Implementing a Strategy of Reliability Centered Maintenance (RCM) in the Libyan Cement Industry
The substantial development of the construction
industry has forced the cement industry, its major support, to focus
on achieving maximum productivity to meet the growing demand for
this material. This means that the reliability of a cement production
system needs to be at the highest level that can be achieved by good
maintenance. This paper studies the extent to which the
implementation of RCM is needed as a strategy for increasing the
reliability of the production systems component can be increased,
thus ensuring continuous productivity. In a case study of four Libyan
cement factories, 80 employees were surveyed and 12 top and middle
managers interviewed. It is evident that these factories usually
breakdown more often than once per month which has led to a
decline in productivity. In many times they cannot achieve the
minimum level of production amount. This has resulted from the
poor reliability of their production systems as a result of poor or
insufficient maintenance. It has been found that most of the factories’
employees misunderstand maintenance and its importance. The main
cause of this problem is the lack of qualified and trained staff, but in
addition it has been found that most employees are not found to be
motivated as a result of a lack of management support and interest. In
response to these findings, it has been suggested that the RCM
strategy should be implemented in the four factories. The results
show the importance of the development of maintenance strategies
through the implementation of RCM in these factories. The purpose
of it would be to overcome the problems that could secure the
reliability of the production systems. This study could be a useful
source of information for academic researchers and the industrial
organizations which are still experiencing problems in maintenance
practices.
[1] B. Al-Najjar, “Cost-Effective & Continuous Improvement of Production
Process and Company’s Business when using Total Quality
Maintenance (TQMain)”, International Conference on Maintenance
Engineering, vol. 1, pp. 1-11, 15-18, Oct. 2006.
[2] H, K. Alfares, “Aircraft maintenance workforce scheduling”, Journal of
Quality in Maintenance Engineering, Vol. 5, No. 2, pp. 78-88, 1999.
[3] N.V. Bhat, “The determinants of maintenance expenditures in chemical
companies”, Journal of Quality in Maintenance Engineering, Vol. 6, No.
2, pp. 106-112, 2000. [4] R. Yam, P. Tse, L. Ling, and F. Fung, “Enhancement of maintenance
management through benchmarking”, Journal of Quality in Maintenance
Engineering, Vol. 6, No. 4,pp. 224-240, 2000.
[5] J. Momme, and H. Hvolby, “An outsourcing framework: action research
in the heavy industry sector”, European Journal of Purchasing & Supply
Management, Vol. 8, No. 4, pp. 185-196, 2002.
[6] S.I. Mostafa, “Implementation of proactive maintenance in the Egyptian
glass company”, Journal of Quality in Maintenance Engineering, Vol.
10, No. 2, pp. 107-122,2004.
[7] W. Chen, “Scheduling with different maintenance policies in a textile
company”, Journal of Quality in Maintenance Engineering, Vol. 11 No.
1, pp. 43-52, 2005.
[8] I. Alsyouf, “Measuring maintenance performance using a balanced
scorecard approach”, Journal of Quality in Maintenance Engineering,
Vol. 12 No. 2, pp. 133-149,2006.
[9] M. Aoudia, and O. Belmokhtar, “Economic impact of maintenance
management ineffectiveness of an oil and gas company”, Journal of
Quality in Maintenance Engineering, Vol. 14, No. 3, pp. 237-261, 2008.
[10] I.P.S. Ahuja, and P. Kumar, “A case study of total productive
maintenance implementation at precision tube mills”, Journal of Quality
in Maintenance Engineering, Vol. 15, No. 3, pp. 241-258, 2009.
[11] E. Vassilakis, “An application of TQM tools at a maintenance division
of a large aerospace company”, Journal of Quality in Maintenance
Engineering, Vol. 15, No. 1,pp. 31-46, 2009.
[12] H. Shafeek, "Continuous improvement of maintenance process for the
cement industry – a case study", Journal of Quality in Maintenance
Engineering, Vol. 20, No.4 pp. 333 – 376, 2014.
[13] H. Bin Jabar, “Plant Maintenance Strategy: Key for Enhancing.
Profitability”, 2003, Maintenance Resources.com
(http://www.maintenanceresources.com/referencelibrary/ezine/chemclea
n.htm) (21 March 2015).
