Dr. Samer Kantakji
Rationalization Of Maintenance Process By Quantitive Methods
Dr. Samer Kantakji
Maintenance jobs were a secondary function in the companies. They meant repairing. Higher management dealt with these works as a sudden disease because of the unexpected extra costs.
But in the later years , studies and researches which are looking for mathematical models and scientific ways to control these increasing costs.
So, the researcher focuses on Maintenance Managing by revering to the maintenance organization methods, by explaining the organization ways (Inner, External, Central, Non-Central organizations). This leads the management to adopt a method or more to organize the maintenance jobs, this management suits its financial and technical sources and its activity nature.
After that the management must use the organization techniques ( manual, EDP, computerized ) to get the best way to control its maintenance selected system to determine : What to do ? Where to do ? When to do ? Who must do ? How to do ?.
When the management gathers these rules in addition to : maintenance jobs planning , builds information systems, manages the human sources, and gets the economic considerations, it will get a suitable maintenance model belonging to its company activity. This model must illustrate the documents and the necessary papers which reflex the documentation cycle to explain the spare parts system and the used buying system.... etc. The main function of the model is to determine the limits of the mixture of repairing and planning maintenance. The researcher applied these concepts in EUT Model with some modifications.
Then the researcher focuses on the Cost Accountancy of Maintenance by explaining the accountancy and production cycles. Cost accountancy is the best tool which the high management followed to obtain a stream of information . So, the researcher focuses on the maintenance documents , maintenance cost items, , preparing the estimating maintenance budget , Preparing the maintenance cost statement. In addition the researcher studies the cost behavior and suggests some optimal standards in maintenance works and maintenance costs.
The benefits of this matter are to apply the responsibility of accountancy in giving the rewards to the good and hardworking workers, while punishing the lazy ones to perform the jobs sincerely to have a stable production basis which secure a real reliability in the company.
At last , the researcher uses A quantitive methods for reducing the maintenance costs by studying the interpretation of Failure potentiality , and apply a Reliable measurements in technical systems to know the failure rate of the systems in the production machines . In addition to studying the life examination by using the Exponential model of distribution an Weibull model of distribution . Then the researcher tries to establish Equipment replacement model to determine when the machines should be replaced by a dynamic programming methods to solve this problem . Then the researcher tries to establish Spare parts stock models to determine when and how much the management must buy.
So the study leads the management to use the scientific methods in maintenance management to close or reduce the gap between the theory and practice.