Using Lean Principles in Water Maintenance Operations with Application to Water Treatment Plant

Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1345-1351

J. Environ. Treat. Tech.

ISSN: 2309-1185

Journal web link: http://www.jett.dormaj.com

https://doi.org/10.47277/JETT/8(4)1351

Using Lean Principles in Water Maintenance

Operations with Application to Water Treatment

Plant

Naser Abdullah Naser Almutairi*

Department of Industrial Engineering, Faculty of Engineering, The Hashemite University, Kuwait

Received: 11/05/2020

Accepted: 17/07/2020

Published: 20/09/2020

Abstract

Water maintenance operations and management are so expensive, and costs too much money, Lean principles can serve maintenance

sector and any sector like manufacturing and services, since it will reduce costs and efforts of workers. Lean principles first used in

Toyota and then distributed in all over the world, it aims to minimize costs and eliminate all wastes in any operation or processes. Costs

of water treatment plants water maintenance operations are so high and contains a lot of wastes. This paper aims to apply Lean principles

in water maintenance operations in all sectors and then apply them in a water treatment plant as a case study. Also the paper discussing

the capability of applying Lean tools like 5S which can be applied on maintenance operation to measure Lean applicability. MTBF,

MTTR, 5S audit scores, Availability and reliability are calculated here. The methodology followed in this study depending of reviewing

related studies and collecting some data from water filtration station maintenance department, then analyze them and deriving some

conclusions to prove the presented claims. Availability and reliability are calculated for some given data from literature and collecting

data from special water treatment plant in Kuwait. It is found that applying lean principles and tools like 5’S and others will enhance

both availability and reliability of the maintenance system. Applying 5S audit scores shows the statues of the maintenance department

and its availability and then reliability to be in good case. The costs and wastes of water maintenance operations in like stations after

applying lean are reduced. Applying lean principles like 5’S tool on maintenance management system and water maintenance operations

will improve the maintenance quality, MTTR, MTBF, availability and reliability and 5S audit scores of the systems are improved and

so number of failures and downtime of the maintained component will be decreased

Keywords: Lean, maintenance, 5S audit, MTTR, MTBF, Reliability, Availability

Introduction¹

•

Proactive: This is something contrary to responsive where the

maintenance activity responds to gear disappointments by

performing fixes. In the proactive maintenance activity the

avoidance of gear disappointments through execution of

preventive and prescient support activities is the target. Fix isn't

comparable to maintenance.

Lean maintenance is a proactive maintenance activity

utilizing arranged and booked maintenance exercises through

all out profitable support (TPM) works on utilizing

maintenance procedures created through utilization of

unwavering quality focused support (RCM) choice rationale

and rehearsed by enabled (self-coordinated) activity groups

utilizing the 5S procedure, week after week Kaizen

improvement occasions, and self-sufficient maintenance

together with multi-talented, support expert performed support

through the submitted utilization of their work request

framework and their PC oversaw maintenance framework

•

Planned and booked: Masterminded support incorporates the

usage of recorded maintenance assignments that recognize task

movement steps, work resource necessities, parts and materials

essentials, time to perform, and concentrated references.

Arranged maintenance is the prioritization of the work,

issuance of a work demand, errand of available work resources,

task of the time period to play out the endeavor (made with

exercises/creation), and breakout and organizing of parts and

materials.

(CMMS) or venture resource the board (EAM) framework.

They are bolstered by a disseminated, lean support/MRO

storeroom that gives parts and materials on a without a moment

to spare (JIT) premise and sponsored by an maintenance and

unwavering quality building bunch that performs underlying

driver disappointment investigation (RCFA), bombed part

examination, maintenance technique viability investigation,

prescient support (PdM) investigation, and inclining and

investigation of condition checking results. That is lean support

basically, yet a fairly enormous nut (aside from a couple of

subtleties that were discarded here however will be shrouded

later in the article). How about we examine the highpoints of

this definition to be certain everybody comprehends the terms

utilized [1]:

•

Total Predictive maintenance: TPM is the establishment of

lean maintenance. It is an activity for enhancing the

unwavering quality and adequacy of assembling gear. TPM is

group based, proactive maintenance and includes each level

and capacity in the association, from top administrators to the

shop floor. TPM addresses the whole creation framework life

cycle and assembles a strong, shop floor-based framework to

forestall all misfortunes. TPM destinations incorporate the end

everything being equal, imperfections, and breakdowns. •

Reliability Centered Maintenance (RCM): RCM is a procedure

used to decide the maintenance necessities of physical

Corresponding author: Naser Abdullah Naser Almutairi, Department of Industrial Engineering, Faculty of Engineering, The Hashemite