[14] R. C. Mishra, and K. Pathak, Maintenance Engineering and
Management, 2nd ed. Newdilhi: PHI Learning, 2012.
[15] D. Telang, and A. Telang, Comprehensive Maintenance Management,
New Delhi: PHI Learning Pvt. Ltd, 2010.
[16] BBC History, “Why the Industrial Revolution happened in Britain”,
2013, BBC History (http://www.bbc.co.uk/history/0/20979973)
(Accessed 14 January 2013)
[17] British Standards Institution, BS EN 13306:2001. Maintenance,
maintenance terminology, London: BSI. , 2001.
[18] C. J. Robinson, and A. Gander, Implementing TPM: The North
American Experience, Portland: Taylor & Francis, 1995.
[19] A. Garg, & S. Deshmukh, “Maintenance management: literature review
and directions”, Journal of Quality in Maintenance Engineering, Vol.12,
No.3, pp.205 – 238, 2006.
[20] R. K. Sharma, D. Kumar, and P. Kumar, “Manufacturing excellence
through TPM implementation: a practical analysis”, Industrial
Management and Data Systems.Vol.106, No. 2, pp. 256-280, 2006.
[21] I.P.S. Ahuja, and J.S.Khamba, “Total productive maintenance: literature
review and directions”, International Journal of Quality & Reliability
Management, Vol. 25, No. 7, pp.709- 756, 2008.
[22] J. Hansson, F. Backlund, and L. Lycke, “Managing commitment:
increasing the odds for successful implementation of TQM, TPM or
RCM”, International Journal of Quality & Reliability Management, Vol.
20, No. 9, pp. 993-1008, 2003.
[23] F. L. Cooke, “Plant maintenance strategy: evidence from four British
manufacturing firms." Journal of Quality in Maintenance Engineering,
Vol. 9, No. 3, pp. 239 -249, 2003.
[24] European Committee for Standardization, EN13306:2001, Maintenance
Terminology, the European Committee for Standardization. Brussels:
CEN., 2006.
[25] I. Alsyouf, “The role of maintenance in improving companies'
productivity and profitability International”, Journal of Production
Economics, Vol.105, No.1, pp.70-78, 2007.
[26] D. Baglee, and M. Knowles, “Maintenance strategy development in the
UK food and drink industry”, International Journal of Strategic
Engineering Asset Management, Vol.1, No. 3, pp. 289-300, 2013.
[27] T. Ömür; and K. Orhan, “Preventive Maintenance Optimization under
Deterioration”, University Journal of Economics & Administrative, Vol.
23, No.4, pp.125-134, 2009.
[28] M. Kans, and A. Ingwald, “Common database for cost-effective
improvement of maintenance performance”, International Journal of
Production Economics, Vol.113, No. 2, pp.734-747, 2008.
[29] L. Swanson, “Linking maintenance strategies to performance”,
International Journal of Production Economics, Vol 70, No. 3, pp.237-
244, 200.
[30] J. Bateman, “Preventive Maintenance: Stand Alone Manufacturing
Compared With Cellular Manufacturing”, Industrial Management, Vol
37 No1, pp. 19-21, 1995.
[31] M. Rausand, “Reliability Centred Maintenance”, Reliability Engineering
and System Safety, Vol 60, No. 2, pp. 12 -132, 1998.
[32] International Atomic Energy Agency (IAEA), “Application of
Reliability Centred Maintenance to Optimize Operation and
Maintenance in Nuclear Power Plants”, 2007, International Atomic
Energy Agency, IAEA report (http://wwwpub.
iaea.org/MTCD/publications/PDF/te_1590_web.pdf) (May 2007)
[33] National Aeronautics and Space Administration (NASA), RCM
Reliability Centred Maintenance Guide for Facilities and Collateral
Equipment”, 2008, National Aeronautics and Space Administration,
NASA Report,
(http://www.hq.nasa.gov/office/codej/codejx/Assets/Docs/ NASARCM
Guide.pdf) (September 2008)
[34] K. Holmberg, A. Adgar, A. Arnaiz, S. Mekid, J. Mascolo, and E.
Jantunen, “E-maintenance”, London: Springer. 2010.
[35] World Business Council for Sustainable Development, “The cement
sustainability initiative”, 2002, World Business Council for Sustainable
Development (wbcsd) (http://www.wbcsd.org/ home.aspx) (02 April
2014).
