2020 Zeinalnezhad
2020 Zeinalnezhad
2020 Zeinalnezhad
Article
Critical Success Factors of the Reliability-Centred
Maintenance Implementation in the Oil and
Gas Industry
Masoomeh Zeinalnezhad 1 , Abdoulmohammad Gholamzadeh Chofreh 2, * , Feybi Ariani Goni 2
and Jiří Jaromír Klemeš 2
1 Department of Industrial Engineering, West Tehran Branch, Islamic Azad University,
Tehran 1468763785, Iran; zeinalnezhad.m@wtiau.ac.ir
2 Sustainable Process Integration Laboratory—SPIL, NETME Centre, Faculty of Mechanical Engineering,
Brno University of Technology—VUT Brno, Technická 2896/2, 61669 Brno, Czech Republic;
goni@fme.vutbr.cz (F.A.G.); jiri.klemes@vutbr.cz (J.J.K.)
* Correspondence: chofreh@fme.vutbr.cz
Received: 5 August 2020; Accepted: 18 September 2020; Published: 23 September 2020
Keywords: reliability centred maintenance (RCM); critical success factors (CSFs); nominal group
technique (NGT); fuzzy analytic network process (FANP); oil and gas industry
1. Introduction
Managers are now looking for various maintenance disciplines to rationalise the achievement
of their business in the face of ongoing challenges to improve plant reliability at a lower cost [1].
In this regard, Reliability Centred Maintenance (RCM) is defined as a systematic methodology for
the optimisation and development of the maintenance requirements of a physical resource [2]. It has
been recently found to be the most efficient strategy in comparison with the existing supervision
of maintenance strategies [2]. This method has been successfully applied for more than 30 y in
several industries, such as aircraft, military forces, nuclear power, and oil and gas companies [3].
Research has confirmed that the RCM method is imperative to reduce maintenance costs and improve
the effectiveness of the maintenance systems [4]. It enables the organisation to minimise maintenance
duration and create a safe environment, which has been an issue of concern to manufacturers [5].
An application of the RCM method is imperative for organisations to optimise their maintenance
activities and to develop a cost-effective method for managing their maintenance procedures [6].
Wang et al. [7] concluded that the system operates under a performance-based contract. RCM helps
service providers to increase profits and improve system performance at lower costs. Similar to them,
Ma et al. [8] confirmed the maintenance cost is minimised via RCM implementation in their case study,
namely, a warm standby cooling system.
Especially in the oil and gas industry, there is an ongoing emphasis on cost management,
where prices are very flexible and vulnerable to changes in supply and demand [9]. Oil and gas plants
produce a wide range of products used as chemicals and fuels, so, maintenance activities within them
remarkably affect their productivity. The use of RCM can help organisations develop a systematic
maintenance program, meeting these requirements in a cost-effective manner [9].
The RCM methods have a close link to sustainability [10]. An organisation that
strives towards effective sustainability requires effective RCM practices and technologies [11].
However, the organisation still faces difficulty and even failure during the RCM implementation.
Plucknette [12] stated that based on the survey of more than 250 companies, over 85% of the RCM
analysis had not been completely implemented. While the fundamental notion of the RCM method is
simple, its implementation is tremendously complicated [13].
An organisation should have effective preparations before they transform their conventional
maintenance systems towards RCM [14]. One of the essential processes in the pre-implementation
phase is considering several Critical Success Factors (CSFs), used as an important measure to implement
the RCM methods successfully. Practitioners often ignore this preparation phase. This problem also
emerged in Iranian manufacturing organisations. Numbers of companies in Iran have considered the
vital role of the RCM to enhance the effectivity and efficiency of the equipment and machinery [15].
This approach has not been applied effectively in Iranian oil industries as it needs proper preparation for
planning [16]. RCM implementation is complex, and organisations need to have adequate preparations
before they implement the RCM methods. In the pre-implementation phase, the number of CSFs, as a
key measure to implement the RCM methods successfully, is necessary. The practitioners often skip
this pre-implementation phase. As a result, the majority of the manufacturing companies face many
problems during the implementation process since they do not have a sufficient preparation plan.
There are a small number of RCM researches that aimed to identify and prioritise the critical factors
for implementing RCM regarding the characteristics of oil and gas organisations [16]. The majority
of them focused on the implementation process without considering the important processes in
the pre-implementation phase. To fill this gap, this study is conducted to identify the CSFs which
are imperative to be addressed by oil and gas organisations using symmetric mechanism involving
fuzzy systems to achieve the desired RCM implementation. It is done using the Nominal Group
Technique (NGT) and Fuzzy Analytic Network Process (FANP). The Analytic Network Process
(ANP) is generally used to rank the decisions without creating assumptions about the unidirectional
hierarchy relationship between decision levels. As ANP lacks a comprehensive consideration of human
intelligence in modelling, fuzzy models have been applied as they have better compatibility with
linguistic explanations and are often ambiguous for making long-term predictions and for making
real-world decisions [17]. Fuzzy logic has been widely applied in numerous fields such as optimisation,
systems engineering, and image processing [18].
