Vehicles Maintenance Workshops Layout and its Management to Reduce Noise Pollution and Improve Maintenance Quality

Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1352-1356

J. Environ. Treat. Tech.

ISSN: 2309-1185

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

https://doi.org/10.47277/JETT/8(4)1356

Vehicles Maintenance Workshops Layout and its

Management to Reduce Noise Pollution and

Improve Maintenance Quality

Hesham Almomani *, Naser Almutairi

Department of Industrial Engineering, Faculty of Engineering, the Hashemite University, Kuwaut

Kuwait Municipality, Kuwait

Received: 06/01/2020

Accepted: 13/04/2020

Published: 20/09/2020

Abstract

Most of vehicle maintenance in Arab world and Jordan is random with low share of management control, this system making

maintenance of vehicles going on with low reliability. The need for managing maintenance operations and workshops layout of

maintenance workshops and reduce noise pollution is crucial. The aim of this paper is to show the importance of maintenance

management and vehicles maintenance workshops management and workshops layout in reduce noise pollution and improving the

operations of maintenance of automobiles. The observations and collecting data about status of maintenance of vehicles workshops in

Jordan is used here. Data and figures about the current status of some studied workshop is presented here. A suggestion for new and

multi alternatives for workshop layouts are analyzed depending on Mean Time TO repair (MTTR). It is found that improving

management methods and maintenance workshops layout will reduce noise pollution and improve the maintenance operations type and

decreasing MTTR for failures. MTTR, costs and quality of maintenance are important factors affected by the maintenance of vehicles

workshop layout, as the layout is arranged in good and flexible way the system becomes better and MTTR decreases.

Keywords: Maintenance, Workshops, Layout vehicles, MTTR

Introduction¹

2 Daily Inspection (DI)

Automobiles need maintenance from time to time.

It is the accountability of

driver or proprietor of

following inspection

Like human beings are required to keep hygiene, in a similar

fashion motors additionally want to be stored clean.

Automobiles have to run on soiled roads and in a polluted

environment. They run on uneven roads with potholes

and different obstructions, and are consequently subjected

to masses which injury them.

a want for normal preservation and servicing of automobiles,

which is typically carried out in auto workshops or

an automobile to lift out

the

and exams daily, before beginning the engine, to keep away

from any kind of breakdown on the road. (i) Check

tire stress in all the tires visually or with the aid of hitting the

tire wall with the assist of a stone and decide the sound (ii)

Check the radiator’s coolant degree (iii) Check the fan belts for

looseness (iv) Check the degree of engine oil (v) Check the

windscreen, rear-view reflect and rear-window glass for their

cleanliness [1].

Therefore,

there

auto provider stations.

a car protection manual.

Every

new car comes

with

The proprietor of

the automobile is anticipated to examine and use this manual,

as it mentions car preservation pointers at some stage

in driving. It has been observed that after getting an auto or

vehicle, the proprietors do no longer care a good deal about

Maintenance Check-up

When one plans a lengthy distance travel, it

is imperative to elevate out a hobbies check-up. One need

to examine the automobile renovation guide for

Some necessary check-ups

are accomplished for higher maintenance. (i) Topping of oil

level; (ii) Proper tension of belt; (iii) Battery for cleanliness and

level of electrolyte (add only distilled water for topping of

electrolyte water); (iv) Brakes; (v) Topping up of coolant, if

required, in the coolant reservoir; (vi) Checking the

serviceability of cooling system hoses; (vii) Proper tyre

inflation pressure; and (viii) Air conditioning.

clarity.

a normal vehicle or automobile maintenance.

the proprietors often carrier their

the automobile protection recommendations given

the automobile preservation guide will

Even

vehicle,

increase the sturdiness or lifestyles of

the automobile to

a super extent. Vehicle protection and servicing is carried out

when the car completes sure kilometers on its ordinary going

for

walks or

when

the car does no

longer provide appropriate performance. It is counseled that

the car proprietors raise out ordinary and periodical exams on

their vehicle, some of which are referred to under [1, 2].

Tips to Extend the Life of a Vehicle

Care

and protection maintain the automobile operating in correct co

ndition. The following tips assist in higher renovation of

Corresponding author: Hesham Almomani, Department of Industrial Engineering, Faculty of Engineering, the Hashemite University.