[36] T. Tourki, “Implementation of Lean within the Cement Industry”, PhD
thesis, De Montfort University, 2010
[37] USGS, “Cement Statistics and Information”, 2014, USGS science for a
changing world: Minerals Information.
(http://minerals.usgs.gov/minerals/pubs/commodity/cement/ ) (15April
20140)
[38] Portland Cement Association, “Report on Sustainable Manufacturing
Tracks Advances in Environmental Performance Portland”, 2008, PAC.
Executive Report (http://www2.cement. org/ exec2 /04-28-08.htm)
(April 28, 2008)
[39] A. S. Ngab, “Libya – The Construction Industry – An Overview”, 2005,
CBM-CI International Workshop, Karachi Pakistan
(http://enpub.fulton.asu.edu/cement/cbm_CI/CBMI_Separate
Articles/Article%2021.pdf) (01 April 20140)
[40] P. Edwards, “North African cement focus”, 2013, Global cement
(http://www.globalcement. com/magazine/articles/816-north-africancement-
focus ) (09 April 20140)
[41] CemNet.com,Global, “Cement Report. Libya”, 2014, CemNet.com
(http://www.cemnet. Com /gcr/country/Libya ) (10 April 2014)
[42] R. A. Hokoma, M. K. Khan, and K. Hussain, “The Current Status of
MRPIl Implementation in Some Key Manufacturing Industries within
Libya: A Survey Investigation”. In: Proceedings of the 22nd
International Conference on CAD CAM, Robotics and Factories of the
Future, India, pp. 483-490, 2006.
[43] M. Graisa, “An Investigation into the Need and Implementation of Total
Productive Maintenance (TPM) in Libyan Cement Industry”, PhD
thesis, Nottingham Trent University, 2011
[44] Alahlia Cement Company, “Company profile”, 2014, (http://
http://www.ahliacement.ly/) (01 April 2013)
[45] H. Essmui, M. Berma, F. Shahadan, and S. Ramlee, “Technical
Efficiency of Manufacturing Enterprises in Libya: A Stochastic Frontier
Analysis”, International Journal of Management & Information
Technology, Vol. 5, No. 2, pp. 528-535, 2013.
[46] M., Rana, M. AzizulBaten, S. Das, and M. Abdul Khaleque, “Technical
Efficiency of Some Selected Manufacturing Industries in Bangladesh: A
Stochastic Frontier Analysis” The Lahore Journal of Economics, Vol.
11, No. 2, pp. 23-41, 2006.
[47] R. Hokoma, M. Khan, and K. Hussain, “Investigation into the
implementation stages of manufacturing and quality techniques and
philosophies within the Libyan cement industry”, Journal of
Manufacturing Technology Management, Vol.19, No.7, pp. 893- 907,
2008.
[48] M. Elmagri, “The reduction of the causal factors of interpersonal conflict
(IPC) in the Libyan cement industry”, PhD thesis, University of Salford,
2013
[49] World Report, “Libya Back on the World Stage, Trade and investment
benefits set to flow, Ancient Heritage”, 2004, World Report
International Ltd (http://www.worldreport-ind.com/libya/interview12.
htm.) (25 September 2004)[50] M. Graisa, and A. Al-Habaibeh, “An investigation into current
production challenges facing the Libyan cement industry and the need
for innovative total productive maintenance (TPM) strategy” Journal of
Manufacturing Technology Management, Vol. 22, No. 4, pp. 541-58,
2010.
[51] C. R. Cassady, W. P. Cassady and E. A. Pohl, “Selective maintenance
for support equipment involving multiple maintenance actions”,
European Journal of Operational Research, Vol. 129, No. 2, pp.252-258,
2001.
[52] M. Al-Muhaisen,and N. Santarisi, “Auditing of the maintenance system
of Fuhais plant/ Jordan Cement Co.”, Journal of Quality in Maintenance
Engineering, Vol. 8, No.1, pp.62-76, 2002.
[53] M. C. Ogajl, and S. D. Probert, “Development and implementation of
preventive-maintenance practices in Nigerian industries”, Applied
Energy, Vol. 83, No.10, pp.1163-1179, 2006.
[1] B. Al-Najjar, “Cost-Effective & Continuous Improvement of Production
Process and Company’s Business when using Total Quality
Maintenance (TQMain)”, International Conference on Maintenance
Engineering, vol. 1, pp. 1-11, 15-18, Oct. 2006.