The structure of this paper is organised as follows. Section 2 provides an analysis of related
studies, which culminates with the identification of the knowledge gap. Section 3 explains the research
Symmetry 2020, 12, 1585 3 of 14
process of the present study. Section 4 presents the data analysis and discussion of the research findings.
Section 52020,
Symmetry concludes
12, x FORthe study
PEER and recommends the numbers of potential research directions. 3 of 15
REVIEW
2. Literature
2. Literature Review
Review
A concept
A concept that
that has
has changed
changed in
in the
the Prognostics
Prognostics and
and Health
Health Management
Management (PHM)(PHM) implementation
implementation
from seeking the remaining useful life to determining extendable useful life [19].
from seeking the remaining useful life to determining extendable useful life [19]. Research in Research in RCM
RCM
area has
area has been
been rapidly
rapidly growing
growing these
these years
years because
because ofof increasing
increasing challenges
challenges and
and expectations
expectations ofof
maintenance [14]. The topic in the RCM area includes RCM implementation,
maintenance [14]. The topic in the RCM area includes RCM implementation, optimisation of the optimisation of the
method, integration
method, integration between
between the
the RCM
RCM with with other
other techniques,
techniques, risk
risk reduction,
reduction, and
and evaluation
evaluation of
of the
the
RCM failures
RCM failures [2].
[2]. This
This study
study categorised
categorised thethe topics
topics into
into three
three phases: RCM pre-implementation,
phases: RCM pre-implementation,
implementation and
implementation and post-implementation,
post-implementation, as as shown
shown in in Figure
Figure 1.
1.
Figure 2. Research
Figure flow offlow
2. Research the study
of the study
AsAsshown
shownin Figure
in Figure2, a 2,
preliminary list oflist
a preliminary success factors,factors,
of success consisting of 20 items,
consisting of 20was identified
items, was identified
based
basedon on
a review of theofliterature
a review and surveys.
the literature These success
and surveys. These factors are then
success introduced
factors are thentointroduced
the RCM to the
team,
RCM which
team,includes ten experts
which includes tenand managers
experts from technical
and managers fromand engineering
technical departments,departments,
and engineering the
strategic planning and development deputy, the support and logistics deputy, and the human
the strategic planning and development deputy, the support and logistics deputy, and the human
resources, deputy. This team has been selected at the discretion of the managers of Persian Gulf Star
resources, deputy. This team has been selected at the discretion of the managers of Persian Gulf Star
Oil Company. It involves people who have been responsible for the maintenance of company and
Oil Company. It involves people who have been responsible for the maintenance of company and
repair program.
repair
The program.
initial factors were validated, modified and scored by team members through discussion
The initial
and voting, which factors
resultedwerein 15validated,
CSFs. Thesemodified
CSFs were andthen
scored by team
prioritised members
using through
fuzzy ANP, discussion and
as shown
voting, which resulted in 15 CSFs. These CSFs were then prioritised using
in phase 2. The Analytic Network Process (ANP) is an extension of the analytical hierarchy process fuzzy ANP, as shown in
which allows analysis of complex systems. As there are limitations in the determination of success which
phase 2. The Analytic Network Process (ANP) is an extension of the analytical hierarchy process
allows
factors, toanalysis
make betterof complex
decisionssystems. As there
in this process, are limitations
the weights of factorsinare
thedetermined
determination of success
by using fuzzy factors,
ANP. In FANP,
to make better the importance
decisions in thisweights
process,ofthe criteria
weights canofbe evaluated
factors using linguistic
are determined values
by using fuzzy ANP.
In FANP, the importance weights of criteria can be evaluated using linguistic values represented by
fuzzy numbers. This technique enables one to overcome uncertainties and inaccuracies in the priority
setting process.
Symmetry 2020, 12, 1585 6 of 14
In phase 2, a questionnaire for paired comparisons is developed. The RCM team members filled in
the surveys and the aggregated pairwise comparison matrices are calculated based on their responses.
To obtain the final priorities in a system that is affected by internal dependence, local priority vectors are
entered in proportion to the columns of the matrix, which is known as the supermatrix. Based on this
matrix, the weights of factors were calculated, through four steps and the critical factors influencing
the success of RCM pre-implementation are prioritised.
4. Results
According to Figure 2, this study was completed in two main phases, namely, determination of
the CSFs and prioritising them through the formation of the supermatrix and calculation of the weight
of factors using FANP. The calculations are made, and the results obtained from the various stages of
the research are presented in this section.
