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MODULE IN METHODS OF RESEARCH
Objectives:
After completing this chapter, you will be able to:
• Review the available literatures in the field of
maintenance integration.
• In addition to the above, review all of the used theoretical
and practical methods.
The organization of this chapter is as follows:
• Integration management theories: review
• Maintenance management: review basic systems and
approaches
• Maintenance management: review basic systems and
approaches
• Maintenance/manufacturing integration losses; causes
and effects
• Systems engineering and six sigma: Phases, Methods
and techniques
CHAPTER 4
LITERATURE SEARCH AND
REVIEW
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MODULE IN METHODS OF RESEARCH
What is review of literature?
What is review of studies?
The aim of a literature review is to show particular reader that researcher have
read, and have a good grasp of, the main published work concerning a particular topic or
question in specific field. This work may be in any format, including online sources. It may
be a separate assignment, or one of the introductory sections of a report, dissertation or
thesis. In the latter cases in particular, the review will be guided by research objective or
by the issue or thesis researcher are arguing and will provide the framework for
researchers’ further work.
It is very important to note that review should not be simply a description of what
others have published in the form of a set of summaries, but should take the form of a
critical discussion, showing insight and an awareness of differing arguments, theories and
approaches. It should be a synthesis and analysis of the relevant published work, linked
at all times to your own purpose and rationale.
Is done to compare and sometimes collate the results of a set of substantially
similar controlled/laboratory simulations/experiments that were done on the same topic,
by different research groups, at different ties. This can be valuable if a number of
conflicting study results have been published over a lengthy time-frame - for instance, on
the correlation between alcohol consumption and heart disease, or the correlation
between BMI and morbidity - because it allows you to consider what differences in their
experimental methodology, execution, or analysis might have contributed to the
contradictory results. It can also be useful when multiple studies have involved only small
groups and are thus statistically inconclusive or insignificant on their own. Sometimes the
authors will then draw an overall conclusion from this. At other times they just identify
gaps or faulty assumptions in the current studies and avenues of future research to
resolve the conflict.
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MODULE IN METHODS OF RESEARCH
Writing of Literature Review
Researcher first need to decide what he/she need to read. In many cases
researcher will be given a booklist or directed towards areas of useful published work.
Make sure to use this help. With dissertations, and particularly thesis, it will be more down
to researcher to decide. It is important, therefore, to try and decide on the parameters of
research. What exactly are objectives and what does researcher need to find out?
In literature review, is researcher looking at issues of theory, methodology, policy,
quantities research, or what? Before researcher start reading it may be useful to compile
a list of the main areas and questions involved, and then read with the purpose of finding
out about or answering these. Unless something comes up which is particularly important,
stick to this list, as it is very easy to get sidetracked, particularly on the internet.
A good literature review needs a clear line of argument. Therefore need to use the
critical notes and comments researcher made while doing reading, to express an
academic opinion. Make sure that:
✓ Researcher include a clear, short introduction which gives an outline of the review,
including the main topics covered and the order of the arguments, with a brief
rationale for this.
✓ There is always a clear link between researcher own arguments and the evidence
uncovered in reading. Include a short summary at the end of each section. Use
quotations if appropriate.
✓ Researcher always acknowledges opinions which do not agree with thesis. If
researcher ignores opposing viewpoints, argument will in fact be weaker.
Literature review must be written in a formal, academic style. Keep writing clear
and concise, avoiding colloquialisms and personal language. Researcher should always
aim to be objective and respectful of others' opinions; this is not the place for emotive
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MODULE IN METHODS OF RESEARCH
Importance of Literature Review
Literature Related to Search Work
Foreign Studies
language or strong personal opinions. If one thought something was rubbish, use words
such as "inconsistent", "lacking in certain areas" or "based on false assumptions".
When introducing someone's opinion, don't use "says", but instead an appropriate
verb which more accurately reflects this viewpoint, such as "argues", "claims" or "states".
Use the present tense for general opinions and theories, or the past when referring to
specific research or experiments.
➢ To define and limit of the research
➢ To place your study in an historical perspective
➢ To avoid unnecessary duplication
➢ To evaluate promising research methods
➢ To relate your findings to previous knowledge and suggest further research
A good literature review, therefore, is critical of what has been written, identifies
areas of controversy, raises questions and identifies areas which need further research.
The issue of efficiency in financial institutions has been the subject of considerable
examination. Berger and others provide a survey of the research on scale and scope
economies, X-inefficiency in banking (which describes all allocate and technical
efficiencies) and the impact on efficiency of bank mergers.
The authors note the research finding that X-inefficiencies account for around 20
percent or more of costs in banking, while scale and product-mix inefficiencies are found
to account for less than 5 percent of costs. They also observe that the measured
inefficiency varies considerably depending on the choice of measurement method. One
interesting finding they highlight is that output inefficiencies are on average larger than
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MODULE IN METHODS OF RESEARCH
Local Studies
Services
Local Literature
input inefficiencies, which suggests that most of the inefficiencies are in the form of
deficient revenues rather than excessive costs. This suggests that focusing on the cost
function could understate bank inefficiency.
As regards the sources of X-inefficiency, the authors highlight research findings
that suggest this could be the result of agency problems between owners and managers,
regulations and organizational and legal structures and scale and scope of operations.
The collection includes books, newspapers and periodicals, maps and plans,
dictionaries, minute books, nineteenth and twentieth century census returns, illustrations
and ephemera. It covers many aspects such as history, geography, industry transport,
health, social life, education, sport and leisure, population, natural history, religion,
economics and one of today’s most popular hobbies, family history.
• A research service is available to costumers unable to visit the department. The
cost and details are available from local studies staff.
• Small group visits to the department by arrangement only.
• Advice on local and family history research.
These are local materials usually printed and found in books, professional journals
and magazines, newspapers and University publication published by the different
colleges and universities in the Philippines.
• Books and Information File at the Filipiniana Unit
• Journals and magazines available in print or text form
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Literature Review observation
✓ Consult the index to periodicals for articles available in local and foreign
titles; also the List of Periodical, Subscription at the Periodicals Unit.
✓ You may search journal and magazine article available on-line from the
following data bases:
a. Computerized Index to Philippine Periodical Articles (CIPPA)
available at campus On-line Journals / Library Workstations.
b. Herdin Neon – for Health Medicine and Allied Sciences
c. Library Link
d. Online Newspapers
e. Philippine e-lib – Bibliographic database
f. Philippine Education Research Journals for Educations
g. Philippines Journals Online
Concerns the comprehensive research of literature in the language of the country
it was written in that includes the study of regional and historical circumstances in which
it was written. While examining the author’s personal history and views and the historical
context the work was written in, researchers must also imagine how and why the
characters in the literatures act the way they do to better grasp the essence of humanity.
