8-9 Feb 2025
This course integrates daily operations with maintenance activities, which an organisation would benefit from minimum breakdowns yet contribute to cost saving in the long run as well as would assure continuous productivity. This course is designed to expose students to maintenance management. The topics covered are introduction to maintenance engineering, total productive maintenance (TPM), six major losses, measuring overall equipment effectiveness (OEE), reliability and maintenance cost. At the end of the course, students should be able to apply knowledge in and basic maintenance concept and develop a total productive maintenance (TPM) programme for facility management (FM) company.
Day 1 (8/2/2025)
Day 2 (9/2/2025)
a) Quiz 1 (10%)
- What is the primary goal of maintenance management according to the British Standard Glossary of terms ?
- A) To increase production speed
- B) To retain or restore an item to a state where it can perform a required function
- C) To reduce the number of employees
- D) To increase the budget for new equipment
- What percentage of a capital-intensive industry’s operating budget is typically consumed by maintenance expenditure?
- A) 10-20%
- B) 20-30%
- C) 40-50%
- D) 60-70%
- Which of the following is NOT a maintenance activity?
- A) Servicing
- B) Overhaul
- C) Marketing
- D) Inspection
- What was the primary focus of maintenance during the pre-World War II era?
- A) Preventive maintenance
- B) Fixing equipment when it breaks
- C) Using computer modeling
- D) Implementing Total Productive Maintenance (TPM)
- Which of the following is a key feature of Third Generation maintenance?
- A) Focus on availability and reliability
- B) Fixing equipment only when it breaks
- C) Reducing the number of maintenance staff
- D) Increasing the budget for new equipment
- What is the main mission of the maintenance department in the Fourth Generation of maintenance?
- A) To increase the number of maintenance staff
- B) To provide excellent support for customers by reducing the need for maintenance
- C) To focus solely on preventive maintenance
- D) To eliminate all maintenance activities
- Which of the following is a consequence of not maintaining equipment?
- A) Increased production speed
- B) Unscheduled plant shutdown
- C) Improved safety
- D) Reduced costs
- What is one of the main objectives of maintenance in relation to production goals?
- A) To increase the number of production staff
- B) To keep production machines and facilities in the best possible condition
- C) To reduce the quality of the product
- D) To increase the downtime of equipment
- Which of the following is a benefit of maintaining equipment?
- A) Increased downtime
- B) Higher energy usage
- C) Cost saving
- D) Reduced accuracy
- What is one of the challenges in maintenance management?
- A) Lack of management attention to maintenance
- B) Overabundance of maintenance staff
- C) Excessive use of quantitative analysis
- D) Easy access to time and cost estimates for maintenance works
Submit Q1 here
b) Group Assignment 1 (10%)
Discuss the evolution of maintenance strategies from the pre-World War II era to the Fourth Generation of maintenance. How have the objectives and focus of maintenance changed over time, and what are the key factors driving these changes? Provide examples of how modern maintenance techniques contribute to the success of world-class companies.
Guidelines for the Essay:
- Introduction: Briefly introduce the concept of maintenance management and its importance in industrial settings.
- Historical Overview: Discuss the evolution of maintenance strategies, starting from the pre-World War II era, through the post-war period, and up to the Fourth Generation of maintenance.
- Key Changes: Highlight the shift from reactive maintenance (fixing equipment when it breaks) to proactive and predictive maintenance strategies. Discuss the role of technology, such as computer modeling and artificial intelligence, in modern maintenance practices.
- Objectives and Focus: Explain how the objectives of maintenance have evolved from merely fixing equipment to ensuring high availability, reliability, and cost-effectiveness. Discuss the growing importance of safety, environmental concerns, and product quality in maintenance strategies.
- Modern Techniques: Provide examples of modern maintenance techniques such as Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM), and Condition Monitoring, and how they contribute to the success of world-class companies.
- Conclusion: Summarize the key points and emphasize the importance of adapting to new maintenance strategies to remain competitive in today’s industrial landscape.
Submit Group Assignment 1 here
c) Group Assignment 2 (20%)
“The Role of 5S in Enhancing Workplace Efficiency, Safety, and Sustainability: A Critical Analysis”
Guidelines:
- Discuss the origins and principles of 5S.
- Analyze how 5S improves workplace organization and productivity.
- Examine the connection between 5S and SDGs, particularly SDG 8, SDG 9, and SDG 12.
- Evaluate real-world applications of 5S in industry and its impact on lean manufacturing.
- Provide recommendations on how organizations can sustain 5S culture effectively.
Submit Group Assignment 2 here
Individual Assignment (20%)
“The Role of Total Productive Maintenance in Enhancing Manufacturing Efficiency and Sustainability”
Guidelines for Writing:
- Introduction: Define TPM and its historical development, including its origins from TQM.
- TPM Principles: Discuss the eight pillars of TPM, focusing on Jishu Hozen, Kobetsu Kaizen, and Planned Maintenance.
- Benefits of TPM: Analyze its impact on productivity, equipment efficiency (OEE), cost reduction, and sustainability.
- TPM and SDGs: Explain how TPM aligns with Sustainable Development Goals (e.g., SDG 9 – Industry, Innovation & Infrastructure).
- Challenges and Solutions: Identify key obstacles in TPM implementation and provide recommendations for successful adoption.
- Conclusion: Summarize the importance of TPM in modern industries and future trends in maintenance technology.
Submit Individual Assignment here
d) Question for PMA (40%)
Write an article on the role of Maintenance Management, 5S, and Total Productive Maintenance (TPM) in optimizing industrial efficiency and sustainability. Your article should be structured to meet the standards of an academic journal and include a critical analysis supported by empirical data or case studies.
Guidelines for Writing the Article:
- Title: Ensure the title is concise, descriptive, and aligned with contemporary issues in maintenance management.
- Abstract (150-250 words): Provide a clear summary of the study, including the problem statement, methodology, key findings, and implications.
- Introduction:
- Define maintenance management and its significance in industrial operations.
- Explain the importance of 5S and TPM as fundamental strategies in modern maintenance.
- State the research objectives and outline the structure of the paper.
- Literature Review:
- Review existing studies on 5S and TPM in maintenance management.
- Discuss the evolution of these concepts and their relevance in achieving operational excellence.
- Identify research gaps and areas for further investigation.
- Methodology:
- Describe the research approach (qualitative, quantitative, or mixed methods).
- Provide details on data collection techniques (e.g., case studies, surveys, experimental analysis).
- Justify the choice of methods based on research objectives.
- Results and Discussion:
- Present findings on the impact of 5S and TPM on equipment efficiency, cost reduction, and workplace safety.
- Use data, graphs, and case studies to support claims.
- Compare results with previous research and discuss practical implications.
- Challenges and Solutions in TPM Implementation:
- Identify barriers to adopting TPM and 5S in industries.
- Suggest best practices and policy recommendations for successful implementation.
- Conclusion and Future Research Directions:
- Summarize key insights and contributions to maintenance management.
- Recommend areas for future research and technological advancements in predictive maintenance.
- References:
- Use APA or IEEE citation style.
- Include at least 20 relevant academic sources, such as journal articles, books, and industry reports.
Submit Question for PMA here