Symbol Sum Mean Mode Max Min Standard Error Variance Skewness Kurtosis
F1 78 7.8 7 9 7 0.75 0.56 0.41 −1.07
F2 43 4.3 4 6 3 0.90 0.81 0.23 −0.35
F3 81 8.1 8 9 7 0.70 0.49 −0.17 −0.73
F4 79 7.9 7 10 7 1.04 1.09 0.86 −0.52
F5 65 6.5 6 8 5 0.81 0.65 0.00 0.11
F6 81 8.1 8 10 7 0.94 0.89 0.61 −0.16
F7 61 6.1 7 7 5 0.83 0.69 −0.22 −1.73
F8 59 5.9 6 8 5 0.94 0.89 1.08 0.91
F9 43 4.3 4 5 3 0.64 0.41 −0.43 −0.28
F10 77 7.7 7 10 6 1.10 1.21 0.73 0.51
F11 71 7.1 7 8 6 0.70 0.49 −0.17 −0.73
F12 83 8.3 9 10 7 1.00 1.01 −0.04 −1.24
F13 47 4.7 5 6 3 0.90 0.81 −0.23 −0.35
F14 55 5.5 6 7 3 1.20 1.45 −0.82 0.25
F15 61 6.1 5 8 5 1.04 1.09 0.39 −1.24
F16 63 6.3 5 8 5 1.19 1.41 0.14 −1.77
F17 37 3.7 2 7 2 1.79 3.21 1.16 0.17
F18 52 5.2 5 6 4 0.60 0.36 −0.13 0.18
F19 39 3.9 2 9 1 2.62 6.89 0.92 −0.67
F20 69 6.9 7 10 5 1.58 2.49 0.56 −0.04
Sum: Summation function; Mean: The average of the numbers; Mode: The number that appears most frequently in
a data set; Max: Maximum function; Min: Minimum function.
The symbols, F1 to F10, are related to the “Items”, introduced in Table 2. Small values of skewness
and kurtosis indicate that in most cases, the data have a normal distribution [34]. The items were
scored using linguistic values represented by fuzzy numbers. The linguistic scales and their fuzzy
levels in this study are developed in the following Table 3.
Symmetry 2020, 12, 1585 7 of 14
The calculated values of the scores related to all 20 factors are given in Table 2. Those that scored
less than 50 points were eliminated, while the items receiving more than 50 points are considered as
the CSFs.
As provided in Table 2, fifteen success factors scored more than 50, and five factors had a score of
less than 50. The final fifteen CFSs for pre-implementation of RCM are listed as follows:
1. Skilled human resources
2. Sufficient budget
3. Awareness of the need for improved maintenance programs in the organisation
4. Technical knowledge and using the best way to select critical equipment for RCM analysis
5. Sufficient time
6. Training
7. RCM knowledge among managers
8. Understand the need to establish an RCM strategy
9. Paying attention to maintenance strategies to reduce costs
10. Motivation among staffs
11. Teamwork
5. Sufficient time
6. Training
7. RCM knowledge among managers
8. Understand the need to establish an RCM strategy
9. Paying
Symmetry 2020, attention
12, 1585 to maintenance strategies to reduce costs 8 of 14
10. Motivation among staffs
11. Teamwork
12. RCM knowledge
12. RCM knowledge among among staff
staff
13. Accessibility
Accessibility to to machinery
machinery information
information
14. Capability
Capability to to change
change the
the design
design of
of equipment
equipment
15. Staffs’
Staffs’ commitment
commitment
C1 Ck Cn
e11 e12 e1m1 ek1 ek 2 ekmk en1 en2 enm
e11
e12
C1
w11 w1k w1n
e1m1
ek 1
Ck ek 2
W = wk1 wkk wkn
ekmk
en1 w
n1 wnk1 wnn
Cn en2
enm
Figure 3.
Figure A generalised
3. A generalised supermatrix
supermatrix (adopted
(adopted from
from Asan
Asan et
et al.
al. [36]).
[36]).
In Figure 3, Cm means the mth cluster with nm elements symbolised as em1 , em2 , ..., emn , where emn
represents the nth element in the mth cluster. Wij is a block matrix consisting of principal eigenvectors
representing the influence of the elements in the ith cluster on the elements in the jth cluster.
g
The weight vectors of each matrix should be calculated using wm = [wm i
] and w g = [wi ] by
considering the Equations (1) and (2), which are developed in this study.
n
1 X aijm
wm
i = n
(1)
n P
j=1 aijm
i=1
n √
g 1X aiju .aijl
wi = n √
(2)
n P
j=1 aiju .aijl
i=1
For this matrix, the Consistency Ratios (CR) obtained were 0.037 and 0.096, which are less than
0.1, meaning the matrix is compatible.
ek = (wlk , wm
w k
, wuk ) k = 1, 2, 3, . . . , n
According to Equations (4) and (5), the final weights were calculated, and the results are shown in
Table 6.