Study of any foreign literature requires acquisition of the language that literature was
written in. for example, in order to study in the field of American English and business
English is carried out concurrently with other studies. Knowledge of the country’s culture,
thinking and daily customs are also essential for understanding the background in which
a work was written.
Our observations are aimed to define the basic requirements to integrate any
industrial system in order to integrate our case study. The previous literatures represent
for the readers the basic elements of any integration process in addition to the used
methods which have been applied in purpose to perform an effective integrated system.
Our observations are as follows:
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MODULE IN METHODS OF RESEARCH
➢ There are two phase for any integration process; define the basic components and
their configuration items using the top down approach and define the interfaces
between these components using bottom up approach.
➢ In order to determining the components and interfaces of the integrated system,
authors suggest the following steps as shown in figure 4.1;
1. Define components and their configurations items using configuration
management to do the configuration items structure.
2. Define interfaces and their inputs and outputs using the interface design
management to do the interface structure.
Figure (4.1), decomposition and integration processes (Danilovic 1999), modified by authors)
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MODULE IN METHODS OF RESEARCH
Maintenance Management Literatures
Maintenance Management; Life cycle, System and Models
The main objective of this literature review is to present a framework for describing
maintenance management systems.
Maintenance management; purposes, importance’s and impacts Many of the key
authors of the maintenance management filed have been discussed the important of the
maintenance role inside the companies, Jonsson (1997) he said “maintenance has
become more important since firms have downsized their organizations, minimized
inventory levels and changed to flexible and time based manufacturing systems, and the
aim of maintenance is to support the maintain efficient production”. The benefits of the
maintenance management systems are:
❖ to improve the equipment availability due to better planning,
❖ improve equipment reliability through the identification of repetitive faults,
❖ Improved stock control to improve maintenance staff productivity by better
organizing and knowledge learning,
❖ Improve quality of the produced products through better manufacturing conditions,
❖ Improve safety by providing detailed standard job procedures, and improve long-
term reduction in maintenance cost and the maintenance related costs which are
divided into direct and indirect costs.
Maintenance management system -as shown in the figure (4.2), consists of five
basic components; maintenance organization systems includes the essential
management activities that guide policies and procedures, workload identification
systems addresses the way(s) in which needed work is brought to the attention of the
maintenance organization and documented, work planning systems to perform work
(prioritizing, planning, estimating, and budgeting all tasks) are evaluated , work
accomplishment systems describe various support activities and requirements (personnel,
materials, equipment, and transportation, training, supervision and contracting
procedures) that enable the maintenance management organization to perform
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MODULE IN METHODS OF RESEARCH
effectively, and maintenance appraisal systems summarizes the information system
features needed to monitor the comparison of actual to planned results . Each of these
components has individual key elements.
Figure 4.2 maintenance management functional areas (Harvey H.Kaiser, 1991)
Harvey H. Kaiser, has defined the basic components of any maintenance management
system. While, the technological changes in the Manufacturing systems affect the
maintenance management systems because of the supporting relation of the
maintenance activities. In fact, these changes have been generated new maintenance
strategies with new maintenance workloads.
Total productive maintenance (TPM) establishes a system of autonomous maintenance
to be performed by the equipment operators. Kelly A (1984 and 1997) and Duffuaa .S
and et al (1998) collected and defined the components of modern maintenance
management system where they have been focused on the following aspects:
• A maintenance system can be viewed as a simple input-output model. The inputs
to such a model are labour, management, tools, spares, equipment, and so forth,
and the output is equipment that is up, reliable, and well configured to achieve the
planned operation of the plant. This enables us to optimize the resources for
maximizing the output of maintenance system. A typical maintenance system is
shown in figure (4.3). The activities needed to make this system functional, namely,
planning, organizing, and control, are shown in this figure, which also presents the
components of a maintenance system that need to be planned, organized, and
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MODULE IN METHODS OF RESEARCH
optimized in order to maximize the output of a maintenance system and achieve
the best utilization of resources.
Figure 4.3, typical maintenance management system (Duffuaa .S et al 1998)
• Maintenance work types; unplanned maintenance (corrective maintenance,
opportunity maintenance), planned maintenance (time- or use- based preventive
maintenance, condition based preventive maintenance, reliability based
maintenance), fault finding, and design modification.
• Maintenance management purposes; the typical maintenance management
system has a purpose to enhance an operational machines and equipment
(availability), modern maintenance management purposes to enhance an efficient
operational machines and equipment, while in more advanced maintenance
techniques like TPM focuses on improving equipment quality and overall
equipment effectiveness and ensure reliability by operator, reliability centered
maintenance focuses on improving equipment reliability specially by design.
• Total maintenance management to improve the maintenance productivity and
maintainability of the productive systems computerized maintenance management
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Different Maintenance Tactical System
Corrective Maintenance
Time- or use based Preventive Maintenance
Reliability based Replacement
Fault Finding
Condition based Preventive Maintenance
system supporting the maintenance management system in order to improve the
utilization of the productive maintenance systems. Total quality maintenance
integrates maintenance techniques in order to optimize the most cost effective
maintenance system.
This type of maintenance is only performed when the equipment is incapable of
further operation. This type of tactical work is sometimes referred to as a run-to-failure
strategy.
This is based typically on either time or use factors, such as cycles, throughput,
and running hours. It is carried out by conducting inspections, cleaning, lubrications,
minor adjustments and other failure prevention actions. Often, records of observed
condition are kept for trend analysis.
Involves replacing the equipment instead of performing maintenance. It is a
planned replacement upon failure.
This is an act or inspection performance to assess the level of failure on set.
Maintaining equipment is based on its measured condition. Examples include
vibration, temperature, stress, contamination, flow, electrical measure and visual
inspection.
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Autonomous Maintenance
Out-sourcing Maintenance
Design out Maintenance
Total Productive Maintenance
This is an especially important pillar of Total Productive Maintenance because it
enlists the intelligence and skills of the people who are most familiar with factory machines
and equipment operators. Operators learn the maintenance skills they need to know
through a seven-step autonomous maintenance program.
Instant maintenance; is a technology for restoring equipment to its dormer state
within three minutes of a breakdown, it is the most important one at the job site.
Major shutdown and overhaul maintenance requires the contracting out of a large
segment of the shutdown work backlog; because there is usually a short, finite time period
to accomplish all the work and not enough capacity within the organization to accomplish
it.
This carried out to bring a piece of equipment to a currently acceptable condition.
It involves improvement and, occasionally, manufacturing and capacity expansion.
Design modification usually requires coordination with engineering and other
departments within the organization.