University, Kuwait, E-mail: nasaradullah@hu.edu.jo

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1345-1351

resources in their present working setting. While TPM

destinations center on keeping up gear dependability and

adequacy, RCM focused on upgrading maintenance viability. •

Empowered (self-coordinated) activity groups: Activity group

exercises are task-arranged and structured with a solid

exhibition center. The group is sorted out to perform entire and

incorporated undertakings, subsequently requiring multi-office

enrollment. The group ought to have characterized self-

governance (that is, power over its very own considerable lot

authoritative capacities, for example, self-assessment and self-

guideline—all with limits characterized). Moreover,

individuals ought to take part in the choice of new colleagues.

Numerous aptitudes are esteemed. This urges individuals to

adjust to arranged changes or event of unforeseen occasions [1,

reports work that uses key execution pointers (KPI). To be

viable, the CMMS must be completely actualized with

complete and exact hardware information, parts and materials

information, and maintenance plans and strategies. • Enterprise

resource the executives. The EAM framework plays out similar

capacities that the CMMS does however on a more association

wide, coordinated premise, fusing all destinations and

resources of an enterprise. Significantly more extensive venture

frameworks fuse completely incorporated modules for all the

significant procedures in the whole association and offer the

guarantee to adequately coordinate all the data streams in the

association. • Distributed, lean maintenance/MRO storeroom.

A few stores areas supplant the concentrated storeroom so as to

put region explicit parts and materials closer to their place of-

utilization. Lean stores utilize institutionalized materials for

basic application use. The lean stores activity additionally

utilizes arranging and determining strategies to settle the

buying and storeroom the executives procedure. This strategy

necessitates that a drawn out gear plan is created and hardware

bills of material (BOM) are gone into the CMMS when the buy

request for new hardware is given. • Parts and materials on an

in the nick of time premise. Stores inventories are radically

diminished (just like the expenses of conveying huge

inventories) through a solid production network supervisory

crew that utilizes JIT providers, and practices, for example,

seller oversaw inventories in which the merchant is given the

obligation regarding keeping up great stock practices in

renewal, in requesting, and in giving the materials. The seller

is accused of the obligation of controlling expenses and stock

levels, the sharing of data with the office, and making

enhancements simultaneously. The inventory network

supervisory crew advocates everyday provider correspondence

and collaboration, free trade of business and specialized data,

responsive win-win dynamic, and provider benefit sharing. •

Maintenance and unwavering quality designing gathering.

Since insights show that up to 70 percent of gear

disappointments are self-prompted, a significant obligation of

support designing includes disclosure of the reasons for all

disappointments. Unwavering quality building is a significant

duty of a support designing gathering. Their duties right now

incorporate assessing preventive maintenance activity

adequacy, creating PdM strategies/methods, performing

condition checking/hardware testing, and utilizing building

procedures to broaden gear life, including determinations for

new/reconstructed gear, exactness modify and establishment,

fizzled part examination, main driver disappointment

]. There are many lean principles and tolls like: 5S, Kaizen,

CMMS and other lean tools which will discussed here.

5S process: There are five exercises for improving the work

•

place condition: sort (expel pointless things), fix (compose),

thoroughly clean (everything), institutionalize (standard

everyday practice to sort, fix, and scour), and spread (extend

the procedure to different zones). • Kaizen improvement

occasions. Kaizen is the way of thinking of nonstop

improvement, which each procedure can and ought to be

consistently assessed and improved regarding time required,

assets utilized, resultant quality, and different perspectives

pertinent to the procedure. These occasions are frequently

alluded to as a Kaizen rush—a quick turnaround (multi week

or less) utilization of Kaizen improvement instruments to

acknowledge brisk outcomes. • Autonomous maintenance.

