cure the work-pieces, 3) the filling of 65 mg of epoxy between the arm and the coil, and that 4) there is no significant impact of the air pressure on the arm coil bonding force. The results of the confirmation test show that the arm coil bonding force is in accordance with customer specifications. The results of the experiment have subsequently been put into practice. Thus, reducing the amount of epoxy wasted in the production process helps save approximately 70,208 Baht per annum, while cleaning without using IPA can save 2,154,240 Baht per annum. In conclusion, applying CT and DOE can help to make overall cost savings of 2,224,448 Baht per annum.
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