Total Productive Maintenance focuses on improving equipment quality; TPM seeks
to maximize equipment efficiency through a total system of preventive maintenance
spanning the life time of the equipment. Figure 4.4 represents the basement and the
pillars of total productive maintenance.
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MODULE IN METHODS OF RESEARCH
Reliability Centered Maintenance
Figure (4.4) Pillars of TPM (Plant Maintenance Resource Center)
Reliability Centered Maintenance is based on the philosophy that maintenance is
a key function of the company. It is crucial for the expected functional performance and
productivity goals to be achieved. Further, maintenance requirements are best developed
by multidisciplinary teams from production, materials, maintenance, and technical
departments, and should be founded on a logical, structural, and engineered approach.
RCM is the optimum mix of reactive, time- or interval-based, condition-based, and
proactive maintenance practices. The basic application of each strategy is shown in figure
(4.5).
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MODULE IN METHODS OF RESEARCH
Manufacturing Management Literatures
Computer Integrated Manufacturing
PM - Preventive Maintenance CBM – Condition Based Maintenance
RCFA – Root Cause Failure Analysis FMEA – Failure Modes and Effects Analysis
Figure (4.5), Components of an RCM (Program National Institute of Building Sciences)
These principal maintenance strategies, rather than being applied independently,
are integrated to take advantage of their respective strengths in order to maximize facility
and equipment reliability while minimizing life-cycle costs. RCM includes reactive, time
based, condition-based, and proactive tasks. In addition, a user should understand
system boundaries and facility envelopes, system/equipment functions, functional failures,
and failure modes, all of which are critical components of the RCM program.
With the increasing use of Computer Numerically Controlled (CNC) machine tools,
and the development of sophisticated computer software packages designed to carry out
administrative functions such as production scheduling and control, automatic materials
ordering, numerous attempts have been made to marry up these activities, and so create
as automated a factory as possible. This is usually referred to as Computer Integrated
Manufacturing (CIM) and is yet another attempt to minimize the time taken to bring a new
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MODULE IN METHODS OF RESEARCH
Kaizen System
product to the market place. One area at the heart of any CIM system is the linking of
Computer-Aided Design (CAD) with computer-aided manufacturing (CAM). CIM systems
consist of subsystems that are integrated into a whole. These subsystems consist of the
following:
✓ Business planning and support
✓ Product design
✓ Manufacturing process planning
✓ Process control
✓ Shop floor monitoring systems; and
✓ Process automation
Organizationally, these sub-systems are usually divided into business planning
functions and business execution functions. Business planning functions include activities
such as forecasting, scheduling, material and resource planning, invoicing, and
accounting. Business execution functions include production and process control,
material handling, testing, and inspection. An efficient CIM system requires a single data
base which is shared by the entire manufacturing organization. Databases consist of up-
to-date, detailed, and accurate data relating to products, designs, machines, processes,
materials, production, finances, purchasing, sales, marketing, and inventory.
In the context of kaizen, management has two major functions: maintenance and
improvement. Maintenance refers to activities directed toward maintaining current
technological, managerial, and operating standards and upholding such standards
through training and discipline. Improvement refers to activities directed toward elevating
current standards. Kaizen signifies small improvement as a result of ongoing efforts. The
major systems that should be in place in order to successfully achieve a kaizen strategy
are:
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Maintenance/Manufacturing Integration Literature Review
Maintenance, Production, Quality and Out-sourcing Maintenance System Losses
• Total quality control/ total quality management
• A just-in-time production system/ lean production system
• Total productive maintenance
• Policy deployment
• A suggestion systems
• Small-group activities
There are three main types of maintenance system in form of overall equipment
effectiveness; the first one related to availability and maintainability improving in order to
increase the uptime of the equipment’s as a one of maintenance objectives, the second
one is related to the performance rate of the equipment where the maintenance system
aims to improve the production rate. Finally, the third type related to the quality of the
finished goods by maintaining the manufacturing conditions in order to reduce the rework
or scrap percentage. There are many types of empirical operational losses collected and
classified by Al-Najjar.B (2002) as a case study in the Volvo trucks component AB in
Köping, the table 3.6 represent these losses. Where the maintenance stoppage time is
consists of the following elements: maintenance personnel response time, fault tracing,
waiting time for resources, repair time, and starting time.
TABLE 4.6 Operational Time Losses
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System Engineering and Six Sigma Methodologies
Maintenance and out-sourcing maintenance; contracting individual workers and
integrating them with the in-house staff can lead to inefficiencies and conflicts, as these
contracted staff may not know the routines, equipment, or working procedures and rules,
thereby reducing the productivity of the entire crew.
From industrial needs to industrial satisfaction using Systems engineering; the
systems engineering is about creating effective solutions to problems, and managing the
technical complexity of the resulting developments. At the outset, it is a creative activity,
defining the requirements and the product/process to be built. Then the emphasis
switches again, to integration and verification, before delivering the system to the
customer. The later phases might involve mass production or to single customer paying
for a one-off development, even while components are being developed, systems
engineering performs a crucial role in technical management.
Systems engineering must bridge the abstract early stages and the grimy detail of
implementation. Systems engineering first establishes what is feasible, and then creates
the architecture for the system to be produced. Systems engineering understand the
technical issues, translate them into user requirements. The systems engineering role
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Define the problem and extracting needs
Extracting Requirements
Define the System and its boundery
must handle whole life cycle in a balanced way. The life cycle defined the order in which
information must be produced, and the users, developers and designers each have
responsibility for separate parts of the information. The systems engineering phases are:
To understand the problem means determine the life cycle processes and
stakeholders requirements.
A System is commonly defined to be “a collection of its elements and procedures
organized to accomplish some common objectives.” The stakeholders for the system hold
these objectives. The objectives of the systems engineers are to provide a system that
accomplishes the primary objectives set by the stakeholders, including those objectives
associated with the creation, application, and updating of the system. A major
characteristic of the systemizing the situation is the attention devoted to the entire life
cycle of the research. This life cycle has been characterized as “birth to death.” The
systems engineers shall define the requirements of the new design, firstly, they define the
research life cycle processes, and then they define the research stakeholders within those
processes. Finally, they extract the requirements from each stakeholder group.
According to Karlson A and Bard H (2002-2007) there are three step of this phase:
• Generate, evaluate and select the conceptual solutions
• Determine the vision and acceptance criteria of the selected concept
• Determine the context diagram of the selected concept
• Define the system requirements: functional (capabilities) and nonfunctional
(characteristics) requirements
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Design the architecture
Verification and Integrations
Six Sigma Methodology
Methods and Technique
The system development includes three separate architectures (functional,
physical, and operational) as a part of its process. The functional architecture defines
what the system must do, that is, the system’s functions and the data that flows between
them. The physical architecture represents the partitioning of physical resources available
to perform the system’s functions. The operational architecture is the mapping of
functions to resources.