This alludes to routine support (e.g., hardware cleaning, grease,

and so on.) performed by the creation line administrator. The

maintenance supervisor and creation administrator should

concede to and set up strategy for where in the creation forms

self-sufficient support will be performed, what level and sorts

of maintenance the administrators will perform, and how the

work procedure for self-sufficient support will stream. Explicit

preparing in the presentation of assigned maintenance duties

must be given to the administrators preceding doling out them

self-governing support obligations. • Multi-gifted, support

professional. Multi-talented maintenance experts are getting

progressively significant in present day fabricating plants

utilizing PLCs, PC-based hardware and procedure control,

mechanized testing, remote procedure checking and control,

and comparative current creation frameworks. Support

specialists who can test and work these frameworks just as

make mechanical and electrical alterations, alignments, and

parts swap forestall the requirement for numerous specialties in

numerous maintenance errands. The plant procedures ought to

decide the requirement for and favorable circumstances of

incorporating numerous abilities preparing in the general

preparing plan.

investigation,

dependability

designing,

remake

accreditation/confirmation, age investigation, and repeat

control [1, 2].

Literature Review

LM term was instituted in the most recent decade of the

•

Work request framework. This framework is utilized to

design, appoint, and plan all maintenance work and to secure

gear execution and dependability information for advancement

of hardware accounts. The work request is the foundation of a

proactive maintenance association's work execution, data

information, and input from the CMMS. All work must be

caught on a work request—8 hours hands on approaches 8

hours on work orders. The sorts of work requests will

incorporate classifications, for example, arranged/planned,

restorative, crisis, and so on. The work request will be the

essential instrument for overseeing work assets and estimating

office viability. • Computer managed maintenance system. The

data (support) the board programming framework performs, as

a base, work request the executives, arranging capacity,

booking capacity, gear history amassing, spending plan/cost

work, work asset the executives, saves the executives, and a

twentieth century. Smith [3] characterizes LM as a proactive

maintenance activity utilizing arranged and booked support

exercises through TPM works on utilizing support systems

created through use of unwavering quality focused

maintenance (RCM) choice rationale and rehearsed by engaged

(self-coordinated) activity groups. LM produces an alluring

result by limiting utilization of information sources (Smith and

Hawkins, 2004). LM speaks to receiving lean standards into the

maintenance, fix, and upgrade (MRO) tasks. It could diminish

unscheduled DT through streamlining maintenance bolster

exercises and support overhead. The lean instruments are

speaking to the lean standards for the execution procedure [4].

To accomplish LM improvement viably, key lean apparatuses,

for example, VSM, 5S, and visual administration should be

utilized [3, 5]. A far reaching lean devices produced for

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1345-1351

maintenance exercises inside an association incorporate 5S,

TPM, OEE, Kaizen, Poka-Yoke, process movement mapping,

Kanban, PC oversaw support framework (CMMS), venture

resource the board (EAM) framework, and Takt time [3, 6].

Regardless of the advantages of LM referenced before, the

audit of past examinations led right now that the examination

on the pertinence of lean standards into maintenance is

peripheral. The current research works have been to a great

extent restricted to the assembling condition where LM is

rehearsed as an essential for lean assembling [7]. This

suggestion has been referenced in Davies and Greenough [6]

underlining on the need of directing more research on handy

utilization of lean assembling standards in maintenance tasks.

It was found that the past investigations for the most part

centered around positioning the support methodologies

dependent on some particular extension. Also, scarcely any

activities have included exhaustive structures or models that

can coordinate lean intuition in operational maintenance

conditions outside of the assembling setting. Ghayebloo and

Shahanaghi [8, 18] plan a model for deciding the insignificant

degree of maintenance prerequisites and fulfilling unwavering

quality level using the lean idea. Tendayi and Fourie [9, 20]

utilize a consolidated methodology among QFD and AHP to

assess the significance of support greatness criteria and

organize the lean apparatuses upon these criteria [3].

Worth stream mapping has supporting strategies that are

frequently utilized in Lean environments to examine and

configuration streams at the framework level (over different

processes). Worth stream mapping dissects both material and

data stream. By drawing the VSM, the professionals had the

option to: envision and plainly observe the whole stream,

recognize the loss in the worth stream, set up the linkage

between the data stream and the material stream and see how

the association will be later on, if all the improvement exercises

are executed appropriately and if the distinguished squanders

were disposed of or evacuated. In spite of the fact that worth

stream mapping is frequently connected with assembling, it is

additionally utilized in support. 5S practices are a part of lean

support which makes space for institutionalized condition for

work, with an attention on squander end and includes five

stages. Effective utilization of 5S may give the accompanying

focal points in support: work environments progressively

proficient, sorted out, spotless, gainful and safe; improvement

of working conditions; better perspective on the issues;

decrease of costs, ineffective time, space and developments;

and decrease of misfortunes related with disappointments and

breaks [2].

