ISSN 1822-6515 ISSN 1822-6515
EKONOMIKA IR VADYBA: 2011. 16 ECONOMICS AND MANAGEMENT: 2011. 16
676
MAINTENANCE MANAGEMENT IN QUICK RESPONSE SYSTEMS
Lenka Branska
University of Pardubice, Czech Republic, lenka.branska@upce.cz
Abstract
A trend has been currently growing to integrate business logistics systems in supply chains and to
implement new methods (such as Quick Response) for logistics performance increasing. All systems based on
synchronization of material flows fail if production facilities in each successive production show a high
number of accidents and subsequent repairs after failure. The maintenance in Quick Response systems is
extremely important. The maintenance system must be clearly focused on prevention. It can be designed
being based on several of modern methods of maintenance, such as TPM and RCM methods, whose
principles it uses and appropriately combines. Moreover, in the maintenance management in companies
involved in the chain, it seems desirable to cooperate in the maintenance with the customers and suppliers. In
this paper is a proposal for modification of maintenance system in an enterprise that is part of a chain
operating on the basis of the Quick Response method.
Keywords: Supply chain management, Quick response, maintenance management, Total productive
maintenance, Reliability centred maintenance.
JEL Classification: M11, M21.
Introduction
A trend has been currently growing to increase efficiency of business logistics chains through their
interlacing with logistics systems of suppliers and customers. Integration of business logistics systems in
supply chains requires the establishment of more or less close cooperation of individual members of the
chain. The supply chain collaboration is often defined as two or more enterprises working together to create
a competitive advantage and higher profits that cannot be achieved by acting alone (Simatupang &
Sridharan, 2005). The highest effects in terms of logistics performance improvement are achieved by
applying modern methods of supply chain management, such as Quick Response (QR), Efficient Consumer
Response (ECR), Vendor Managed Inventory (VM) or Collaborative Planning, Forecasting and
Replenishment (CPFR). According to McMichael at al (McMichel & Mackay & Altman, 2000) QR is
defined as a consumer driven business strategy of cooperative planning by supply chain partners, to ensure
that the right goods, are in the right place, at the right time, using IT and flexible manufacturing to eliminate
inefficiencies from the entire supply chain.
A necessary precondition for the implementation of material flow by the supply chain based on the
methods described above is the reliability of production facilities constituting the production system of each
company. All systems based on synchronization of material flows fail if production facilities in each
successive production show a high number of accidents and subsequent repairs after failure. For this reason,
the maintenance in Quick Response systems is extremely important.
Professional literature has not as yet addressed the problem of how to manage the maintenance in the
Quick Response systems. In general, it deals with methods which allow increasing reliability of the
production equipment, such as the TPM and RCM methods in particular. Mostly, however, these methods
are described and discussed in isolation. Radical increase in maintenance efficiency can be achieved,
however, just through a combination of principles of these methods. The professional literature also has not
yet substantially dealt with the way the implementation of the Quick Response influences supporting
business processes. For now, one can not find any theoretical view on how the maintenance system should be
modified due to application of the Quick Response method. Therefore, the publication is focused on this
issue.
The main goal of this paper is a proposal for modification of maintenance system in an enterprise that
is part of a supply chain operating on the basis of the Quick Response method.
The proposal accents two main ideas, namely:
• This maintenance system must be clearly focused on prevention. It should be conceived on the
basis of some modern methods of maintenance, such as TPM and RCM methods. But a modern,
fully functional maintenance system can be designed being based on several of these methods,
whose principles it uses and appropriately combines. ISSN 1822-6515 ISSN 1822-6515
EKONOMIKA IR VADYBA: 2011. 16 ECONOMICS AND MANAGEMENT: 2011. 16
677
• Moreover, in the maintenance management in companies involved in the chain, it seems desirable
to establish cooperation in this area with other chain links, i.e. cooperate in the maintenance with
the customers and business suppliers. Maintenance in any enterprise then takes place in the
context of the maintenance management in other companies involved in the chain. This should
enable inter-company linked, mainly tactical and operational management of maintenance that
must be based on the principles of maintenance management of the manufacturing facility in
multi-stage productions.