System Integration is the process of assembling the system from its components,
which must be assembled from their configuration items. Qualification is the process of
verifying and validating the system design and then obtaining the stakeholders’
acceptance of the system design. Recall that verification is the determination that the
system was built right; while validation determines that the right system was built. The
operational validity is the matching of the capabilities of the designed system to the
operational concept; this naturally occurs late in the integration phase after the designed
system has been verified. In addition to that, the conceptual validity, requirements validity,
and design. Validity is important aspects of validity and need to be addressed early in the
design phase.
The managerial thrust of a six sigma program is to effectively provide a framework
and associated methodologies to analyze and evaluate business processes with the
overall goal of reducing waste. The six sigma improvement process typically begins with
identifying a problem to be solved and then defining a project to solve that problem. The
process used by the project team is often referred to as DMAIC, which stands for define,
measure, analysis, improve, and control.
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MODULE IN METHODS OF RESEARCH
Auditing
Process Modeling
Brief summary of ARIS Toolst
The purpose of a maintenance management audit; is to ensure that management
is carrying out its mission, meeting its goals and objectives, following proper procedures,
and managing resources effectively and efficiently. An audit of a specific functional
service area, such as maintenance management, focuses on efficiency of operations. In
contrast to the more traditional measurement of manufacturing productivity, where units
of labour and material can be compared to costs and rates of production, factors must be
identified that can lead to improvements in both cost efficiencies and levels and quality
of service.
✓ Business modeling methods; the whole point of business modeling; is it have a
consistent way of documenting and analyzing whole business, a global modeling
method would be the ideal, but of course no such method exists. However, there
are a number of well-known businesses modeling methods and standards such
IDEF. These methods all have slightly different approaches and emphasis; some
are specific to particular vendor.
✓ Business modeling tools; one of the hardest parts of establishing a common
modeling approach for a process is to ensure some degree of standardization.
Using a modeling method provides a framework for standardization and using a
tool helps enforce that standard. You can use a method without the support of a
tool, but using a tool makes it much easier. Tools normally come with pre-defined
symbols, diagrams types and relationships which all help the users to follow the
method.
The Architecture Integrated Information Systems (ARIS) was developed by
Professor August-Wilhelm Scheer. The concept is intended to provide a framework that
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MODULE IN METHODS OF RESEARCH
Process Measurement
Method I: Overall Process Efficiency
spans the gap between theory and information and communication technology. The core
of the ARIS concept is the representation of business processes in diagrammatic form as
chains of Events and process tasks. Each model contains many items and many
connections. In order to provide structure the models are organized into four Views:
• Organization view – static model of the structure of the organization. Includes:
people resources, technical resources and communication networks.
• Data view – static models of business information, includes: data models,
knowledge structure, information carriers, and technical terms and databases
models.
• Function view – static models of the process tasks. Includes: function hierarchies,
business objectives, supporting systems and software applications.
• Process (control) view – dynamic models that show the behavior processes and
how they relate to the resource. Data and functions of the process environment.
Includes: event-driven process chains, information flow, materials flow,
communications diagrams, products definitions, flow charts and value add
diagrams.
The first three views concentrate on the structure of the organization, while the process
view concentrates on behavior.
Based on the problem formulation of thesis we try to find the most suitable
measurement method for which support the developed model, where in the TQMain
theory prof. Al-Najjar was developed a modified version of the previous measures to fit
the measuring processes of the integrated systems.
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The performance measure used in TQMain is Overall Process Efficiency (OPE), a
modified version of OEE. It is a breakdown of OEE into its basic factors. The definition of
OPE is: "a measure of process effectiveness which reveals the contribution of basic
process element to the process total effectiveness, e.g. the effect of environmental
conditions on machinery availability, performance of manufacturing procedures or
product quality". As shown in the following table 3.7.
I. The machinery availability rate is the time the process is really running, versus the
time it could have been running. A low availability rate reflects downtime losses:
process failures and setup and adjustments.
II. The performance rate is the quantity produced during the running time, versus the
potential quantity, given the designed speed of the equipment. A low performance
rate reflects speed losses: Idling and minor stoppages and Reduced speed
operation.
III. The quality rate is the amount of good products versus the total amount of products
produced. A low quality rate reflects defect losses: Scrap and rework and Start-
up losses.
Table 4.7 Overall Process Efficiency
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MODULE IN METHODS OF RESEARCH
Method II: Man Machine Chart
For the data collection of the required parameters, most of practical literature
reviews indicate to use the man-machine chart (worker- machine chart) and especially to
show the stoppages, non-utilized time, interfaces between the manpower like an operator
and the resources like a machine.
When a person and equipment operate together to perform a productive process,
interest focuses on the efficient use of the person’s time and equipment time. When the
operator’s working time is less than the equipment run time, a man – machine chart is a
useful device in analysis. If the operator can operate several pieces of equipment, the
problem is to find the most economical combination of operator and equipment, when the
combined cost of the idle time of a particular combination of equipment and the idle time
for the worker is at a minimum.
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MODULE IN METHODS OF RESEARCH
Causse-effect Analysis
Pugh EvaluationMatrix
Table 4.8 Multi –Man & Multi - Machine chart
A cause is anything that affects a result. But in root cause analysis we generally
think of causes as bad. Therefore we need a different term to include both adverse
influences and beneficial influences. For example, a factor (X) that has an impact on a
response variable (Y); a source of variation in a process or a product or a system.
Refers to a matrix that helps determine which items or potential solutions are more
important or 'better' than others. It is a scoring matrix used for concept selection, in which
options are assigned scores relative to criteria. The selection is made based on the
consolidated scores. Before you start your detailed design you must have many options
so that you choose the best out of them. This tool is also known as 'Criteria Based Matrix'.
The Pugh matrix allows you to:
❖ Compare different concepts.
❖ Create strong alternative concepts from weaker concepts.
❖ Arrive at an optimum concept that may be a hybrid or variant of the best of other
concepts
The Pugh matrix encourages comparison of several different concepts against a
base concept, creating stronger concepts and eliminating weaker ones until an optimal
concept finally is reached. Also, the Pugh matrix is useful because it does not require a
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MODULE IN METHODS OF RESEARCH
IDEF0 Method
great amount of quantitative data on the design concepts, which generally is not available
at this point in the process.
A method designed to model the decisions, actions, and activities of an
organization or system. IDEF0 is useful in establishing the scope of an analysis,
especially for a functional analysis. The "box and arrow" graphics of an IDEF0 diagram
show the function as a box and the interfaces to or from the function as arrows entering
or leaving the box. To express functions, boxes operate simultaneously with other boxes,
with the interface arrows "constraining" when and how operations are triggered and
controlled. The basic syntax for an IDEF0 model is shown in the figure below 3.9.
