Strategic maintenance technique selection using combined quality function deployment, the analytic hierarchy process and the benefit of doubt approach

The business performance of manufacturing organizations depends on the reliability and productivity of equipment, machineries and entire manufacturing system. Therefore, the main role of maintenance and production managers is to keep manufacturing system always up by adopting most appropriate maintenance methods. There are alternative maintenance techniques for each machine, the selection of which depend on multiple factors. The contemporary approaches to maintenance technique selection emphasize on operational needs and economic factors only. As the reliability of production systems is the strategic intent of manufacturing organizations, maintenance technique selection must consider strategic factors of the concerned organization along with operational and economic criteria. The main aim of this research is to develop a method for selecting the most appropriate maintenance technique for manufacturing industry with the consideration of strategic, planning and operational criteria through involvement of relevant stakeholders. The proposed method combines quality function deployment (QFD), the analytic hierarchy process (AHP) and the benefit of doubt (BoD) approach. QFD links strategic intents of the organizations with the planning and operational needs, the AHP helps in prioritizing the criteria for selection and ranking the alternative maintenance techniques, and the BoD approach facilitates analysing robustness of the method through sensitivity analysis through setting the realistic limits for decision making. The proposed method has been applied to maintenance technique selection problems of three productive systems of a gear manufacturing organization in India to demonstrate its effectiveness.