3.3 5’S Policy

In order to solve some portion of the weaknesses identified

by the association's conclusion, for example, the absence of the

executives of extra parts and supplies, the absence of adherence

to the techniques in the stockroom and the sloppiness and

request in some work zones, 5S was actualized in the offices

referenced previously. Related to the mechanical designing

zone, before starting the main period of the 5S execution, an

appraisal was made of the shop's present circumstance. At that

point, the group talked about and recorded the exercises

required to finish the usage and characterized a Gantt outline

where dates, agents, dependable and rates of satisfaction were

set up. Among the most significant strides in the execution of

5S in the shop we can make reference to: ID and grouping of

manual devices disposing of the superfluous or unused ones,

making of a 5S guide where the restriction of every manual

apparatus in the shop is shown, migration of the current

hardware as indicated by fix schedules, meaning of cleaning

schedules where the fundamental capable is the relating

administrator, and so forth. Likewise, the visual administration

actualized permits to know the state in which the machines are.

With this, both the administrator and the maintainer can know

whether they are in conditions for their activity or on the off

chance that they require any support activity. Through another

circulation of hardware and workstations in the workshop, it

was conceivable to characterize courses with complete

wellbeing, all around characterized working areas, crisis exits

and hence, the advancement of accessible space. The instance

of the extra parts stockroom was very surprising from the one

of the workshops. Sloppiness, poor dissemination of room and

lost extra parts largely affect the support and viability of gear.

The exertion that was made in the distribution center was a lot

more noteworthy than in the workshop. For this case, new racks

were joined so as to have the option to accomplish an ideal

dissemination of the pre-owned space, ordering materials and

extra parts by producing unit, recurrence of utilization,

measurements, and different qualities. A great deal of material

was disposed of, for example, effectively utilized extra parts,

old parts and unusable basic material. These were sold, creating

about USD 20,000 in additional benefits that were utilized to

back different pieces of the tasks.

One

the ways that are employed

in years to

enhance maintenance functions is Lean Maintenance.

In each improvement project, it's necessary to outline and

apply a procedure to guide to higher operational results. Lean

Maintenance isn't Associate in nursing exception. Therefore,

they developed

phases required to implement the lean thinking in water

maintenance operations in an

exceedingly thermoelectrical power [10, 19]. Ayeni [11] tried

to gift however competitive advantage will be achieved

procedure that covers all the

through flourishing Lean realization in aviation water

maintenance operations. it absolutely was found that the

aviation

MRO) worth Delivery

additionally diagrammatical providing the

intervals that Lean is to

Maintenance

and

Repair

Operations

(VDS) is

whole system at

deployed

(

System

(as hostile the current restricted application of Lean in

operational context alone).

Methodology

.1 Lean Maintenance Tools and Its Effectiveness

The Maintenance work needs to actualize plans to

incorporate and develop its strategies to satisfy the new needs

set on it by Lean Manufacturing. A far-reaching lean

instruments created for maintenance exercises inside an

association incorporate VSM, 5S, by and large gear viability

(OEE), Kaizen, work institutionalization TPM, SMED, PC

support oversaw framework (CMMS). The previously

mentioned lean maintenance instruments are utilized in

ventures speaking to various businesses, aftereffects of level

execution are assessed with measurements and markers of

budgetary and non-money related character. Lean philosophy

aim to decrease the costs of operations. The cost of

maintenance activities could be ranged from 15% to 70% of the

total production costs [12]. The cost is considered as the second

largest after energy costs of the operational budget [13].

.2 Worth Stream Mapping - VSM

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2020, Volume 8, Issue 4, Pages: 1345-1351

Figure 1 Implementing 5’S phases [21]

It was conceivable to confirm significant advances in

cleaning, new dispersion of physical space, utilization of visual

administration for data, acknowledgment of existing stock,

Availability is typically specified in nines notation. For

example 3-nines availability corresponds to 99.9%

availability. A 5-nines availability corresponds to 99.999%

availability. The failure rate λ can be given as:

foundation

new

administration

pointers

and

institutionalization of calculated systems inside the distribution

center [14]. Applying or implementing 5’S on any industrial or

service sectors like maintenance going through many phases

shown in figure 1 below [15]. We need here to calculate what

is called 5S score such that

λ=1/MTBF

(5)

Reliability R(t) can be given as:

R(t)=e ^–⁽^λ^t⁾

(6)

in

S score 

(1)

where t is the time in hours.



i1

.4 Data collected and calculations

Applying 5S in maintenance including the use of 5S audit

where X is audit point grade mark (i.e. 1 for compliance and 0

for incompliance), and I is the 5S assessment points. Other

parameters used to measure the effects of using lean tools

such as 5’S tool in improving water maintenance operations.