Figure 3.9 IDEF0 Box and Arrow Graphics
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MODULE IN METHODS OF RESEARCH
Video links:
Literature review Keywords and Search strategy
• https://m.youtube.com/watch?v=LxkN5mM3--I
How to write literature review?
• https://m.youtube.com/watch?v=rnHvO5aRXq0
Refference
• https://shodhganga.inflibnet.ac.in/bitstream/10
603/291359/7/chapter%20%202.pdf
• https://study.sagepub.com/sites/default/files/O
nwuegbuzie%20%26%20Frels.pdf
• https://www.quora.com/What-is-the-difference-
between-a-literature-review-and-a-review-of-
studies

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Chapter4-Methods_of_Research-Module.pdf

  • 1. 1 MODULE IN METHODS OF RESEARCH Objectives: After completing this chapter, you will be able to: • Review the available literatures in the field of maintenance integration. • In addition to the above, review all of the used theoretical and practical methods. The organization of this chapter is as follows: • Integration management theories: review • Maintenance management: review basic systems and approaches • Maintenance management: review basic systems and approaches • Maintenance/manufacturing integration losses; causes and effects • Systems engineering and six sigma: Phases, Methods and techniques CHAPTER 4 LITERATURE SEARCH AND REVIEW
  • 2. 2 MODULE IN METHODS OF RESEARCH What is review of literature? What is review of studies? The aim of a literature review is to show particular reader that researcher have read, and have a good grasp of, the main published work concerning a particular topic or question in specific field. This work may be in any format, including online sources. It may be a separate assignment, or one of the introductory sections of a report, dissertation or thesis. In the latter cases in particular, the review will be guided by research objective or by the issue or thesis researcher are arguing and will provide the framework for researchers’ further work. It is very important to note that review should not be simply a description of what others have published in the form of a set of summaries, but should take the form of a critical discussion, showing insight and an awareness of differing arguments, theories and approaches. It should be a synthesis and analysis of the relevant published work, linked at all times to your own purpose and rationale. Is done to compare and sometimes collate the results of a set of substantially similar controlled/laboratory simulations/experiments that were done on the same topic, by different research groups, at different ties. This can be valuable if a number of conflicting study results have been published over a lengthy time-frame - for instance, on the correlation between alcohol consumption and heart disease, or the correlation between BMI and morbidity - because it allows you to consider what differences in their experimental methodology, execution, or analysis might have contributed to the contradictory results. It can also be useful when multiple studies have involved only small groups and are thus statistically inconclusive or insignificant on their own. Sometimes the authors will then draw an overall conclusion from this. At other times they just identify gaps or faulty assumptions in the current studies and avenues of future research to resolve the conflict.
  • 3. 3 MODULE IN METHODS OF RESEARCH Writing of Literature Review Researcher first need to decide what he/she need to read. In many cases researcher will be given a booklist or directed towards areas of useful published work. Make sure to use this help. With dissertations, and particularly thesis, it will be more down to researcher to decide. It is important, therefore, to try and decide on the parameters of research. What exactly are objectives and what does researcher need to find out? In literature review, is researcher looking at issues of theory, methodology, policy, quantities research, or what? Before researcher start reading it may be useful to compile a list of the main areas and questions involved, and then read with the purpose of finding out about or answering these. Unless something comes up which is particularly important, stick to this list, as it is very easy to get sidetracked, particularly on the internet. A good literature review needs a clear line of argument. Therefore need to use the critical notes and comments researcher made while doing reading, to express an academic opinion. Make sure that: ✓ Researcher include a clear, short introduction which gives an outline of the review, including the main topics covered and the order of the arguments, with a brief rationale for this. ✓ There is always a clear link between researcher own arguments and the evidence uncovered in reading. Include a short summary at the end of each section. Use quotations if appropriate. ✓ Researcher always acknowledges opinions which do not agree with thesis. If researcher ignores opposing viewpoints, argument will in fact be weaker. Literature review must be written in a formal, academic style. Keep writing clear and concise, avoiding colloquialisms and personal language. Researcher should always aim to be objective and respectful of others' opinions; this is not the place for emotive
  • 4. 4 MODULE IN METHODS OF RESEARCH Importance of Literature Review Literature Related to Search Work Foreign Studies language or strong personal opinions. If one thought something was rubbish, use words such as "inconsistent", "lacking in certain areas" or "based on false assumptions". When introducing someone's opinion, don't use "says", but instead an appropriate verb which more accurately reflects this viewpoint, such as "argues", "claims" or "states". Use the present tense for general opinions and theories, or the past when referring to specific research or experiments. ➢ To define and limit of the research ➢ To place your study in an historical perspective ➢ To avoid unnecessary duplication ➢ To evaluate promising research methods ➢ To relate your findings to previous knowledge and suggest further research A good literature review, therefore, is critical of what has been written, identifies areas of controversy, raises questions and identifies areas which need further research. The issue of efficiency in financial institutions has been the subject of considerable examination. Berger and others provide a survey of the research on scale and scope economies, X-inefficiency in banking (which describes all allocate and technical efficiencies) and the impact on efficiency of bank mergers. The authors note the research finding that X-inefficiencies account for around 20 percent or more of costs in banking, while scale and product-mix inefficiencies are found to account for less than 5 percent of costs. They also observe that the measured inefficiency varies considerably depending on the choice of measurement method. One interesting finding they highlight is that output inefficiencies are on average larger than
  • 5. 5 MODULE IN METHODS OF RESEARCH Local Studies Services Local Literature input inefficiencies, which suggests that most of the inefficiencies are in the form of deficient revenues rather than excessive costs. This suggests that focusing on the cost function could understate bank inefficiency. As regards the sources of X-inefficiency, the authors highlight research findings that suggest this could be the result of agency problems between owners and managers, regulations and organizational and legal structures and scale and scope of operations. The collection includes books, newspapers and periodicals, maps and plans, dictionaries, minute books, nineteenth and twentieth century census returns, illustrations and ephemera. It covers many aspects such as history, geography, industry transport, health, social life, education, sport and leisure, population, natural history, religion, economics and one of today’s most popular hobbies, family history. • A research service is available to costumers unable to visit the department. The cost and details are available from local studies staff. • Small group visits to the department by arrangement only. • Advice on local and family history research. These are local materials usually printed and found in books, professional journals and magazines, newspapers and University publication published by the different colleges and universities in the Philippines. • Books and Information File at the Filipiniana Unit • Journals and magazines available in print or text form
