Case Studies
Jun 15, 2016

Using QFD to Conduct Performance Assessment for Turnaround Maintenance in Petrochemical Infrastructure

Publication: Journal of Infrastructure Systems
Volume 23, Issue 1

Abstract

This paper presents a state-of-the-practice of turnaround maintenance (TAM). It also develops an assessment tool for TAM projects based on quality function deployment (QFD). A modified QFD methodology was used in a case study to investigate how TAM projects can be implemented successfully. To build the QFD matrix, the research identified the technical and stakeholder requirements from three survey sources: literature, industry, and expert opinions. The findings presented three levels of technical requirements: phases (4), attributes (10), and detailed (32). It also defines nine stakeholders (internal and external) with a 24 requirements. In addition, the weights of the technical requirements are found by using the QFD framework. The weights are used to build an assessment matrix based on a Likert scaling. A case study is presented to demonstrate the assessment tool for a petrochemical facility in Saudi Arabia. The assessment found deficiencies in four TAM attributes. Finally, the research proposed actions to improve the deficient attributes. The implementation of this tool helped TAM management to improve their practices of TAM.

Get full access to this article

View all available purchase options and get full access to this article.

Acknowledgments

The authors thank King Fahd University of Petroleum and Minerals for the support and facilities that made this research possible. The authors also acknowledge the anonymous reviewers for their valuable suggestions that improved the content of this paper.