E-mail: heshamalmomani@hu.edu.jo

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1352-1356

vehicle, and ought to be discovered in daily life. (i) drive the

vehicle with care every day; (ii) be patient during the accident

or breakdown of a vehicle, call helpline number of vehicle; (iii)

buy petrol from reputed and trustworthy service stations; (iv)

do not fill up fuel if your vehicle is parked around an oil tanker;

safety. Globally thousands and thousands of motors are

produced annually. These automobiles want preservation and

restore as the want can also be. Statistics exhibit that, in the US,

over 75% of all jobs, of which the motor car maintenances and

restore is an quintessential part, is in the offerings sector. The

carrier quarter additionally creates over 85% of newly-created

jobs in the U.S. Over 60% of the Gross National Product (GNP)

of the U.S is similarly generated via the offerings sector. In

creating nations such as Brazil 54.5% of GNP is generated via

the offerings region (Cauchick, Miguel Salomi, 2004). In

Malaysia, about 58% of financial things to do in phrases of cost

are from the offerings area (Elistina & Naemah, 2011). The

motor car enterprise in South Africa offers with over 30

manufacturers on the market and over one thousand mode

versions (Anon, 2006). Foster (2006) then again reordered forty

two manufacturers in South Africa with over 1200 mannequin

variants, developing 10,000 jobs. The motor automobile

enterprise in South Africa consequently contributes about 7.6%

to the GNP of the USA [2].

The gadget of preservation and restore works randomly,

with overload or below load, violating techniques - selection

rules. A specific challenge in making choices is due to the

reality that in the passenger park there are extra than a hundred

automobiles of more than a few capacities. The most

complicated graph of buses consists of many components of

units, units, the carrier nomenclature of which exceeds dozens

of operations. In turn, the upkeep and restore complex, the most

complicated queuing system, consists of a multitude of

(v) Car keychain should be light; (vi) Preserve the car during

long-term storage (vii) clean the inside too; (viii) clean dash

gauges carefully; (ix) preserve door and window seals; (x) do

not carry too much load (xi) use upholstery cleaners on soiled

seats; (xii) place a towel under baby seats; (xiii) protect car

paint from the sun by parking it in a spot that is out of direct

sunlight. You can also apply high-quality wax as it prevents sun

damage to car paint from ultraviolet radiation (xiv) Maintain

proper tire inflation; (xv) Check for uneven wear; (xvi) Rotate

your tyres; (xvii) Get wheel alignment checked; (xviii) top off

brake fluid; (xix) care for anti-lock brakes; (xx) check engine

oil at every other fill-up; (xxi) change oil frequently; (xxii) do

not mix coolants; (xxiii) avoid hose hassles; (xxiv) check drive-

belt tension; (xxv) clean your engine; (xxvi) keep the AC

functional, even occasionally during winters; (xxvii) maintain

your car’s battery; (xxviii) seal a leaky radiator; and (xxix)

dilute your coolant [1].

Vehicle service procedure

Additionally one

have observed that licensed car carrier facilities undertake pos

itive processes for the duration of the carrier of a vehicle. In

this session, we will talk about the frequent things to do carried

out in the carrier center. One of the most vital phase is job card

and its filling procedure.

subsystems,

fashions

of regulatory,

informational,

organizational, technological and monetary support. Therefore,

these days it is tough to think about the method of

administration and decision-making besides the availability of

records applied sciences for digitizing the manifestation of

random events, for developing regulatory technologies,

accounting and manipulate systems, and technological know-

how to motivate employees to make bigger productiveness and

satisfactory of work in the upkeep and restore system. Research

and enhancement of methods, strategies of administration and

making sure a excessive degree of reliability, durability, safety,

and affectivity of MTE and motor motors (MV), which include

the use of records technologies, are carried out through

scientists from more than a few fields of transport, data applied

sciences and different areas. However, the introduction of such

administration schemes and software program merchandise

aimed at the renovation (prevention) device of the automobiles

is instead restrained and as a result, in some enterprises, the

report glide is fashioned solely in paper form, which

complicates data evaluation tactics [3-9].

Common Activities in the Workshop

(

i) Job card and its filling procedure

ii) Washing of vehicle and Washing Procedure

iii) Engine minor tune up

iv) Oil replacement

v) Checking of battery — electrolyte level and top-up

vi) Clutch and brake-free play and their adjustment

vii) Lighting system, its various parts and their checking

viii) Identification of greasing points of wheelers and

procedure of greasing

(

[

ix) Checking of tyre inflation and procedure of inflation

1].