  • 6. 6 MODULE IN METHODS OF RESEARCH Literature Review observation ✓ Consult the index to periodicals for articles available in local and foreign titles; also the List of Periodical, Subscription at the Periodicals Unit. ✓ You may search journal and magazine article available on-line from the following data bases: a. Computerized Index to Philippine Periodical Articles (CIPPA) available at campus On-line Journals / Library Workstations. b. Herdin Neon – for Health Medicine and Allied Sciences c. Library Link d. Online Newspapers e. Philippine e-lib – Bibliographic database f. Philippine Education Research Journals for Educations g. Philippines Journals Online Concerns the comprehensive research of literature in the language of the country it was written in that includes the study of regional and historical circumstances in which it was written. While examining the author’s personal history and views and the historical context the work was written in, researchers must also imagine how and why the characters in the literatures act the way they do to better grasp the essence of humanity. Study of any foreign literature requires acquisition of the language that literature was written in. for example, in order to study in the field of American English and business English is carried out concurrently with other studies. Knowledge of the country’s culture, thinking and daily customs are also essential for understanding the background in which a work was written. Our observations are aimed to define the basic requirements to integrate any industrial system in order to integrate our case study. The previous literatures represent for the readers the basic elements of any integration process in addition to the used methods which have been applied in purpose to perform an effective integrated system. Our observations are as follows:
  • 7. 7 MODULE IN METHODS OF RESEARCH ➢ There are two phase for any integration process; define the basic components and their configuration items using the top down approach and define the interfaces between these components using bottom up approach. ➢ In order to determining the components and interfaces of the integrated system, authors suggest the following steps as shown in figure 4.1; 1. Define components and their configurations items using configuration management to do the configuration items structure. 2. Define interfaces and their inputs and outputs using the interface design management to do the interface structure. Figure (4.1), decomposition and integration processes (Danilovic 1999), modified by authors)
  • 8. 8 MODULE IN METHODS OF RESEARCH Maintenance Management Literatures Maintenance Management; Life cycle, System and Models The main objective of this literature review is to present a framework for describing maintenance management systems. Maintenance management; purposes, importance’s and impacts Many of the key authors of the maintenance management filed have been discussed the important of the maintenance role inside the companies, Jonsson (1997) he said “maintenance has become more important since firms have downsized their organizations, minimized inventory levels and changed to flexible and time based manufacturing systems, and the aim of maintenance is to support the maintain efficient production”. The benefits of the maintenance management systems are: ❖ to improve the equipment availability due to better planning, ❖ improve equipment reliability through the identification of repetitive faults, ❖ Improved stock control to improve maintenance staff productivity by better organizing and knowledge learning, ❖ Improve quality of the produced products through better manufacturing conditions, ❖ Improve safety by providing detailed standard job procedures, and improve long- term reduction in maintenance cost and the maintenance related costs which are divided into direct and indirect costs. Maintenance management system -as shown in the figure (4.2), consists of five basic components; maintenance organization systems includes the essential management activities that guide policies and procedures, workload identification systems addresses the way(s) in which needed work is brought to the attention of the maintenance organization and documented, work planning systems to perform work (prioritizing, planning, estimating, and budgeting all tasks) are evaluated , work accomplishment systems describe various support activities and requirements (personnel, materials, equipment, and transportation, training, supervision and contracting procedures) that enable the maintenance management organization to perform
  • 9. 9 MODULE IN METHODS OF RESEARCH effectively, and maintenance appraisal systems summarizes the information system features needed to monitor the comparison of actual to planned results . Each of these components has individual key elements. Figure 4.2 maintenance management functional areas (Harvey H.Kaiser, 1991) Harvey H. Kaiser, has defined the basic components of any maintenance management system. While, the technological changes in the Manufacturing systems affect the maintenance management systems because of the supporting relation of the maintenance activities. In fact, these changes have been generated new maintenance strategies with new maintenance workloads. Total productive maintenance (TPM) establishes a system of autonomous maintenance to be performed by the equipment operators. Kelly A (1984 and 1997) and Duffuaa .S and et al (1998) collected and defined the components of modern maintenance management system where they have been focused on the following aspects: • A maintenance system can be viewed as a simple input-output model. The inputs to such a model are labour, management, tools, spares, equipment, and so forth, and the output is equipment that is up, reliable, and well configured to achieve the planned operation of the plant. This enables us to optimize the resources for maximizing the output of maintenance system. A typical maintenance system is shown in figure (4.3). The activities needed to make this system functional, namely, planning, organizing, and control, are shown in this figure, which also presents the components of a maintenance system that need to be planned, organized, and
  • 10. 10 MODULE IN METHODS OF RESEARCH optimized in order to maximize the output of a maintenance system and achieve the best utilization of resources. Figure 4.3, typical maintenance management system (Duffuaa .S et al 1998) • Maintenance work types; unplanned maintenance (corrective maintenance, opportunity maintenance), planned maintenance (time- or use- based preventive maintenance, condition based preventive maintenance, reliability based maintenance), fault finding, and design modification. • Maintenance management purposes; the typical maintenance management system has a purpose to enhance an operational machines and equipment (availability), modern maintenance management purposes to enhance an efficient operational machines and equipment, while in more advanced maintenance techniques like TPM focuses on improving equipment quality and overall equipment effectiveness and ensure reliability by operator, reliability centered maintenance focuses on improving equipment reliability specially by design. • Total maintenance management to improve the maintenance productivity and maintainability of the productive systems computerized maintenance management
  • 11. 11 MODULE IN METHODS OF RESEARCH Different Maintenance Tactical System Corrective Maintenance Time- or use based Preventive Maintenance Reliability based Replacement Fault Finding Condition based Preventive Maintenance system supporting the maintenance management system in order to improve the utilization of the productive maintenance systems. Total quality maintenance integrates maintenance techniques in order to optimize the most cost effective maintenance system. This type of maintenance is only performed when the equipment is incapable of further operation. This type of tactical work is sometimes referred to as a run-to-failure strategy. This is based typically on either time or use factors, such as cycles, throughput, and running hours. It is carried out by conducting inspections, cleaning, lubrications, minor adjustments and other failure prevention actions. Often, records of observed condition are kept for trend analysis. Involves replacing the equipment instead of performing maintenance. It is a planned replacement upon failure. This is an act or inspection performance to assess the level of failure on set. Maintaining equipment is based on its measured condition. Examples include vibration, temperature, stress, contamination, flow, electrical measure and visual inspection.