References

Amaran, S., et al. (2014). “Long-term turnaround planning for integrated chemical sites.” Comput. Chem. Eng., 72, 145–158.
Anderson, N. C., and Kovach, J. V. (2014). “Reducing welding defects in turnaround projects: A lean six sigma case study.” Qual. Eng., 26(2), 168–181.
Bolar, A., Tesfamariam, S., and Sadiq, R. (2014). “Management of civil infrastructure systems: QFD-based approach.” J. Infrastruct. Syst., 04013009.
Brown, M. V. (2004). Managing shutdowns, turnarounds, and outages, Wiley.
Carmignani, G. (2009). “Modified QFD and problem-solving techniques integrated approach implementing corrective actions: A case study in an Italian manufacturing plant.” Qual. Reliab. Eng. Int., 25(2), 241–252.
Chan, L. K., and Wu, M. L. (2002). “Quality function deployment: A literature review.” Eur. J. Oper. Res., 143(3), 463–497.
Chen, H. G. (2011). “Implementation decision-making model on equipment maintenance improvement.” Syst. Eng. Theory Pract., 31(5), 954–960.
Cormier, B., and Gillard, C. F. (2009). “Beyond turnaround planning.” Pet. Technol. Q., 14(1), 77.
Duffuaa, S. O., Rouf, A., and Campbell, J. (1999). Maintenance planning and control: Modelling and analysis, Wiley, New York.
Eldin, N., and Hikle, V. (2003). “Pilot study of quality function deployment in construction projects.” J. Constr. Eng. Manage., 314–329.
Ghazali, Z., and Halib, M. (2011a). “The organization of plant turnaround maintenance in process-based industries: Analytical framework and generic processes.” J. Int. Bus. Manage. Res., 2(3), 30–43.
Ghazali, Z., and Halib, M. (2011b). “Towards an alternative organizational structure for plant turnaround maintenance: An experience of PETRONAS Gas Berhad, Malaysia.” Eur. J. Soc. Sci., 26(1), in press.
Hadidi, L. A., and Khater, M. A. (2015). “Loss prevention in turnaround maintenance projects by selecting contractors based on safety criteria using the analytic hierarchy process (AHP).” J. Loss Prev. Process Ind., 34, 115–126.
Hernandez, D. J. D., and Aspinwall, E. (2007). “Improvement methods in U.K. and Mexican construction industries: A comparison.” Qual. Reliab. Eng. Int., 23(1), 59–70.
Houtermans, M., AlGhumgham, M., and Capelle, T. V. (2007). “Reliability engineering & data collection to improve plant safety and availability.” Proc., 2nd Int. Conf. on Systems, ICONS ’07, IEEE, New York.
Kahraman, C., Ertay, T., and Büyüközkan, G. (2006). “A fuzzy optimization model for QFD planning process using analytic network approach.” Eur. J. Oper. Res., 171(2), 390–411.
Kianfar, A., and Kianfar, F. (2010). “Methodology and theory: Plant function deployment via RCM and QFD.” J. Qual. Maintenance Eng., 16(4), 354–366.
Kong, Z. (2007). “Multi-objective optimization model and method for maintenance function deployment.” Comput. Integr. Manuf. Syst.-Beijing, 13(4), 649.
Krings, D. (2001). Proactive approach to shutdowns reduces potlatch maintenance cost, Pulp and Pap, 27–29.
Kutucuoglu, K. Y., Hamali, J., Irani, Z., and Sharp, J. M. (2001). “A framework for managing maintenance using performance measurement systems.” Int. J. Oper. Prod. Manage., 21(1–2), 173–195.
Lazreg, M., and Gien, D. (2009). “Integrating six sigma and maintenance excellence with QFD.” Int. J. Prod. Qual. Manage., 4(5–6), 676–690.
Lenahan, T. (1999). Turnaround management, Butterworth-Heinemann, U.K.
Lenahan, T. (2006). “Turnaround shutdown and outage management.” Effective planning and step-by-step execution of planned maintenance operations, Elsevier, Oxford, U.K.
Levitt, J. (2004). Managing maintenance shutdowns and outages, Industrial.
Megow, N., Möhring, R. H., and Schulz, J. (2011). “Decision support and optimization in shutdown and turnaround scheduling.” INFORMS J. Comput., 23(2), 189–204.
Oliver, R. (2002). “Complete planning for maintenance turnarounds will ensure success.” Oil Gas J., 54–62.
Pokharel, S., and Jiao, J. (2008). “Turn-around maintenance management in a processing industry: A case study.” J. Qual. Maintenance Eng., 14(2), 109–122.
Pramod, V. R., Devadasan, S. R., and Jagathy Raj, V. P. (2006a). “Customer voice adoption for maintenance quality improvement through MQFD and its receptivity analysis.” Int. J. Manage. Pract., 2(2), 83–108.
Pramod, V. R., Devadasan, S. R., Muthu, S., Jagathyraj, V. P., and Dhakshina Moorthy, G. (2006b). “Integrating TPM and QFD for improving quality in maintenance engineering.” J. Qual. Maintenance Eng., 12(2), 150–171.
Pramod, V. R., Devadasan, S. R., Muthu, S., and Jagathy Raj, V. P. (2006c). “MQFD: A model for synergising TPM and QFD.” Int. J. Process Manage. Benchmarking, 1(2), 176–200.
Pramod, V. R., Devadasan, S. R., Raj, V. P. J., and Murugesh, R. (2008). “MQFD and its receptivity analysis in an Indian electronic switches manufacturing company.” Int. J. Manage. Pract., 3(1), 82–95.
Pramod, V. R., Sampath, K., Devadasan, S. R., Jagathy Raj, V. P., and Moorthy, G. D. (2007). “Multicriteria decision making in maintenance quality function deployment through the analytical hierarchy process.” Int. J. Ind. Syst. Eng., 2(4), 454–478.
Roup, J. (2004). “Processing: Strategy maximizes turnaround performance.” Oil Gas J., 102(20), 46–48.
Saleh, N., Sharawi, A. A., Elwahed, M. A., Petti, A., Puppato, D., and Balestra, G. (2015). “Preventive maintenance prioritization index of medical equipment using quality function deployment.” IEEE J. Biomed. Health Inf., 19(3), 1029–1035.
Singh, B. (2012). “Executive leadership-essential to ensure world-class turnarounds.” Hydrocarbon Process., 91(3), in press.
Sun, G. X. (2010). “Research on maintenance strategy of marine construction equipment system based on reliability function deployment.” Proc., 2010 Chinese Control and Decision Conf. (CCDC), IEEE, New York, 1174–1179.
Valavi, D., and Pramod, V. (2015). “A hybrid fuzzy MCDM approach to maintenance quality function deployment.” Decis. Sci. Lett., 4(1), 79–108.
Wen, J., and Li, Q. (2009). “A method to analysis maintenance support capability of aircraft based on QFD.” Proc., 8th Int. Conf. on Reliability, Maintainability and Safety, IEEE, New York, 621–625.
Woldesenbet, A., and Jeong, H. D. (2014). “Highway data quality report card (HDQRC): A conceptual framework of pavement management data.” Proc., Construction Research Congress 2014: Construction in a Global Network, ASCE, Reston, VA, 2021–2031.
Xu, J., Xu, X., and Xie, S. Q. (2010). “A comprehensive review on recent developments in quality function deployment.” Int. J. Prod. Qual. Manage., 6(4), 457–494.
Yang, C. H., Wei, J., and Yao, L. (2009). “Synthetic evaluation of maintenance accessibility for complex equipment based on QFD and D-S theory.” Comput. Integr. Manuf. Syst., 11, 013.
Yin, R. K. (2009). Case study research: Design and methods, 4th Ed., Sage, Thousand Oaks, CA.
Younus, B., and Iqbal, A. (2011). “Leveraging quality function deployment to enhance the productivity of an aviation maintenance repair and overhaul organization.” Proc., 2011 IEEE Int. Conf. on Quality and Reliability (ICQR), IEEE, New York, 115–119.
Zhang, Z., and Chu, X. (2010). “A new approach for conceptual design of product and maintenance.” Int. J. Comput. Integr. Manuf., 23(7), 603–618.

