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Proceedings on Engineering
Sciences
www.pesjournal.net
Marcelo Oliveira1
Wagner Andrade
Isabella dos Santos
Received 31.05.2022.
Menfecy Amaral Accepted 21.09.2022.
Gisele Cintra UDC – 005.934.2
ABSTRACT
Keywords:
Maintenance Management; Maintenance Maturity The present work focuses on a case study applying a maintenance
Model; Management System; Continuous management system model based on the degree of maturity in a
Improvement; Lean Maintenance. thermoplastic industry. The system must support the decisions of the
organization and promote progress in the company's continuous
improvement system. The study was based on the answers to a
questionnaire submitted to the maintenance, production, and
process engineering sectors. The internal perception was compared
with external perception in order to perform an analysis of the field
of view of the three sectors on the current position of the
maintenance sector in relation to the maintenance maturity model
used for this analysis. From the application of the model, it was
possible to develop a strategic action plan based on lean practices,
so that the maintenance areas advance towards the higher levels of
the maturity scale, aiming to reach and maintain performance levels
recognized as excellence.
© 2022 Published by Faculty of Engineeringg
1
Corresponding author: Marcelo Oliveira
Email: marcelooliveira@ufam.edu.br 543
Proceedings on Engineering Sciences, Vol. 04, No. 4 (2022) 543-550, doi: 10.24874/PES04.04.014
The need to increase operational availability has been In this sense, companies differ mainly in their maintenance
driven by the requirements of productivity, quality strategies by the combination of decisions made within the
increase, competitiveness, and market opening, among various activities involved in maintenance management, as
others, and thus maintenance management ensures tools diverse operational aspects and business requirements tend
and techniques to improve efficiency and minimize the to influence these decisions, as studies by several
impact of equipment corrective failures such as Total researchers in this area (Fernandez et al., 2003; Horner et
Productive Maintenance (TPM) and Failure Mode and al., 1997; Hwang et al., 2007; Murthy et al., 2002; Nodem
Effects Analysis (FMEA) based on indicators such as et al., 2011; Swanson, 2001; Tsang, 2002; Waeyenbergh
MTBF (Mean Time Between Failures) and MTTR (Mean & Pintelon, 2004).
Time Between Repairs).
2.2 Maturity Models
Companies have differentiated their maintenance
strategies by combining decisions made within the various Maturity models have emerged from the need to evaluate
activities that involve maintenance management, as there the quality of processes applied in an organization,
are several aspects that we must consider in order to create whether industry or institution and are currently being used
a consistent strategic plan for the sector. These are the to improve the services and products of organizations.
issues that tend to influence decisions such as operational Maturity levels establish levels of process evolution,
aspects, for example, the administrative culture of the characterizing stages of process implementation
organization and other business requirements. improvement in the organization. The maturity level of an
organization allows it to predict its future performance by
This article is organized as follows. The first section executing one or more processes.
introduces the lean approach to maintenance management.
The second section presents the literature review, According to Maier et al. (2009) and Maier et al. (2012),
describing maintenance management, maturity models, many maturity models have been proposed to evaluate a
and maturity models focused on the area. The third section range of capabilities, including quality management,
deals with the application of the selected model and field software development, supplier relationships, research and
studies report. Results and analysis are discussed in the development efficiency, product development,
fourth section. Finally, the fifth section brings the collaboration, and communication that each of these
conclusion of the research. assessments focus on a particular domain of knowledge.
2. LITERATURE REVIEW Fraser et al. (2002) pointed out that producing a maturity
model that is generic and completely rigorous is extremely
The following topics cover the academic background that complicated. In addition, they suggest that some
supports this article. compromise will be necessary and appropriate in the
interest of producing a suitable and usable tool. However,
2.1 Maintenance Management we can cite as an example at least 30 maturity models
focused on various areas, such as software engineering,
As defined by NP EN:13306 (2007), the concept of process engineering, performance engineering, and quality
maintenance as being the combination of all technical, management (Jokela et al., 2006; Tiku et al., 2007; Wilson,
administrative, and management actions during the life 2015), as shown in Figure 1.