[2] H, K. Alfares, “Aircraft maintenance workforce scheduling”, Journal of
Quality in Maintenance Engineering, Vol. 5, No. 2, pp. 78-88, 1999.
[3] N.V. Bhat, “The determinants of maintenance expenditures in chemical
companies”, Journal of Quality in Maintenance Engineering, Vol. 6, No.
2, pp. 106-112, 2000. [4] R. Yam, P. Tse, L. Ling, and F. Fung, “Enhancement of maintenance
management through benchmarking”, Journal of Quality in Maintenance
Engineering, Vol. 6, No. 4,pp. 224-240, 2000.
[5] J. Momme, and H. Hvolby, “An outsourcing framework: action research
in the heavy industry sector”, European Journal of Purchasing & Supply
Management, Vol. 8, No. 4, pp. 185-196, 2002.
[6] S.I. Mostafa, “Implementation of proactive maintenance in the Egyptian
glass company”, Journal of Quality in Maintenance Engineering, Vol.
10, No. 2, pp. 107-122,2004.
[7] W. Chen, “Scheduling with different maintenance policies in a textile
company”, Journal of Quality in Maintenance Engineering, Vol. 11 No.
1, pp. 43-52, 2005.
[8] I. Alsyouf, “Measuring maintenance performance using a balanced
scorecard approach”, Journal of Quality in Maintenance Engineering,
Vol. 12 No. 2, pp. 133-149,2006.
[9] M. Aoudia, and O. Belmokhtar, “Economic impact of maintenance
management ineffectiveness of an oil and gas company”, Journal of
Quality in Maintenance Engineering, Vol. 14, No. 3, pp. 237-261, 2008.
[10] I.P.S. Ahuja, and P. Kumar, “A case study of total productive
maintenance implementation at precision tube mills”, Journal of Quality
in Maintenance Engineering, Vol. 15, No. 3, pp. 241-258, 2009.
[11] E. Vassilakis, “An application of TQM tools at a maintenance division
of a large aerospace company”, Journal of Quality in Maintenance
Engineering, Vol. 15, No. 1,pp. 31-46, 2009.
[12] H. Shafeek, "Continuous improvement of maintenance process for the
cement industry – a case study", Journal of Quality in Maintenance
Engineering, Vol. 20, No.4 pp. 333 – 376, 2014.
[13] H. Bin Jabar, “Plant Maintenance Strategy: Key for Enhancing.
Profitability”, 2003, Maintenance Resources.com
(http://www.maintenanceresources.com/referencelibrary/ezine/chemclea
n.htm) (21 March 2015).
[14] R. C. Mishra, and K. Pathak, Maintenance Engineering and
Management, 2nd ed. Newdilhi: PHI Learning, 2012.
[15] D. Telang, and A. Telang, Comprehensive Maintenance Management,
New Delhi: PHI Learning Pvt. Ltd, 2010.
[16] BBC History, “Why the Industrial Revolution happened in Britain”,
2013, BBC History (http://www.bbc.co.uk/history/0/20979973)
(Accessed 14 January 2013)
[17] British Standards Institution, BS EN 13306:2001. Maintenance,
maintenance terminology, London: BSI. , 2001.
[18] C. J. Robinson, and A. Gander, Implementing TPM: The North
American Experience, Portland: Taylor & Francis, 1995.
[19] A. Garg, & S. Deshmukh, “Maintenance management: literature review
and directions”, Journal of Quality in Maintenance Engineering, Vol.12,
No.3, pp.205 – 238, 2006.
[20] R. K. Sharma, D. Kumar, and P. Kumar, “Manufacturing excellence
through TPM implementation: a practical analysis”, Industrial
Management and Data Systems.Vol.106, No. 2, pp. 256-280, 2006.
[21] I.P.S. Ahuja, and J.S.Khamba, “Total productive maintenance: literature
review and directions”, International Journal of Quality & Reliability
Management, Vol. 25, No. 7, pp.709- 756, 2008.
[22] J. Hansson, F. Backlund, and L. Lycke, “Managing commitment:
increasing the odds for successful implementation of TQM, TPM or
RCM”, International Journal of Quality & Reliability Management, Vol.