  • 12. 12 MODULE IN METHODS OF RESEARCH Autonomous Maintenance Out-sourcing Maintenance Design out Maintenance Total Productive Maintenance This is an especially important pillar of Total Productive Maintenance because it enlists the intelligence and skills of the people who are most familiar with factory machines and equipment operators. Operators learn the maintenance skills they need to know through a seven-step autonomous maintenance program. Instant maintenance; is a technology for restoring equipment to its dormer state within three minutes of a breakdown, it is the most important one at the job site. Major shutdown and overhaul maintenance requires the contracting out of a large segment of the shutdown work backlog; because there is usually a short, finite time period to accomplish all the work and not enough capacity within the organization to accomplish it. This carried out to bring a piece of equipment to a currently acceptable condition. It involves improvement and, occasionally, manufacturing and capacity expansion. Design modification usually requires coordination with engineering and other departments within the organization. Total Productive Maintenance focuses on improving equipment quality; TPM seeks to maximize equipment efficiency through a total system of preventive maintenance spanning the life time of the equipment. Figure 4.4 represents the basement and the pillars of total productive maintenance.
  • 13. 13 MODULE IN METHODS OF RESEARCH Reliability Centered Maintenance Figure (4.4) Pillars of TPM (Plant Maintenance Resource Center) Reliability Centered Maintenance is based on the philosophy that maintenance is a key function of the company. It is crucial for the expected functional performance and productivity goals to be achieved. Further, maintenance requirements are best developed by multidisciplinary teams from production, materials, maintenance, and technical departments, and should be founded on a logical, structural, and engineered approach. RCM is the optimum mix of reactive, time- or interval-based, condition-based, and proactive maintenance practices. The basic application of each strategy is shown in figure (4.5).
  • 14. 14 MODULE IN METHODS OF RESEARCH Manufacturing Management Literatures Computer Integrated Manufacturing PM - Preventive Maintenance CBM – Condition Based Maintenance RCFA – Root Cause Failure Analysis FMEA – Failure Modes and Effects Analysis Figure (4.5), Components of an RCM (Program National Institute of Building Sciences) These principal maintenance strategies, rather than being applied independently, are integrated to take advantage of their respective strengths in order to maximize facility and equipment reliability while minimizing life-cycle costs. RCM includes reactive, time based, condition-based, and proactive tasks. In addition, a user should understand system boundaries and facility envelopes, system/equipment functions, functional failures, and failure modes, all of which are critical components of the RCM program. With the increasing use of Computer Numerically Controlled (CNC) machine tools, and the development of sophisticated computer software packages designed to carry out administrative functions such as production scheduling and control, automatic materials ordering, numerous attempts have been made to marry up these activities, and so create as automated a factory as possible. This is usually referred to as Computer Integrated Manufacturing (CIM) and is yet another attempt to minimize the time taken to bring a new
  • 15. 15 MODULE IN METHODS OF RESEARCH Kaizen System product to the market place. One area at the heart of any CIM system is the linking of Computer-Aided Design (CAD) with computer-aided manufacturing (CAM). CIM systems consist of subsystems that are integrated into a whole. These subsystems consist of the following: ✓ Business planning and support ✓ Product design ✓ Manufacturing process planning ✓ Process control ✓ Shop floor monitoring systems; and ✓ Process automation Organizationally, these sub-systems are usually divided into business planning functions and business execution functions. Business planning functions include activities such as forecasting, scheduling, material and resource planning, invoicing, and accounting. Business execution functions include production and process control, material handling, testing, and inspection. An efficient CIM system requires a single data base which is shared by the entire manufacturing organization. Databases consist of up- to-date, detailed, and accurate data relating to products, designs, machines, processes, materials, production, finances, purchasing, sales, marketing, and inventory. In the context of kaizen, management has two major functions: maintenance and improvement. Maintenance refers to activities directed toward maintaining current technological, managerial, and operating standards and upholding such standards through training and discipline. Improvement refers to activities directed toward elevating current standards. Kaizen signifies small improvement as a result of ongoing efforts. The major systems that should be in place in order to successfully achieve a kaizen strategy are:
  • 16. 16 MODULE IN METHODS OF RESEARCH Maintenance/Manufacturing Integration Literature Review Maintenance, Production, Quality and Out-sourcing Maintenance System Losses • Total quality control/ total quality management • A just-in-time production system/ lean production system • Total productive maintenance • Policy deployment • A suggestion systems • Small-group activities There are three main types of maintenance system in form of overall equipment effectiveness; the first one related to availability and maintainability improving in order to increase the uptime of the equipment’s as a one of maintenance objectives, the second one is related to the performance rate of the equipment where the maintenance system aims to improve the production rate. Finally, the third type related to the quality of the finished goods by maintaining the manufacturing conditions in order to reduce the rework or scrap percentage. There are many types of empirical operational losses collected and classified by Al-Najjar.B (2002) as a case study in the Volvo trucks component AB in Köping, the table 3.6 represent these losses. Where the maintenance stoppage time is consists of the following elements: maintenance personnel response time, fault tracing, waiting time for resources, repair time, and starting time. TABLE 4.6 Operational Time Losses
  • 17. 17 MODULE IN METHODS OF RESEARCH System Engineering and Six Sigma Methodologies Maintenance and out-sourcing maintenance; contracting individual workers and integrating them with the in-house staff can lead to inefficiencies and conflicts, as these contracted staff may not know the routines, equipment, or working procedures and rules, thereby reducing the productivity of the entire crew. From industrial needs to industrial satisfaction using Systems engineering; the systems engineering is about creating effective solutions to problems, and managing the technical complexity of the resulting developments. At the outset, it is a creative activity, defining the requirements and the product/process to be built. Then the emphasis switches again, to integration and verification, before delivering the system to the customer. The later phases might involve mass production or to single customer paying for a one-off development, even while components are being developed, systems engineering performs a crucial role in technical management. Systems engineering must bridge the abstract early stages and the grimy detail of implementation. Systems engineering first establishes what is feasible, and then creates the architecture for the system to be produced. Systems engineering understand the technical issues, translate them into user requirements. The systems engineering role
  • 18. 18 MODULE IN METHODS OF RESEARCH Define the problem and extracting needs Extracting Requirements Define the System and its boundery must handle whole life cycle in a balanced way. The life cycle defined the order in which information must be produced, and the users, developers and designers each have responsibility for separate parts of the information. The systems engineering phases are: To understand the problem means determine the life cycle processes and stakeholders requirements. A System is commonly defined to be “a collection of its elements and procedures organized to accomplish some common objectives.” The stakeholders for the system hold these objectives. The objectives of the systems engineers are to provide a system that accomplishes the primary objectives set by the stakeholders, including those objectives associated with the creation, application, and updating of the system. A major characteristic of the systemizing the situation is the attention devoted to the entire life cycle of the research. This life cycle has been characterized as “birth to death.” The systems engineers shall define the requirements of the new design, firstly, they define the research life cycle processes, and then they define the research stakeholders within those processes. Finally, they extract the requirements from each stakeholder group. According to Karlson A and Bard H (2002-2007) there are three step of this phase: • Generate, evaluate and select the conceptual solutions • Determine the vision and acceptance criteria of the selected concept • Determine the context diagram of the selected concept • Define the system requirements: functional (capabilities) and nonfunctional (characteristics) requirements
  • 19. 19 MODULE IN METHODS OF RESEARCH Design the architecture Verification and Integrations Six Sigma Methodology Methods and Technique The system development includes three separate architectures (functional, physical, and operational) as a part of its process. The functional architecture defines what the system must do, that is, the system’s functions and the data that flows between them. The physical architecture represents the partitioning of physical resources available to perform the system’s functions. The operational architecture is the mapping of functions to resources. System Integration is the process of assembling the system from its components, which must be assembled from their configuration items. Qualification is the process of verifying and validating the system design and then obtaining the stakeholders’ acceptance of the system design. Recall that verification is the determination that the system was built right; while validation determines that the right system was built. The operational validity is the matching of the capabilities of the designed system to the operational concept; this naturally occurs late in the integration phase after the designed system has been verified. In addition to that, the conceptual validity, requirements validity, and design. Validity is important aspects of validity and need to be addressed early in the design phase. The managerial thrust of a six sigma program is to effectively provide a framework and associated methodologies to analyze and evaluate business processes with the overall goal of reducing waste. The six sigma improvement process typically begins with identifying a problem to be solved and then defining a project to solve that problem. The process used by the project team is often referred to as DMAIC, which stands for define, measure, analysis, improve, and control.