Symmetry 2020, 12, 1585 10 of 14
According to Table 6, it can be concluded that the most important factors are formulated in
Figure 4. Most of these items are discussed in other improvement projects, such as the variation of
CSFs with different degrees of importance. The key to building a successful RCM project starts with a
pre-implementation phase. In this phase, some questions that need to be answered are: How much it
costs? Do we have the necessary resources? Who will be responsible for leading the effort? Do the
manager and staff have sufficient knowledge about RCM? How do you manage the implementation of
RCM tasks? Who will be involved? The spirit of employees’ cooperation before the implementation of
RCM also needs to be increased to support the success of RCM pre-implementation.
Symmetry 2020, 12, x FOR PEER REVIEW 12 of 15
Prioritising the determining factors using Fuzzy ANP. As a result, fifteen success factors are important
to be considered by organisations before they implement the RCM. Awareness of the need for improved
maintenance programs in the organisation was classed as the highest priority, with a final weight
of 0.113, followed by technical knowledge and using the best way to select critical equipment for
RCM analysis, with a final weight of 0.101. The third priority is staffs’ commitment with a final
weight of 0.092. The fourth priority is sufficient time, with a final weight of 0.078. The fifth priority is
paying attention to maintenance strategies to reduce costs, with a final weight of 0.07. The sixth and
seventh priorities are sequentially placed by RCM knowledge among staff and a sufficient budget,
which received a similar final weight of 0.068. The eighth priority is RCM knowledge among managers,
with a final weight of 0.066. The ninth priority is understanding the need to establish an RCM strategy,
with a final weight of 0.065. The tenth priority is the capability to change the design of equipment,
with a final weight of 0.064. The eleventh and twelfth priorities are consecutively represented by
accessibility to machinery information and skilled human resources, with similar final weights of 0.059.
The thirteenth priority is teamwork, with a final weight of 0.051. The fifteenth priority is training,
with a final weight of 0.04. The lowest priority is the motivation among staff, with a final weight
of 0.032.
This study contributes to both theoretical development and practice. From an academic point of
view, this study would advance the growth of RCM research by filling the knowledge gap in the related
topic. The method used in this study, namely the nominal group approach, is still rarely applied for
determining the CSFs. From a practical perspective, the identification of CSFs is useful for maintaining
strategic planning efforts. They are important for organisations to avoid and mitigate unpredictable
problems that emerge during RCM implementation. These CSFs would improve the strategic analysis
and thinking required to implement RCM effectively. The framework proposed here can be applied as
a decision support system for senior managers and practitioners involved in maintenance strategies.
This paper contributes to existing knowledge as it provides an objective approach for practitioners to
focus on the most critical factors and improve overall performance by progressively considering the
identified CSFs.
This study was carried out by considering the characteristics of oil and gas organisations,
which emphasises on improving the reliability of refineries. Petrochemical industries are classified as
high-risk companies with a dire need for cost management, where prices are very flexible and vulnerable
to changes in supply and demand. Their components are toxic, explosive, and flammable, so it is
necessary to have a systematic maintenance program to ensure safety and consistency cost-effectiveness.
This program can be further extended to other industries, such as manufacturing, through the
application of additional criteria. Customising, according to the circumstances of the situations,
the identified CSFs and the proposed framework, can be applied in other industries, particularly in
developing countries. The CSFs ranking is distinctive for each country and, therefore, the outcomes of
the present study cannot be directly applied to other countries. The CSF ranking also varies from one
country to another, even the priority o each CSF may change over time.
Further studies need to be done to advance the results of this study. A study proposing a
strategic planning process with the identified CSFs that culminate the development of an integrated
strategic planning framework for the implementation of RCM would be valuable for the manufacturing
organisations. It would provide some holistic strategic plans that describe the current status of
organisations, targets, goals for the future, and approaches for going forward.
Author Contributions: M.Z.: Developing the methodology, investigation, writing the manuscript. A.G.C.:
Developing the first draft, developing the methodology, manuscript checking and editing. F.A.G.: Extending the
methodology, writing the manuscript. J.J.K.: Project supervision and coordination, funding acquisition, adjusting
the methodology, manuscript checking and editing. All authors have read and agreed to the published version of
the manuscript.
Symmetry 2020, 12, 1585 13 of 14
Funding: This research has been supported by the EU project “Sustainable Process Integration Laboratory—SPIL”,
project No. CZ.02.1.01/0.0/0.0/15_003/0000456 funded by EU “CZ Operational Programme Research, Development
and Education”, Priority 1: Strengthening capacity for quality research.
Conflicts of Interest: The authors declare no conflict of interest.
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