Abstract:
Modelling of dynamic strategies for manufacturing and maintenance in the production industry under competitive environment was considered in this study. Structured questionnaires were administered to determine the latent and prominent challenges facing manufacturing industries in Nigeria. Responses were analyzed using Likert scale, and the outcomes were used to determine manufacturing and machine maintenance parameters which are failure time and time to repair. These parameters were used to determine appropriate strategies in manufacturing, maintenance and marketing, from which an integrated mathematical model was developed. The maintenance dynamics based on alternatives choice of maintenance strategies among preventive, condition based and breakdown were achieved using the modular models developed. Fuzzy logic was used as tool for decision module for the choice of manufacturing methods (conventional, automatic and just-in-time), maintenance strategies (preventive and corrective based condition monitoring) and marketing (market share and demand population). The resulting algorithms for the decision modules were used to develop the software named “Production and Machines Condition Monitoring Software (PMCMS)”. A hardware sub-system was developed for the system for the acquisition and transmission of information on machine conditions into PMCMS via wireless arrangement in two stages namely; base station and sub stations. The developed software and its hardware were tested on industrial machineries of the polyethylene bag production industry in Akure, Ondo State. The hardware was embedded into the machines and the readings of machines’ conditions were read on computer transmitted through wireless network. The validation of the system was carried out using data obtained from the industry. Statistical analytical tool of Statistical Package for Social Science (SPSS 16.0) was used to determine the level of significance between conventional method and the new scheme. The performance of the machines in terms of functionality and availability from the new scheme were compared with the past output of 55 % from the industry. There is 74.2 % gain of machines functionality and 90.6 % product turnover recorded as compared with the past production activities of the industry.