cycle of an element intended to conserve or restore it to a
state in which it performs the required function. Maturity Models
1. Capability Maturity Model Integration (CMMI) 16. eGovernment Maturity Model
2. Capability Maturity Model for Software (SW-CMM) 17. Earned Value Management Maturity Model
Maintenance management sets goals and objectives 3. People Capability Maturity Model (P-CMM) 18. Outsourcing Management Maturity Model
through work standards and procedures to make the best 4. Software Acquisition Capability Maturity Model 19. Change Proficiency Maturity Model
use of available resources, whether personal, equipment, 5. Software Engineering Capability Maturity Model 20. Performance Engineering Maturity Model
or materials. In this way, it is considered strategic when it 6. Integrated Product Development Capability Maturity 21. Architecture Maturity Model
7. IT Service Capability Maturity Model 22. Information Process Maturity Model
is focused on the business results of the organization, and
8. Organizational Project Management Maturity Model 23. Project Management Maturity Model (PMMM)
this implies that, in addition to having to ensure the 9. Services Maturity Model 24. Programme Management Maturity Model
functional availability of equipment and facilities in a 10. Self-Assessment Maturity Model (SAMM) 25. Learning Management Maturity Model (LM3)
production or service process, maintenance management 11. Test Maturity Model (TMM) 26. Automated Software Testing Maturity Model
needs to combine reliability, safety, environmental 12. Web Services Maturity Model 27. Website Maturity Model
preservation, and moderate cost factors. 13. Security Maturity Model (SMM) 28. PM2 Maturity Model
14. Operations Maturity Model 29. Internet Maturity Model
15. e-Learning Maturity Mode 30. Usability Maturity Model
In addition, proper management establishes maintenance
performance indicators to support management in order to Figure 1. Maturity models developed in several areas
achieve maintenance excellence and use fixed assets in a
competitive manner (NP EN:15341, 2009).
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Oliveira et al., Evaluation of maintenance management of a thermoplastic industry using a maintenance maturity
model: a case in Manaus industrial POLE
2.3 Maintenance Maturity Models Oliveira (2017) was also used during the interview, so
that they were analyzed, class by class, according to the
According to Oliveira and Lopes (2020), maturity models order proposed by the model. Participated in this
have been approached in various knowledge segments, meeting: Expert advisor; Maintenance supervisor
and the practical characterization of their conclusions has (Graduated in mechanics); Electrical engineer; Technical
contributed to the achievement of better results in coordinator of electrical maintenance (Software
organizations in general. As in other areas of knowledge, specialist), and Maintenance Technician.
maturity models have been developed for maintenance
management, with the aim of identifying improvement The object of study is a company in the thermoplastic
opportunities and thus improving maintenance practices sector, which has four units in operation in Brazil. The
and their results in line with organizations' strategic unit of this study, located in the Industrial Pole of
objectives. The models available for maintenance are Manaus, manufactures plastic lids for beverages, bi-
based on process improvements, the need for computer oriented polypropylene films for food product packaging
support and performance indicators. and overpacks, in addition to PP (Polypropylene) and PS
(Polystyrene) sheets.
In the context of maintenance Antil (1991), proposed a
maturity model strongly based and inspired by the maturity The maintenance sector has 72 people and is divided into
model developed by Crosby in 1979 for the quality area. electrical maintenance and mechanical maintenance,
This model was later used by Fernandez et al., (2003) in each with their respective leaders. Among the areas
the application of a customized maintenance management where the maintenance team works are the BOPP (Bi-
system. Wireman (1992) also proposes a model like that Oriented Polypropylene) film extrusion sector, the
developed by Crosby, containing five stages and seven cutting sector (primary and secondary), packaging and,
classes. Such a model shows the progressive stages of best finally, the plates and lids sector.
maintenance practices. As an adaptation to the Crosby
model, although not all issues/areas are applicable in all At the time of our interview, the managers did not have
areas of maintenance, much can be gained from the number of machines under their responsibility, but
comparative practical evaluations. they claim that the amount exceeds 100 pieces of
equipment (after the interview, 104 pieces of equipment
Campbell and Reyes-Picknell (2006) propose a model, were confirmed in the entire plant). The maintenance
based on field research and the use of the Pyramid of structure consists of technicians, technical assistants,
Excellence concept, containing ten classes and five stages. supervision, and a single manager for the three subareas.