The main target thus identified will be achieved partly on the basis of literature research (analysis of
literary data sources and the subsequent synthesis of established facts) and partly using results from primary
qualitative researches undertaken from 2008 to 2010. These were conducted in Czech companies of the
chemical and petrochemical industries.
Maintenance Tasks in Quick Response Systems
The main task of maintenance is to ensure proper and efficient operation of production equipment.
Proper maintenance means removal of all accidents or breakdowns resulting in unplanned downtimes or
cutbacks in production, that being at a reasonable cost. Means of achieving the desired level of reliability of
production equipment (creating the production system in the company and in the chain, too) are business
maintenance systems. They must, however, be adapted to the management of material flow by both the
company and the chain while being able to effectively promote it.
Maintaining the production equipment must be managed in the QR systems so that:
• it guaranteed high reliability operation of the equipment with minimal repairs after failure,
• the duration of repairs was as short as possible,
• downtimes for repairs in interconnected production systems were linked to each other in a smooth
and synchronized manner and caused the least possible, even short-term increases in stock,
• the maintenance management within the QR system avoided disruption of the maintenance
economy. The maintenance management should be adapted in the businesses to the position that
the selected manufacturing facilities became part of the material flow management based on the
QR method.
To meet these requirements, it is usually necessary to modify the current method of the maintenance
management in the individual companies of the chain.
Ensuring the Reliability of the Production Facilities in the Quick Response Systems
Each production manager must sometimes face the situation that a malfunction occurs in the
manufacturing equipment, consequently resulting in the loss of production. Accidents on the production
facilities usually have more consequences, such as the growth of overall maintenance costs, the emergence of
extraordinary environmental costs (payment of fines), threat to the health of enterprise workers, and
impairment of the company’s goodwill. It is therefore necessary to take such steps and build such a system of
manufacturing equipment maintenance in enterprises that are part of the chain, so that these situations were
at possible minimum, the need was as little as possible of operational, unscheduled maintenance and repair
after the failure.
To reduce the number of breakdowns of production equipment, we may apply the TPM method (Total
Productive Maintenance). TPM combines the practice of preventive maintenance with the concepts of total
quality (Rusell & Taylor, 2006). The methodology is defined by Nakajima (Nakajima, 1988) as plant
improvement methodology, which enables continuous and rapid improvement of manufacturing processes
through use of employee involvement, employee empowerment and closed loop measurement of results.
The objective of TPM is to maximize the efficiency of production equipment through a comprehensive
prevention system, which covers the entire life of the production equipment. The substance of the method is
to involve every employee, in all departments and at all levels, in the system so that they were motivated to
voluntarily participate in the maintenance of the production equipment, through their involvement in small
groups (Imai, 2007). One of the key elements of TPM is the autonomous maintenance. The main idea in the
implementation of the autonomous maintenance is that it is the workmen themselves, i.e. operators of
production equipment, who knows the facilities best in the normal operation, and they should be able to
identify best the differences from the correct operation. Their ability to detect impending problems and the
imminent repair after the failure may be increased through the maintenance training. Consequently, it is ISSN 1822-6515 ISSN 1822-6515
EKONOMIKA IR VADYBA: 2011. 16 ECONOMICS AND MANAGEMENT: 2011. 16
678
possible to use their increased qualifications to better assess the current state of the equipment, but also to
use it in the implementation of the simplest maintenance tasks, including routine repairs, which they can
either perform themselves or they can assist in it. Their deployment is possible not only in the scheduled
maintenance, but also in the repairs after failure, which will shorten their duration.
