Journal of Quality in Maintenance Engineering
Journal of Quality in Maintenance Engineering
Journal of Quality in Maintenance Engineering
Emerald Article: Maintenance strategy selection using AHP and ANP algorithms:
a case study
Selim Zaim, Ali Turkyilmaz, Mehmet F. Acar, Umar Al-Turki, Omer F. Demirel
Article information:
To cite this document: Selim Zaim, Ali Turkyilmaz, Mehmet F. Acar, Umar Al-Turki, Omer F. Demirel, (2012),"Maintenance strategy
selection using AHP and ANP algorithms: a case study", Journal of Quality in Maintenance Engineering, Vol. 18 Iss: 1 pp. 16 - 29
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Abstract
Purpose – The purpose of this paper is to demonstrate the use of two general purpose decision-
making techniques in selecting the most appropriate maintenance strategy for organizations with
critical production requirements.
Design/methodology/approach – The Analytical Hierarchical Process (AHP) and the Analytical
Network Process (ANP) are used for the selection of the most appropriate maintenance strategy in a
local newspaper printing facility in Turkey.
Findings – The two methods were shown to be effective in choosing a strategy for maintaining the
printing machines. The two methods resulted in almost the same results. Both methods take into
account the specific requirements of the organization through its own available expertise.
Practical implications – The techniques demonstrated in this paper can be used by all types of
organizations for selecting and adopting maintenance strategies that have higher impact on
maintenance performance and hence overall business productivity. The two methods are explained in
a step-by-step approach for easier adaptation by practitioners in all types of organizations.
Originality/value – The value of the paper is in applying AHP and ANP decision-making
methodologies in maintenance strategy selection. These two methods are not very common in the
area of maintenance, and hence add to the pool of techniques utilized in selecting maintenance
strategies.
Keywords Maintenance planning, AHP, ANP, Maintenance strategy, Strategy selection,
Maintenance, Turkey
Paper type Case study
Journal of Quality in Maintenance
Engineering Vol. 18 No. 1, 2012 pp.
16-29 q Emerald Group Publishing
Limited 1355-2511
DOI 10.1108/13552511211226166
The authors acknowledge the support of both Fatih University and King Fahd University. They
also acknowledge the anonymous referees for their constructive comments. They thank Sedat
Maintenance
strategy
selection
Kızıltunc for his is becoming increasingly critical with the increasing
collaboration. They also competition in the business environment. The
wish to acknowledge the
support provided by
competition is leading to more focus on cost reduction
upper management of in operations and maintenance. Cost reduction may
Zaman newspaper. immediately be reflected on pricing and hence, gaining
1 edge over competitors. Maintenance cost constitutes a
major portion of total operations cost and hence is
.
central to most cost
I reduction programs. Such programs should be done with care so that other 17
requirements such as quality are not sacrificed.
n
t Maintenance costs can reach to 15-70 percent of
production costs according to different sectors
r
(Bevilacqua and Braglia, 2000). Moreover,
o
maintenance directly or indirectly influences product
d quality, safety and reliability. Nowadays, maintenance
u is considered as “profit contributor” and “partner” for
c worldclass competitiveness (Waeyenberg and Pintelon,
t 2002). Rausand (1998) identified the four probable
i consequences of failure:
o (1) safety of personnel;
n
(2) environmental impact;
T
h (3) production availability; and
e (4) cost of material loss.
a
n
d
s
e
m
i ultimate goal of the problem, while the second level of
- the hierarchy consists of four main maintenance policy
s selection criteria, which are namely: added value, cost,
t safety, and implementation.
r
u
22
c
t
u
r
e
d Figure 1.
AHP and ANP scores
i
n
t These criteria are decomposed into various sub-criteria
e that may affect the manager’s decision for a particular
r maintenance policy. Finally, the bottom level of the
v hierarchy represents the alternative maintenance
i policies. Each selection criterion in the tree diagram is
e briefly described below.
w The sub-criteria for each main
s criteria are identified as follows:
(1) Value adding is viewed in four
u possible dimensions (sub-
n criteria) as follows:
d
e
.
On time delivery: During the production process,
some machines may fail causing delays in order
Maintenance
strategy
selection
in product quality showing as damaged paper
or unreadable text.
. .
Image: The image of the firm is largely affected
by production and maintenance performance.
Late deliveries, low quality printing, shortage
in quantities are some examples causing
image damage.
(2) The cost criterion includes the
following:
.
Hardware: To apply predictive maintenance, the firm
may need to acquire some new machines or
equipments.