Job Card and Its Filling Procedure

When a car proprietor enters the carrier center, he or she is

attended by means of the supervising engineer. The consumer

informs about the automobile defect. After getting comments

from the automobile proprietor or driver related to defects of

the vehicle, the supervising engineer in a provider station or

workshop inspects it. The defects pointed out or listed are stated

down in a general format, which is known as the job card or

work order. In order to point out his pleasure with the prognosis

made with the aid of the supervising engineer, the client of the

automobile symptoms the job card earlier than the repairs on

the car are started. Work is then assigned to the worried

individual to lift out repairs and the supervisor signs and

symptoms the job card too. The work order or job card is

organized replica [1]. Motor motors want to be frequently

maintained and repaired when essential in order to make certain

vehicular health, toughness as properly as human and car

The answer for growing overall performance of

preservation workshops of cars is represented through

developing a correct workshop diagram like that in determine

below. The design format of the facility now proceeds

specifying the place of automobile hoists, required offerings

such as oil reticulation, compressed air supply, water provide

and waste oil services. All unique measurements will be

mentioned in relation to places of equipment, such as

automobile hoists, to allow the correct documentation of

electricity and different operational provider needs. The

diagram offers you the client, a visible effect of the structure

the carrier workshop will take after thinking about all elements

preferred to grant the superior end result in the area available.

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1352-1356

Figure 1: The modern and standard maintenance workshops layout [12]

Additionally, we can furnish a CAD drawing giving a

greater full point of view of the layout. The achieved graph

sketch is correctly a working drawing to hand over to the

builder, electrician, plumber etc. Figure 1 indicates one of the

contemporary amenities or workshops design [12]. A devoted

hose reel should be used for every kind of fluid, motor oil,

equipment oil, compressed air, grease, water, etc. A appropriate

manage valve is then related to every hose end. In the case of

lubricants, manipulate valves consist of a volumetric meter

with partial register for controlling the extent of oil delivered at

every provider and a totalizer to point out the whole quantity of

oil dispensed. Hose reels can be floor, wall or ceiling set up and

can additionally be established inside lubrication pits, for

convenient get right of entry to greasing factors and tools oil

fills. A shut off valve ought to be established between each and

every hose reel inlet hose and the fluid distribution line. Other

tools to think about in the working region are cell waste oil

drainers and cellular devices for the distribution of grease and

lesser used lubricants [12]. Layout is an integral part of a Lean

Manufacturing and Maintenance Strategy. Meaningful re-

structuring requires corresponding physical changes in the

layout. Conversely, a layout re-design can be the catalyst for

space plan: (a) space planning units (aka Activity Areas or

SPUs), (b) affinities, (c) space, (d) cSonstraints. Levels of

Detail help organize facility planning into manageable sub-

projects. Each sub-project has a series of tasks that the design

team must complete. The tasks and their sequence differ for

each level. These levels are: (I) global (Site Location), (II)

supra (Site Planning), (III) macro (Building Layout), (IV)

micro (work cell/department layout), (V) sub-micro

(workstation design), and elements of a plant or facility layout.

Every layout has four fundamental elements: Space Planning

Units (SPUs), Affinities, Space and Constraints. These

fundamental elements apply to any size facility and at any level.

Just as a few chemical elements give rise to an infinite number

of compounds, the four layout elements and their variations can

produce an almost infinite number of factory layouts [10-12].

•SPUs combine with Affinities to form an Affinity

Diagram. The Affinity Diagram is an idealized spatial

arrangement that eventually becomes a layout.

•Each SPU requires some finite space whether great or

small. Space, added to the Affinity Diagram, distorts it into

the Layout Primitive.

•Constraints are conditions, assumptions, policies or edicts

that restrict the design is some way. For example, "The

layout must fit into the existing building." Constraints

further modify the spatial arrangement and a Macro- layout

results.

re-structuring.

layout project, properly done, can

demonstrate the need for change to an organization reluctant to

tear itself apart and rebuild.

•

Product-Focused work cells

Focused Plant-Within-Plant Factories

Reduced Storage & Handling Space

Kanban Stock points

Direct Delivery of Raw Materials

Integrated Support Areas

Levels of Facility Planning

Factory layout is the focal point of facility design. It

dominates the thinking of most managers. But factory layout is

only one of several detail levels. At Strategies, we find it useful

to think of facility planning at five levels: (I) global (Site

Location); (II) supra (Site Planning); (III) macro (Building

Layout); (IV) micro (Work cell/Department Layout); and (V)

sub-Micro (Workstation Design). At the Global level, we pick

out a website online location. This entails elements such as

freight cost, labor cost, talent availability and web site focus.