Cholasuke et al. (2004) from a study in British industries,
proposed a maturity model for the management of In order to collect the necessary information for the
maintenance activities containing ten classes and only application of the model, after the interview with the
three stages. managers of the maintenance area, in order to deepen the
items covered by the model and considering the proposed
Maturity models developed to assess the level of classes, some considerations were made regarding the
maintenance management maturity in organizations were organization and management of the company's
made available by different researchers (Antil, 1991; April maintenance area by the Consultant.
& Abran, 2009; Chemweno, Pintelon, Horenbeek, et al.,
2015; Cholasuke et al., 2004; Hauge & Mercier, 2003; The company's maintenance team participated in the
IAM, 2015; Anja M. Maier et al., 2012; Xu et al., 2021). interview phase and in the application of the maturity
model, according to their point of view. At this stage of
3. METHODOLOGY the research, a meeting was requested for feedback after
the specialist's visit, with the production, maintenance,
The methodology of this work consisted of applying the and process engineering sectors, to jointly assess the
maintenance maturity model developed for maintenance view of internal maintenance customers.
management processes by Oliveira and Lopes (2020).
The model was applied according to the current moment Therefore, the internal analysis was carried out with the
of the organization's maintenance area. However, managers of the production, maintenance, and process
improvement actions are being studied and made engineering areas. According to them, the view that
possible by managers, so that we can establish a internal customers have of the organizational level of
comparison between the current state and the future state maintenance management is quite distorted from the
of the maintenance area belonging to the organization, view that maintenance has of itself, and the presence of
based on the proposed maturity model. superior managers was necessary to collect more
complete data on the relationships. between sectors.
Information regarding the company's maintenance
management was obtained through an interview by the
external consultant with the current Maintenance
Managers. The questionnaire system developed by
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Proceedings on Engineering Sciences, Vol. 04, No. 4 (2022) 543-550, doi: 10.24874/PES04.04.014
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Oliveira et al., Evaluation of maintenance management of a thermoplastic industry using a maintenance maturity
model: a case in Manaus industrial POLE
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Proceedings on Engineering Sciences, Vol. 04, No. 4 (2022) 543-550, doi: 10.24874/PES04.04.014
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Oliveira et al., Evaluation of maintenance management of a thermoplastic industry using a maintenance maturity
model: a case in Manaus industrial POLE
5. CONCLUSION Just as improvement points were identified and adjusted
through this work, other points can be identified for the
Presenting the overview obtained from the model used in other units of the company, such as the application of the
this paper, it is observed that the model proposed is easy model in the group's petrochemical industry segment.
to understand and, for those who work or have worked in
the areas of maintenance management, it uses With the improvement actions proposed by this work, in
maintenance-oriented quality management concepts. order to be able to advance in the levels proposed by the
maturity model, we seek to increase the physical
The model leads us to reflect on the path we are taking to availability of equipment, reduce losses due to machine
improve corrective actions in the maintenance sector, and defects, qualify maintenance and production teams, and
the production involved with maintenance. During the decreased part replacement time.
work, the model brought a clear view of the current
situation of the maintenance sector of the company under Properly applied models of maturity are perfectly aligned
study. There were no difficulties with using the model. with the lean strategies of organizations, by
Given information not compatible between maintenance implementing the recommended actions in the studies
and production, after internal analysis, it was noted that and their continuous monitoring
there is a lack of agreement between both parties. Acknowledgment: Special thanks to the Graduate
Program in Production Engineering (PPGEP) of the
Production attributes to the maintenance of lack of Federal University of Amazonas (UFAM) for the support
technical knowledge, claiming that even preventive of its professors in the research carried out. This study
workings occur sloppily while maintenance demonstrates was carried out in partnership with UFAM within the
that the huge amount of line breakage occurs due to the scope of the PPGEP. The authors thank the Fundação de
simple lack of availability of production lines for Amparo à Pesquisa do Estado do Amazonas (FAPEAM)
preventive maintenance. for supporting this work within the scope of the
POSGRAD Project (Resolution No. 008/2021-
POSGRAD).
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