Such of these measures are as following [16].

score which depends on using a checklist of existing of

components and scheduled steps of maintenance during the

water maintenance operations Table 1 below shows a segment

of this checklist used usually in these calculations [17].

Mean Time to Repair (MTTR)

The MTTR can be calculated by dividing the downtime

period by the total number of downtimes:

4 Results and Discussion

Tables followed shows the results of applying 5S on

maintenance of water treatment station taken as a case study.

The 5S score calculations is applied here in the availability of

the spare parts in the store which are required for water

maintenance operations in the water treatment station. Table 1

shows the results of applying 5S on the store of spare parts and

its score which gets 3/4. The following data were collected

from literature review and experts in water treatment

maintenance stations which represented a components of water

filtration station [14]-Table 2 represents the data collected.

Table 3 shows the results of calculating reliability and

availability of the last data for t=1000 hrs. It can be noticed that

both availability and reliability are increasing after the use of

the lean tool (5’S). It is clearer in some elements like pump,

while in other elements it is small, this depends mainly on

MTTR and MTBF values. Figure 2 shows the effects of

applying 5’S on no the reliability and availability of the pump

maintenance in last system.

MTTR= (SUM of downtime periods/ total number of repairs)

(

Mean Time between Failures (MTBF)

MTBF is calculated by divide the total operational time by

the number of failures:

MTBF= (SUM of operational time/total number of failures) (3)

Availability of the module is the percentage of time when

system is operational. Availability of a hardware/software

module can be obtained by the formula given below.

AV.=(MTBF) / (MTBF+MTTR)

(4)

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1345-1351

Table 1 5S audit checklist [17]

In this case if the answer on the question is yes it is a score of available items else it will not be considered, as an example in the above table the scores

of question 2 is 2/2 because yes are in two items of just two available questions.

Table 2: Selection of Parts

Are all items stored in the area, in Score 3/4

a designated location & either

Available /NA

Available

labeled or marked?

Yes

Not Available

Pump

Tank Sand filtering part

Filtered water pump part

Pump/osmosis high pressure part

Inverse osmosis filter part

Micro filters stand part

Table 2: Data collected

Before applying 5’S

After Applying 5’S

Equipment

Pump

MTTR (h)

364

620

MTBF(h)

1314

100000

1179

1847

2856

MTTR (h)

354

603

MTBF(h)

1324

100000

1181

1848

2873

Tank Sand filtering

Filtered water pump

Pump/osmosis high pressure

Inverse osmosis filter

Micro filters stand

3446

3447

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1345-1351

Table 3 the results of calculating reliability and availability of the last data for t=1000 hrs

Before applying 5’S

Reliability

0.467

After Applying 5’S

Availability Reliability

Equipment

Availability

78.3%

Pump

%78.9

0.469

Tank Sand filtering

Filtered water pump

Pump/osmosis high pressure

Inverse osmosis filter

Micro filters stand

100%

0.990

0.428

0.5819

0.7045

100%

0.990

95.38%

98.98%

82.16%

99.165%

95.55%

99.03%

82.65%

99.194%

0.4288

0.5821

0.7061

0.7482

0.7481

Ethical issue

Authors are aware of, and comply with, best practice in

publication ethics specifically with regard to authorship

Effect of applying 5'S on Av. and Rel. in

maintenance

(avoidance of guest authorship), dual submission, manipulation

of figures, competing interests and compliance with policies on

research ethics. Authors adhere to publication requirements

that submitted work is original and has not been published

elsewhere in any language.

Competing interests

The authors declare that there is no conflict of interest that

would prejudice the impartiality of this scientific work.

Authors’ contribution

All authors of this study have a complete contribution for

data collection, data analyses and manuscript writing.

.00% 20.00% 40.00% 60.00% 80.00% 100.00%

REL.After5'S

Av. After 5'S

REL. Before 5'S

Av. Before 5'S

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