At the Supra-Layout degree we format the site. This consists .

Facility Planning Series

The links below take you to a series of pages that

summarize the basics of Facility Planning and Plant Layout.

Four fundamental facility elements go into every layout or

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1352-1356

of number, size, and vicinity of buildings. It consists of

infrastructure such as roads, water, gasoline and rail. This

diagram have to seem in advance to plant expansions and

eventual web site saturation The Macro-Layout plans every

building, shape or different sub-unit of the site. Operating

departments are described and positioned at this level.

Frequently, this is the most necessary degree of planning. A

Macro-Layout group The Micro Level IV determines the

region of particular gear and furniture. The emphasis shifts

from gross cloth float to private house and communication.

Socio-Technical issues dominate. The sub micro degree

focuses on person workers. Here we format workstations for

efficiency, effectiveness and safety. Ergonomics is key.

Ideally, the sketch progresses from Global to Sub-Micro in

distinct, sequential phases. At the stop of every phase, the plan

is "frozen" by way of consensus [12, 13, 15]. Layout is

complicated by multiple often competing objectives such as

minimize investment in equipment, minimize overall

production time, provide for employee/customer convenience,

maintain flexibility of arrangement/operation, minimize

material handling cost, utilize existing space most efficiently,

and can have a huge effect on productivity [12, 14]

Figure 2: a, b the suggested layouts for the workshop

It can be noticed that the first alternative is better since

department no.4 is connected with two adjacent important

departments (+0.1), more flexible (+0.1) and having

dependency between departments lower than alternative 2

+0.1) which means that MTTR is lower by 30% than layout 2.

Figure 3 shows a comparison between the two alternatives

depending on MTTR.

(

0 Methodology

The data is collected from a random vehicle large workshop

(

Rashad maintenance workshop-Swaieleh-Jordan), it executes

00%

80%

60%

maintenance works randomly, it presents maintenance

operations to about 100 automobiles/day, having about 15

technicians). The works of such workshop is random, no queue,

no management and no fixed prices for same works. This

workshop is disorder has many problems with customers and

no regular policy. This study aims to classify and re-layout of

the workshop. And also in this work the effects of layout on

mean time to repair (MTTR) and faults is studied. One of

suggestions studied is to rearrange the studied vehicle

maintenance workshop to have 5 departments with the

following specifications-Table 1.

MTTR

Table 1 Data collected

Area

10%

Department Dept. Name

Tiles

(

m )

MTTR alternative 1

MTTR alternative2

Engine

Brake and wheels services

Gear

Figure 3: MTTR for layouts alternatives

Reception and customer

services and spare parts

Exhaust and radiator

It can be noticed from figure 3 that MTTR in the case of

more accurate and flexible and low dependency layout is better,

the vehicles needs lower time for maintenance and repair.

Each tile is 4 m

2 Conclusions

1 Results and discussion

The task here is to select between many alternatives of

Layout and facility planning play a vital role in improving

automobiles maintenance operations, the better layout of the

workshop improving maintenance operations by reducing

MTTR and quality of maintenance and also costs.

layouts. In this study the main base to select the best alternative

is MTTR. The best alternative is the layout offers min MTTR.

This will be achieved depending on the relation between

maintenance department, spare parts location, workers moving

between departments and size of departments. For the two

following suggested layouts, MTTR is calculated and

compared. The dependency of department will be considered

as follows: (1, 2):0.25; (1, 3):0.7; (1, 4):0.9; (1, 5):0.9;

Ethical issue

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

publication ethics specifically with regard to authorship

(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.

(

2,3):0.6; (2,4):0.9; (2, 5):0.25; (3,4):0.9; (3, 5):0.25; (4, 5):0.9.

If cars go from left to right the alternative number 1 has more

fexibility than two since the reception and customer services is

in a good position and so it needs less time to be classified and

maintained. The dependency of alternative

is:

.9*0.9*0.6*0.25=0.1215. The dependency of alternative 2 is

.7*0.9*0.25*0.9=0.14175.

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Journal of Environmental Treatment Techniques

2020, Volume 8, Issue 4, Pages: 1352-1356

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.

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