Table 3: Value point for MTTR
International Journal of Scientific & Engineering Research, Volume 2, Issue 12, December-2011 1
ISSN 2229-5518
Selection of Maintenance Practice through Value
Engineering
Prof. Malay Niraj
Abstract --In this study the techniques of value engineering have been studied for finding the suitable maintenance practice. Value engineering is a one of the most powerful decision making techniques which depends upon factor. The VE process identifies; opportunities to remove unnecessary costs while assuring that quality, reliability, performance, and other critical factors will meet or exceed the customer’s expectat ions. The improvements are the result of recommendations made by multidisciplinary teams representing all parties involved. VE is a rigorous, systematic effort to improve the value and optimize the life cycle cost of a facility. Using factor comparison study has been made between different maintenance practice .and finally select best maintenance practice based of value engineering.
Key-words- Maintenance Practice, Functional Analysis, Value engineering
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E is the most popular technique amongst all Industrial Engineering (IE) techniques for cost reduction.VE cells are available in all the Leading industries like TML,
SAIL, and BHEL etc. The leading national body, INVEST is selling the concept of VE through seminars etc. and well appreciated by all Managements,VE is a decision making technique for selection of best of one. Decision is what we do when we solve a problem. Decision maker and engineering are linked together in most of projects. When decision maker solve a problem or satisfy a need, they often use appropriate engineering technology. Appropriate technology can be low or high technology. It is any type of technology that suits the way it is being used. Therefore VE plays an important role in determining the situation and in choosing better Engineering solution. Value engineering approach [1] is selected as a communication platform between industrial designers and engineering designers. Expanding on the meaning of value, the product needs to be not only mechanically efficient but also to satisfy human needs, which are often irrational. Value engineering is based on function analysis and customer information to optimize design related factors in particular situations, and has been utilized in the construction industry for many years.
Mr. Lou [2] studied value engineering and risk management. In a complicated system development, the decision is made through an organization structure, which consists of people with different backgrounds. The undetermined factors in the project often confuse the team member in decision-making. Value engineering can be utilized as a systematic development framework and can be helpful in risk management.
Mr. Kou [3] studied the vertical cooperate framework in Taiwan’s electronic industry. The research investigated the switching mode power supply industry to find out how to use value engineering to enhance the product function, reduce the product size and keep the thermal management ability within a reasonable range. Function modeling analyzed the product based upon the functions of its components and outside elements [4]. These outside
elements, which intersect in a relevant way with the components of the system, are called super system elements. By defining functions, we are able to describe the problematic interaction and the performance of the system at a higher level of abstraction. Functions are relationships between components and are performed to affect the parameters and the characteristics of the components. Functions can be described as useful and harmful functions. The qualitative definition of function is then provided the actual value of function’s parameters, the acceptable value of parameter as well as the ideal value .Sharma, D.V.S [5] again has beautifully applied the techniques of VE in elimination of child lab our in his article presented in the seminar in Indian Institution of Industrial Engineering and published in the proceeding of IIIE.According to O’Brien, J.J [6] VE Recognizes the increased benefit from early implementation.
A decision that improves quality but increases cost to a point where the product is no longer marketable is as unacceptable as one to avoid confusing the cost with value. If added cost does not improve quality or the ability to perform the necessary functions, then value is decreased. Three basic elements provide a measure of value to the user: function, quality, and cost. These elements can be interpreted by the following relationship:
Value=Function Quality/Cost
Where: Function = the specific work that a design/item must perform.
Quality = the owner’s or user’s needs, desires, and expectations.
Cost = the life cycle cost of the product.
Therefore, we can say that:
Value = the most cost-effective way to reliably accomplish a
function that will meet the user’s needs, desires, and expectations. The main objective of VE is to improve value, and VE techniques can overcome many of the roadblocks to achieving good value.
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International Journal of Scientific & Engineering Research, Volume 2, Issue 12, December-2011 2
ISSN 2229-5518
Cost
Safety
Quality
Severity factor
MTTR
different maintenance practice for cost through comparison, here less cost of maintenance has more value than high cost of maintenance, so low cost car getting more value.
Table 1: Value point for cost
Break down maintenance | 4 |
Maintenance prevention | 5 |
Corrective maintenance | 6 |
Condition base maintenance | 8 |
Time base maintenance | 9 |
Table 4: Value point for quality
Maintenance type | Point out of 10 |
Break down maintenance | 9 |
Maintenance prevention | 8 |
Corrective maintenance | 7 |
Condition base maintenance | 6 |
Time base maintenance | 5 |
Table 2: Value point for safety
Table 5: Value point for severity factor
Maintenance type | Point out of 10 |
Break down maintenance | 3 |
Maintenance prevention | 5 |
Corrective maintenance | 6 |
Condition base maintenance | 8 |
Time base maintenance | 8 |
Table 3: Value point for MTTR
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International Journal of Scientific & Engineering Research, Volume 2, Issue 12, December-2011 3
ISSN 2229-5518
1) Cost (A)
2) Safety (B)
3) MTTR (C)
4) Quality (D)
5) Severity factor (E)
Major Difference (3)
Medium Difference (2)
Minor Difference (1)
No Difference (0)
Assuming one company has the following requirements while selecting maintenance practice
Cost - Aveg.
Safety- High
MTTR -Very high
Quality -High
Severity factor- Very high
Table 6: table for paired comparison
Table 7: table for criteria evaluation matrix
The proposed processes for maintenance practice are based on weighted points scored as shown in evaluation matrix table. And finally TBM Maintenance practice get highest point, and alternately it should be selected as a best maintenance.
With the help of VE we evaluate one of the best Maintenance practice, in this study we had taken five parameters for selection of Maintenance practice which are Cost, Safety, MTTR, Quality and Severity, and with the help of different phase of VE we found the best maintenance practice as a TBM since it got highest score point in evaluation phase.
The study is very helpful for new industry or small scale industry for selecting the best maintenance practice for economic point of view it is new concept for selection of maintenance practice and enhance the moral of employee for taking a strong decision. The time consumption for taking a decision is less in this concept comparison to other technique with the help of VE
Some of the salient features of the proposed model include-
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International Journal of Scientific & Engineering Research, Volume 2, Issue 12, December-2011 4
ISSN 2229-5518
VE has emerged as the most effective and appropriate management tool for achieving quick result in cost reduction through best maintenance selection.
It is a technique with immense possibilities, and systematically employed, it can achieve great economies and increased efficiency.
[1]. Jose Arocha, Introduction to the Innovative Technology of
Design, Invention Machine Corporation, 1-6, (1999).
[2]. S.H. Lou, Value Engineering in Risk Management, master thesis, Taiwan University, (2001).
[3]. M.H. Kou, Value Engineering and its application in electronic industry, master thesis, (2001).
[4]. Y.Shimomura, Representation of design object based on functional evolution process model, Journal of Mechanical Design, 120(6), 22-230 (1998).
[5].Sarma DVS,Proceedings of IIIE,Elimination of child labour through Value Engineering,(2002)
[6].O’Brien,J.J Value analysis in design and construction, McGraw Hill,inc,New york(1976)
Assistant Professor
Mechanical Engineering Department, National Institute of
Technology, Jamshedpur, INDIA E-mail: malay9mednit@yahoo.in
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