The TPM method may also be combined with other methods recommended for the improvement of
maintenance services, namely the RCM methods (Reliability Centred Maintenance). Both RCM and TPM
view maintenance in the broader business context and take into a
ISSN 1822-6515 ISSN 1822-6515
EKONOMIKA IR VADYBA: 2011. 16 ECONOMICS AND MANAGEMENT: 2011. 16
676
MAINTENANCE MANAGEMENT IN QUICK RESPONSE SYSTEMS
Lenka Branska
University of Pardubice, Czech Republic, lenka.branska@upce.cz
Abstract
A trend has been currently growing to integrate business logistics systems in supply chains and to
implement new methods (such as Quick Response) for logistics performance increasing. All systems based on
synchronization of material flows fail if production facilities in each successive production show a high
number of accidents and subsequent repairs after failure. The maintenance in Quick Response systems is
extremely important. The maintenance system must be clearly focused on prevention. It can be designed
being based on several of modern methods of maintenance, such as TPM and RCM methods, whose
principles it uses and appropriately combines. Moreover, in the maintenance management in companies
involved in the chain, it seems desirable to cooperate in the maintenance with the customers and suppliers. In
this paper is a proposal for modification of maintenance system in an enterprise that is part of a chain
operating on the basis of the Quick Response method.
Keywords: Supply chain management, Quick response, maintenance management, Total productive
maintenance, Reliability centred maintenance.
JEL Classification: M11, M21.
Introduction
A trend has been currently growing to increase efficiency of business logistics chains through their
interlacing with logistics systems of suppliers and customers. Integration of business logistics systems in
supply chains requires the establishment of more or less close cooperation of individual members of the
chain. The supply chain collaboration is often defined as two or more enterprises working together to create
a competitive advantage and higher profits that cannot be achieved by acting alone (Simatupang &
Sridharan, 2005). The highest effects in terms of logistics performance improvement are achieved by
applying modern methods of supply chain management, such as Quick Response (QR), Efficient Consumer
Response (ECR), Vendor Managed Inventory (VM) or Collaborative Planning, Forecasting and
Replenishment (CPFR). According to McMichael at al (McMichel & Mackay & Altman, 2000) QR is
defined as a consumer driven business strategy of cooperative planning by supply chain partners, to ensure
that the right goods, are in the right place, at the right time, using IT and flexible manufacturing to eliminate
inefficiencies from the entire supply chain.
A necessary precondition for the implementation of material flow by the supply chain based on the
methods described above is the reliability of production facilities constituting the production system of each
company. All systems based on synchronization of material flows fail if production facilities in each
successive production show a high number of accidents and subsequent repairs after failure. For this reason,
the maintenance in Quick Response systems is extremely important.
Professional literature has not as yet addressed the problem of how to manage the maintenance in the
Quick Response systems. In general, it deals with methods which allow increasing reliability of the
production equipment, such as the TPM and RCM methods in particular. Mostly, however, these methods
are described and discussed in isolation. Radical increase in maintenance efficiency can be achieved,
however, just through a combination of principles of these methods. The professional literature also has not
yet substantially dealt with the way the implementation of the Quick Response influences supporting
business processes. For now, one can not find any theoretical view on how the maintenance system should be
modified due to application of the Quick Response method. Therefore, the publication is focused on this
issue.
The main goal of this paper is a proposal for modification of maintenance system in an enterprise that
is part of a supply chain operating on the basis of the Quick Response method.
The proposal accents two main ideas, namely:
• This maintenance system must be clearly focused on prevention. It should be conceived on the
basis of some modern methods of maintenance, such as TPM and RCM methods. But a modern,
fully functional maintenance system can be designed being based on several of these methods,
whose principles it uses and appropriately combines. ISSN 1822-6515 ISSN 1822-6515
EKONOMIKA IR VADYBA: 2011. 16 ECONOMICS AND MANAGEMENT: 2011. 16
677
• Moreover, in the maintenance management in companies involved in the chain, it seems desirable
to establish cooperation in this area with other chain links, i.e. cooperate in the maintenance with
the customers and business suppliers. Maintenance in any enterprise then takes place in the
context of the maintenance management in other companies involved in the chain. This should
enable inter-company linked, mainly tactical and operational management of maintenance that
must be based on the principles of maintenance management of the manufacturing facility in
multi-stage productions.