.
Software: Different software may be required to
evaluate information which is obtained from
equipments used for predictive maintenance.
.
Training: Technicians or managers may be
required to go through special training for
effective use of equipments and software that
are used in predictive maintenance.
.
Inventory of spare parts: Maintenance
strategies, especially corrective maintenance,
some spare parts should be available in
inventory. The cost of holding spare parts
adds to the overall maintenance cost.
.
Cost of advising and consulting: For corrective
and periodic maintenance strategies, the firm
may need some special maintenance experts
to plan and control maintenance operations.
These costs are mostly necessary regardless of the type
of maintenance strategy adopted whether corrective,
periodic or predictive. However, the costing elements
vary in amount between strategies:
(3) The safety criterion consists of the following:
.
23
.
Internal environment: Safety policies and
procedures maintains healthy working
environment. Interruptions in operations due
to failure may form a source of hazard to
people and the whole internal environment.
.
External environment: Safety outside the
factory is another crucial element, especially
JQME
18,1
f e or chemical spills in the printing house may
o cause unrecoverable damage to the
r surrounding environment.
.
Personnel: Last, some breakdowns and/or
n maintenance activities may directly or
u indirectly harm workers. Therefore, it is
c essential to seek their opinion about the
l possible maintenance practices.
e
(4) The implementation criterion includes the
a
following:
r
.
Technology: Technology is an important for
o predictive maintenance, because there are no
r special equipments for some machines to
apply condition-based maintenance.
c .
Desire of workers: Some of workers may not
h want to predictive maintenance, because
e workers do some extra duties in condition-
m based maintenance.
i .
Desire of top management: Sometimes top
c managers do not want to apply predictive
a maintenance, because its setup cost which is
l sourced from buying of hardware and
software is high.
p
l
.
Decision of service company: There are lots
a companies which supply maintenance service
n as business for other companies, so this is a
t criterion for firms.
s Based on the identified criteria and sub-criteria, a
. hierarchical model is constructed and relations are
determined for our case study. The model is shown in
I Figure 2.
n
Step 5: Pair wise comparison among criteria and sub-
c criteria
a
Pair wise comparisons are done among related criteria
s
and sub-criteria following the scale suggested by Saaty.
e
A special questionnaire form is used to complete the
pair-wise comparison matrix. In this comparison,
o
criteria, sub criterias are used for comparing alternative
f
maintenance strategies by experts in the field.
f
i Step 6: Applying AHP and ANP algorithms
r These algorithms give weight to each alternative based
on which the best strategy is chosen.
Maintenance
strategy
selection
I ria and the scores of the alternatives, which are called
n local priorities, are considered as decision elements in
the second step of the decision process. The decision-
t maker is required to provide his preferences by
h
e
A
H
P
24
a
p
p
r
o
a
c
h
,
t
h
e
w Figure 2.
e The hierarchical model for
i maintenance strategy
selection criteria
g
h
t
s pairwise comparisons, with respect to the weights and
scores. The values of the weights vi and scores rij are
o elicited from these comparisons and represented in a
f decision table. The last step of the AHP aggregates all
local priorities from the decision table by a weighted
t sum of the type:
h X
e Rj ¼ vi · rij
i
c
r The global priorities Rj thus obtained are finally used for
i ranking of the alternatives and selection of the best one.
t In the ANP approach, two matrices are calculated;
e the weighted super matrix and the limit matrix. The
weighted super matrix permits a resolution of the
JQME
18,1
in a partitioned matrix where each sub-matrix is
te composed of a set of relationships between and within
r the levels, as represented by the model. The entries of
d the super matrix are imported from the pair-wise
e comparison matrices of interdependencies. Since there
p are 20 such pairwise comparisons matrices, one for
e each interdependent criterion, the super matrix contains
n 20 non-zero columns. The weighted super matrix is
d obtained by multiplying all the elements in a
e component of the unweighted super matrix by the
n corresponding cluster weight. In other words, the
ci values in the cluster matrix are used to weight the
e unweighted super matrix by multiplying the value in
s the cell of the cluster matrix times the value in each cell
th in the component of the unweighted super matrix to
at produce the weighted super matrix. The resulting
e weighted super matrix is shown in Table II. The limit
xi super matrix is obtained by raising the weighted super
st matrix to the power 2k þ 1 where k is an arbitrarily
a large number, allows convergence of the
m interdependent relationships. When the column of
o numbers is the same for every
n column, the limit matrix has been reached and the matrix multiplication process
g is 25 halted. The limit super matrix for the Model is shown in Table III.
