Title:
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An investigation into the impact on manufacturing performance of the linkage between manufacturing and maintenance strategy
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Maintenance organisations are rarely seen to add value to the business because they are
often working in ways not obviously beneficial, or failing to utilise appropriate tools
and approaches. It is therefore vital to focus and co-ordinate the work of Maintenance
through properly considered and documented strategies. To ensure strategic cohesion, it
is also important for the maintenance strategy to be linked to manufacturing and
business goals. The primary aim of this thesis was to investigate the impact on
manufacturing performance of linking maintenance and manufacturing strategy to
ensure one enhances the other.
The research began with a literature review which established the `state of the art'. This
search failed to locate a suitable model or framework which linked maintenance and
manufacturing strategies in a coherent way. Theory building was used to develop a new
conceptual model and fill this gap. To maintain rigour the work was supported by
existing literature as well as expert knowledge in maintenance and manufacturing
strategy and operations. The result was a new model -a concise but comprehensive
framework which describes the functional and cross-functional relationships between
maintenance and manufacturing strategy and their internal and external links. From the
matrix structure of the model a diagnostic tool evolved and, coupled with a specially
designed questionnaire, a fully operational test instrument was produced. This tool
proved highly suitable for measuring the situation in a manufacturing plant with respect
to manufacturing and maintenance strategy, operations, performance, and the links
between these. Although other contributions are made in this research, the development
of the new conceptual model and diagnostic tool represents the main contribution.
The model and diagnostic tool were tested in four manufacturing companies, as real-life
case studies. The process involved a programme of semi-structured interviews held at
the four case study sites. The questionnaire and diagnostic tool provided a framework
for these interviews and furnished the `rich' data needed for the cross-case analysis.
The research findings underlined the importance of coherently linking manufacturing
and maintenance strategies together. As part of this work a number of inhibitors and
enablers were identified. These were further themed to provide five generic
recommendations for manufacturing practitioners to follow. The four case studies
produced individual diagnostic footprints, each providing a snapshot of the situation in
the company at the time of measurement. It was particularly evident that many
manufacturing companies are not producing documented strategies and plans and there
tends to be a lack of basic systems and procedures. More focus is needed on Human
Resource management so that systems and cultural issues are addressed.
Further longitudinal and action research would be beneficial to the case study
companies involved in this research. The diagnostic footprints produced could serve as
a benchmark, from which the organisations could measure improvements in
performance which result from recommendations made as a result of the initial
diagnostic and measurement. Other organisations could then utilise the tool as a means
of identifying opportunities for performance improvement
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