The main target thus identified will be achieved partly on the basis of literature research (analysis of
literary data sources and the subsequent synthesis of established facts) and partly using results from primary
qualitative researches undertaken from 2008 to 2010. These were conducted in Czech companies of the
chemical and petrochemical industries.
Maintenance Tasks in Quick Response Systems
The main task of maintenance is to ensure proper and efficient operation of production equipment.
Proper maintenance means removal of all accidents or breakdowns resulting in unplanned downtimes or
cutbacks in production, that being at a reasonable cost. Means of achieving the desired level of reliability of
production equipment (creating the production system in the company and in the chain, too) are business
maintenance systems. They must, however, be adapted to the management of material flow by both the
company and the chain while being able to effectively promote it.
Maintaining the production equipment must be managed in the QR systems so that:
• it guaranteed high reliability operation of the equipment with minimal repairs after failure,
• the duration of repairs was as short as possible,
• downtimes for repairs in interconnected production systems were linked to each other in a smooth
and synchronized manner and caused the least possible, even short-term increases in stock,
• the maintenance management within the QR system avoided disruption of the maintenance
economy. The maintenance management should be adapted in the businesses to the position that
the selected manufacturing facilities became part of the material flow management based on the
QR method.
To meet these requirements, it is usually necessary to modify the current method of the maintenance
management in the individual companies of the chain.
Ensuring the Reliability of the Production Facilities in the Quick Response Systems
Each production manager must sometimes face the situation that a malfunction occurs in the
manufacturing equipment, consequently resulting in the loss of production. Accidents on the production
facilities usually have more consequences, such as the growth of overall maintenance costs, the emergence of
extraordinary environmental costs (payment of fines), threat to the health of enterprise workers, and
impairment of the company’s goodwill. It is therefore necessary to take such steps and build such a system of
manufacturing equipment maintenance in enterprises that are part of the chain, so that these situations were
at possible minimum, the need was as little as possible of operational, unscheduled maintenance and repair
after the failure.
To reduce the number of breakdowns of production equipment, we may apply the TPM method (Total
Productive Maintenance). TPM combines the practice of preventive maintenance with the concepts of total
quality (Rusell & Taylor, 2006). The methodology is defined by Nakajima (Nakajima, 1988) as plant
improvement methodology, which enables continuous and rapid improvement of manufacturing processes
through use of employee involvement, employee empowerment and closed loop measurement of results.
The objective of TPM is to maximize the efficiency of production equipment through a comprehensive
prevention system, which covers the entire life of the production equipment. The substance of the method is
to involve every employee, in all departments and at all levels, in the system so that they were motivated to
voluntarily participate in the maintenance of the production equipment, through their involvement in small
groups (Imai, 2007). One of the key elements of TPM is the autonomous maintenance. The main idea in the
implementation of the autonomous maintenance is that it is the workmen themselves, i.e. operators of
production equipment, who knows the facilities best in the normal operation, and they should be able to
identify best the differences from the correct operation. Their ability to detect impending problems and the
imminent repair after the failure may be increased through the maintenance training. Consequently, it is ISSN 1822-6515 ISSN 1822-6515
EKONOMIKA IR VADYBA: 2011. 16 ECONOMICS AND MANAGEMENT: 2011. 16
678
possible to use their increased qualifications to better assess the current state of the equipment, but also to
use it in the implementation of the simplest maintenance tasks, including routine repairs, which they can
either perform themselves or they can assist in it. Their deployment is possible not only in the scheduled
maintenance, but also in the repairs after failure, which will shorten their duration.
The TPM method may also be combined with other methods recommended for the improvement of
maintenance services, namely the RCM methods (Reliability Centred Maintenance). Both RCM and TPM
view maintenance in the broader business context and take into a
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