Information & Authors

Information

Published In

Go to Journal of Infrastructure Systems
Journal of Infrastructure Systems
Volume 23Issue 1March 2017

History

Received: Jul 7, 2015
Accepted: Apr 11, 2016
Published online: Jun 15, 2016
Discussion open until: Nov 15, 2016
Published in print: Mar 1, 2017

Permissions

Request permissions for this article.

Authors

Affiliations

Salih O. Duffuaa, Ph.D.
Professor, Dept. of Systems Engineering, King Fahd Univ. of Petroleum and Minerals, Dhahran, Saudi Arabia 31261.
Laith A. Hadidi, Ph.D. [email protected]
Assistant Professor, Dept. of Construction Engineering and Management, King Fahd Univ. of Petroleum and Minerals, Dhahran, Saudi Arabia 31261 (corresponding author). E-mail: [email protected]

Metrics & Citations

Metrics

Citations

Download citation

If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.

Cited by

View Options

Get Access

Access content

Please select your options to get access

Log in/Register Log in via your institution (Shibboleth)
ASCE Members: Please log in to see member pricing

Purchase

Save for later Information on ASCE Library Cards
ASCE Library Cards let you download journal articles, proceedings papers, and available book chapters across the entire ASCE Library platform. ASCE Library Cards remain active for 24 months or until all downloads are used. Note: This content will be debited as one download at time of checkout.

Terms of Use: ASCE Library Cards are for individual, personal use only. Reselling, republishing, or forwarding the materials to libraries or reading rooms is prohibited.
ASCE Library Card (5 downloads)
$105.00
Add to cart
ASCE Library Card (20 downloads)
$280.00
Add to cart
Buy Single Article
$35.00
Add to cart

Get Access

Access content

Please select your options to get access

Log in/Register Log in via your institution (Shibboleth)
ASCE Members: Please log in to see member pricing

Purchase

Save for later Information on ASCE Library Cards
ASCE Library Cards let you download journal articles, proceedings papers, and available book chapters across the entire ASCE Library platform. ASCE Library Cards remain active for 24 months or until all downloads are used. Note: This content will be debited as one download at time of checkout.

Terms of Use: ASCE Library Cards are for individual, personal use only. Reselling, republishing, or forwarding the materials to libraries or reading rooms is prohibited.
ASCE Library Card (5 downloads)
$105.00
Add to cart
ASCE Library Card (20 downloads)
$280.00
Add to cart
Buy Single Article
$35.00
Add to cart

Media

Figures

Other

Tables

Share

Share

Copy the content Link

Share with email

Email a colleague

Share