20, No. 9, pp. 993-1008, 2003.
[23] F. L. Cooke, “Plant maintenance strategy: evidence from four British
manufacturing firms." Journal of Quality in Maintenance Engineering,
Vol. 9, No. 3, pp. 239 -249, 2003.
[24] European Committee for Standardization, EN13306:2001, Maintenance
Terminology, the European Committee for Standardization. Brussels:
CEN., 2006.
[25] I. Alsyouf, “The role of maintenance in improving companies'
productivity and profitability International”, Journal of Production
Economics, Vol.105, No.1, pp.70-78, 2007.
[26] D. Baglee, and M. Knowles, “Maintenance strategy development in the
UK food and drink industry”, International Journal of Strategic
Engineering Asset Management, Vol.1, No. 3, pp. 289-300, 2013.
[27] T. Ömür; and K. Orhan, “Preventive Maintenance Optimization under
Deterioration”, University Journal of Economics & Administrative, Vol.
23, No.4, pp.125-134, 2009.
[28] M. Kans, and A. Ingwald, “Common database for cost-effective
improvement of maintenance performance”, International Journal of
Production Economics, Vol.113, No. 2, pp.734-747, 2008.
[29] L. Swanson, “Linking maintenance strategies to performance”,
International Journal of Production Economics, Vol 70, No. 3, pp.237-
244, 200.
[30] J. Bateman, “Preventive Maintenance: Stand Alone Manufacturing
Compared With Cellular Manufacturing”, Industrial Management, Vol
37 No1, pp. 19-21, 1995.
[31] M. Rausand, “Reliability Centred Maintenance”, Reliability Engineering
and System Safety, Vol 60, No. 2, pp. 12 -132, 1998.
[32] International Atomic Energy Agency (IAEA), “Application of
Reliability Centred Maintenance to Optimize Operation and
Maintenance in Nuclear Power Plants”, 2007, International Atomic
Energy Agency, IAEA report (http://wwwpub.
iaea.org/MTCD/publications/PDF/te_1590_web.pdf) (May 2007)
[33] National Aeronautics and Space Administration (NASA), RCM
Reliability Centred Maintenance Guide for Facilities and Collateral
Equipment”, 2008, National Aeronautics and Space Administration,
NASA Report,
(http://www.hq.nasa.gov/office/codej/codejx/Assets/Docs/ NASARCM
Guide.pdf) (September 2008)
[34] K. Holmberg, A. Adgar, A. Arnaiz, S. Mekid, J. Mascolo, and E.
Jantunen, “E-maintenance”, London: Springer. 2010.
[35] World Business Council for Sustainable Development, “The cement
sustainability initiative”, 2002, World Business Council for Sustainable
Development (wbcsd) (http://www.wbcsd.org/ home.aspx) (02 April
2014).
[36] T. Tourki, “Implementation of Lean within the Cement Industry”, PhD
thesis, De Montfort University, 2010
[37] USGS, “Cement Statistics and Information”, 2014, USGS science for a
changing world: Minerals Information.
(http://minerals.usgs.gov/minerals/pubs/commodity/cement/ ) (15April
20140)
[38] Portland Cement Association, “Report on Sustainable Manufacturing
Tracks Advances in Environmental Performance Portland”, 2008, PAC.
Executive Report (http://www2.cement. org/ exec2 /04-28-08.htm)
(April 28, 2008)
[39] A. S. Ngab, “Libya – The Construction Industry – An Overview”, 2005,
CBM-CI International Workshop, Karachi Pakistan
(http://enpub.fulton.asu.edu/cement/cbm_CI/CBMI_Separate
Articles/Article%2021.pdf) (01 April 20140)
[40] P. Edwards, “North African cement focus”, 2013, Global cement
(http://www.globalcement. com/magazine/articles/816-north-africancement-
focus ) (09 April 20140)
[41] CemNet.com,Global, “Cement Report. Libya”, 2014, CemNet.com
(http://www.cemnet. Com /gcr/country/Libya ) (10 April 2014)
[42] R. A. Hokoma, M. K. Khan, and K. Hussain, “The Current Status of
MRPIl Implementation in Some Key Manufacturing Industries within
Libya: A Survey Investigation”. In: Proceedings of the 22nd
International Conference on CAD CAM, Robotics and Factories of the
Future, India, pp. 483-490, 2006.