th
e
c
o Step 7: Prioritization
m It simply means listing alternatives in descending order
p of their weights according to both AHP and ANP
o algorithms.
n The AHP algorithm resulted in the following ranking
e (best to worst) of maintenance strategies; predictive,
nt periodic and corrective maintenance respectively and
s using the ANP algorithm; the resulting strategy ranking
o (best to worst) is; predictive, periodic and corrective
f maintenance, respectively as shown in Figure 1.
a
s Step 8: Compare results and make the decision
y The two solutions, AHP and ANP, are compared and
st evaluated by experts to make the best decision.
e The analysis clearly shows that predictive
m maintenance is to be the best strategy by both AHP and
. ANP methods. However, in the real situation,
It “ZAMAN” is using periodic maintenance for
is maintaining its printing house. In fact, predictive
Maintenance
strategy
selection
m unnecessary expenditure for “ZAMAN”. This is not
a recognized by the firm since the maintenance
i effectiveness is quite high on the expense of efficiency
n in resource utilization. Furthermore, technicians and
t experts are occasionally interfering with the
e maintenance operations based on their intuitions before
n the time of periodic maintenance. This can be seen as
a predictive maintenance, hence, in fact, both predictive
n and periodic maintenance are used in ad-hoc basis.
c Currently there are plans underway in “ZAMAN” to
e adopt an ERP system for planning and controlling
maintenance operations and at the same time be used to
i estimate and report the cost of maintenance.
s
5. Conclusion
s
In this research, some criteria are determined about
h
maintenance selection and according to these criteria,
o
AHP and ANP models are constituted. Three
w
maintenance policies are considered; these are
n
corrective, periodic (time-based) and predictive
(condition-based) maintenance. Moreover, with the
b
help of experts and engineers, these AHP and ANP
y
models are used for machines in printing house of the
daily newspaper, “ZAMAN”. At the end of these
b
analyses, weights of three different maintenance
o
policies are determined. This research shows that
t
predictive maintenance is the most suitable
h
maintenance policy for this newspaper firm in both
AHP and ANP analyses. In the future, AHP and ANP
m
models can be used with fuzzy logic for maintenance
e
selection and new models can be done for firms that are
t
in other sectors. Further research on testing other
h
decision making tools including fuzzy logic, may be
o
done. This study can also be extended by adding a new
d
selection factor to the existing model.
s
t
o
c
a
u
s
e
18,1
Table II.
JQME
P1P2P3GS1S2S3V1V2V3V4C1C2C3C4C5I1I2I3
P10.0000.0000.0000.0000.7090.2870.2900.2900.4670.1760.2901.0001.0000.0001.0000.0000.0771.0000.091
P20.0000.0000.0000.0000.1790.6350.6550.6550.4670.2800.6550.0000.0000.7500.0000.0000.4620.0000.091
P30.0000.0000.0000.0000.1130.0780.0550.0550.0670.0440.0550.0000.0000.2500.0001.0000.4620.0000.818
G0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
S10.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
S20.0000.0000.0000.4000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
S30.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
V10.0000.0000.0000.0000.0000.0000.0000.0000.0000.3330.0000.0000.0000.0000.0000.0000.0000.0000.000
V20.0000.0000.0000.0000.0000.0000.0000.0000.0000.1110.0000.0000.0000.0000.0000.0000.0000.0000.000
V30.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
V40.0000.0000.0000.2780.0000.0000.0000.0000.0000.0560.0000.0000.0000.0000.0000.0000.0000.0000.000
C10.1810.0750.0420.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
C20.0850.0750.0420.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
C30.0170.6770.5890.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
C40.2020.0750.0420.1440.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
C50.0150.0970.2860.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
I10.1000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
I20.3000.0000.0000.1780.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
I30.1000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
P1P2P3GS1S2S3V1V2V3V4C1C2C3C4C5I1I2I3
P10.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.2270.227
P20.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.1460.146
P30.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.1270.127
G0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
S10.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
S20.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
S30.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
V10.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
V20.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
V30.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
V40.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
C10.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.0570.057
C20.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.0360.036
C30.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.1780.178
27
Table III. Limit matrix
JQME In addition, other well known multi-criteria methods such as TOPSIS, ELECTRE can 18,1 be used to
compare the results of this work.
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Corresponding author
Omer F. Demirel can be contacted at: odemirel@fatih.edu.tr