Identification and Solution of Maintenance Challenges in a Production Line

Abstract

This work attempts to identify the root causes of machine and equipment breakdowns in a production line. The evil effects of machine shutdown on manufacturing targets in volume and deadlines are comprehensively highlighted. The relevant data were obtained in a field survey of three reputable production companies in a given business and budget year. The result shows that the major maintenance challenges in a typical production line are poor spare parts inventory management, lack of technical competence of production and maintenance operatives, ageing machines and equipment, inadequate maintenance budget, and poor leadership of the firm’s management team. The work suggested robust technical solutions as remedies which include aadequate consideration of maintenance during the projection initiation phase, application of N+1 philosophy, strategic inventory control, adoption of computerized maintenance management system (CMMS), adherence to condition based maintenance or predictive maintenance, aaggressive pursuit of total productive maintenance (TPM), and staff competence development and motivation.

Key words: Machine-breakdown, Production, Manufacturing, Condition-monitoring, preventive-maintenance, predictive-maintenance, total-productive-maintenance.