[43] M. Graisa, “An Investigation into the Need and Implementation of Total
Productive Maintenance (TPM) in Libyan Cement Industry”, PhD
thesis, Nottingham Trent University, 2011
[44] Alahlia Cement Company, “Company profile”, 2014, (http://
http://www.ahliacement.ly/) (01 April 2013)
[45] H. Essmui, M. Berma, F. Shahadan, and S. Ramlee, “Technical
Efficiency of Manufacturing Enterprises in Libya: A Stochastic Frontier
Analysis”, International Journal of Management & Information
Technology, Vol. 5, No. 2, pp. 528-535, 2013.
[46] M., Rana, M. AzizulBaten, S. Das, and M. Abdul Khaleque, “Technical
Efficiency of Some Selected Manufacturing Industries in Bangladesh: A
Stochastic Frontier Analysis” The Lahore Journal of Economics, Vol.
11, No. 2, pp. 23-41, 2006.
[47] R. Hokoma, M. Khan, and K. Hussain, “Investigation into the
implementation stages of manufacturing and quality techniques and
philosophies within the Libyan cement industry”, Journal of
Manufacturing Technology Management, Vol.19, No.7, pp. 893- 907,
2008.
[48] M. Elmagri, “The reduction of the causal factors of interpersonal conflict
(IPC) in the Libyan cement industry”, PhD thesis, University of Salford,
2013
[49] World Report, “Libya Back on the World Stage, Trade and investment
benefits set to flow, Ancient Heritage”, 2004, World Report
International Ltd (http://www.worldreport-ind.com/libya/interview12.
htm.) (25 September 2004)[50] M. Graisa, and A. Al-Habaibeh, “An investigation into current
production challenges facing the Libyan cement industry and the need
for innovative total productive maintenance (TPM) strategy” Journal of
Manufacturing Technology Management, Vol. 22, No. 4, pp. 541-58,
2010.
[51] C. R. Cassady, W. P. Cassady and E. A. Pohl, “Selective maintenance
for support equipment involving multiple maintenance actions”,
European Journal of Operational Research, Vol. 129, No. 2, pp.252-258,
2001.
[52] M. Al-Muhaisen,and N. Santarisi, “Auditing of the maintenance system
of Fuhais plant/ Jordan Cement Co.”, Journal of Quality in Maintenance
Engineering, Vol. 8, No.1, pp.62-76, 2002.
[53] M. C. Ogajl, and S. D. Probert, “Development and implementation of
preventive-maintenance practices in Nigerian industries”, Applied
Energy, Vol. 83, No.10, pp.1163-1179, 2006.
@article{"International Journal of Business, Human and Social Sciences:70164", author = "Khalid M. Albarkoly and Kenneth S. Park", title = "Implementing a Strategy of Reliability Centered Maintenance (RCM) in the Libyan Cement Industry", abstract = "The substantial development of the construction
industry has forced the cement industry, its major support, to focus
on achieving maximum productivity to meet the growing demand for
this material. This means that the reliability of a cement production
system needs to be at the highest level that can be achieved by good
maintenance. This paper studies the extent to which the
implementation of RCM is needed as a strategy for increasing the
reliability of the production systems component can be increased,
thus ensuring continuous productivity. In a case study of four Libyan
cement factories, 80 employees were surveyed and 12 top and middle
managers interviewed. It is evident that these factories usually
breakdown more often than once per month which has led to a
decline in productivity. In many times they cannot achieve the
minimum level of production amount. This has resulted from the
poor reliability of their production systems as a result of poor or
insufficient maintenance. It has been found that most of the factories’
employees misunderstand maintenance and its importance. The main
cause of this problem is the lack of qualified and trained staff, but in
addition it has been found that most employees are not found to be
motivated as a result of a lack of management support and interest. In
response to these findings, it has been suggested that the RCM
strategy should be implemented in the four factories. The results
show the importance of the development of maintenance strategies
through the implementation of RCM in these factories. The purpose
of it would be to overcome the problems that could secure the
reliability of the production systems. This study could be a useful
source of information for academic researchers and the industrial
organizations which are still experiencing problems in maintenance
practices.", keywords = "Libyan cement industry, maintenance, production,
reliability centered maintenance, reliability.", volume = "9", number = "6", pages = "1903-10", }