  • 20. 20 MODULE IN METHODS OF RESEARCH Auditing Process Modeling Brief summary of ARIS Toolst The purpose of a maintenance management audit; is to ensure that management is carrying out its mission, meeting its goals and objectives, following proper procedures, and managing resources effectively and efficiently. An audit of a specific functional service area, such as maintenance management, focuses on efficiency of operations. In contrast to the more traditional measurement of manufacturing productivity, where units of labour and material can be compared to costs and rates of production, factors must be identified that can lead to improvements in both cost efficiencies and levels and quality of service. ✓ Business modeling methods; the whole point of business modeling; is it have a consistent way of documenting and analyzing whole business, a global modeling method would be the ideal, but of course no such method exists. However, there are a number of well-known businesses modeling methods and standards such IDEF. These methods all have slightly different approaches and emphasis; some are specific to particular vendor. ✓ Business modeling tools; one of the hardest parts of establishing a common modeling approach for a process is to ensure some degree of standardization. Using a modeling method provides a framework for standardization and using a tool helps enforce that standard. You can use a method without the support of a tool, but using a tool makes it much easier. Tools normally come with pre-defined symbols, diagrams types and relationships which all help the users to follow the method. The Architecture Integrated Information Systems (ARIS) was developed by Professor August-Wilhelm Scheer. The concept is intended to provide a framework that
  • 21. 21 MODULE IN METHODS OF RESEARCH Process Measurement Method I: Overall Process Efficiency spans the gap between theory and information and communication technology. The core of the ARIS concept is the representation of business processes in diagrammatic form as chains of Events and process tasks. Each model contains many items and many connections. In order to provide structure the models are organized into four Views: • Organization view – static model of the structure of the organization. Includes: people resources, technical resources and communication networks. • Data view – static models of business information, includes: data models, knowledge structure, information carriers, and technical terms and databases models. • Function view – static models of the process tasks. Includes: function hierarchies, business objectives, supporting systems and software applications. • Process (control) view – dynamic models that show the behavior processes and how they relate to the resource. Data and functions of the process environment. Includes: event-driven process chains, information flow, materials flow, communications diagrams, products definitions, flow charts and value add diagrams. The first three views concentrate on the structure of the organization, while the process view concentrates on behavior. Based on the problem formulation of thesis we try to find the most suitable measurement method for which support the developed model, where in the TQMain theory prof. Al-Najjar was developed a modified version of the previous measures to fit the measuring processes of the integrated systems.
  • 22. 22 MODULE IN METHODS OF RESEARCH The performance measure used in TQMain is Overall Process Efficiency (OPE), a modified version of OEE. It is a breakdown of OEE into its basic factors. The definition of OPE is: "a measure of process effectiveness which reveals the contribution of basic process element to the process total effectiveness, e.g. the effect of environmental conditions on machinery availability, performance of manufacturing procedures or product quality". As shown in the following table 3.7. I. The machinery availability rate is the time the process is really running, versus the time it could have been running. A low availability rate reflects downtime losses: process failures and setup and adjustments. II. The performance rate is the quantity produced during the running time, versus the potential quantity, given the designed speed of the equipment. A low performance rate reflects speed losses: Idling and minor stoppages and Reduced speed operation. III. The quality rate is the amount of good products versus the total amount of products produced. A low quality rate reflects defect losses: Scrap and rework and Start- up losses. Table 4.7 Overall Process Efficiency
  • 23. 23 MODULE IN METHODS OF RESEARCH Method II: Man Machine Chart For the data collection of the required parameters, most of practical literature reviews indicate to use the man-machine chart (worker- machine chart) and especially to show the stoppages, non-utilized time, interfaces between the manpower like an operator and the resources like a machine. When a person and equipment operate together to perform a productive process, interest focuses on the efficient use of the person’s time and equipment time. When the operator’s working time is less than the equipment run time, a man – machine chart is a useful device in analysis. If the operator can operate several pieces of equipment, the problem is to find the most economical combination of operator and equipment, when the combined cost of the idle time of a particular combination of equipment and the idle time for the worker is at a minimum.
  • 24. 24 MODULE IN METHODS OF RESEARCH Causse-effect Analysis Pugh EvaluationMatrix Table 4.8 Multi –Man & Multi - Machine chart A cause is anything that affects a result. But in root cause analysis we generally think of causes as bad. Therefore we need a different term to include both adverse influences and beneficial influences. For example, a factor (X) that has an impact on a response variable (Y); a source of variation in a process or a product or a system. Refers to a matrix that helps determine which items or potential solutions are more important or 'better' than others. It is a scoring matrix used for concept selection, in which options are assigned scores relative to criteria. The selection is made based on the consolidated scores. Before you start your detailed design you must have many options so that you choose the best out of them. This tool is also known as 'Criteria Based Matrix'. The Pugh matrix allows you to: ❖ Compare different concepts. ❖ Create strong alternative concepts from weaker concepts. ❖ Arrive at an optimum concept that may be a hybrid or variant of the best of other concepts The Pugh matrix encourages comparison of several different concepts against a base concept, creating stronger concepts and eliminating weaker ones until an optimal concept finally is reached. Also, the Pugh matrix is useful because it does not require a
  • 25. 25 MODULE IN METHODS OF RESEARCH IDEF0 Method great amount of quantitative data on the design concepts, which generally is not available at this point in the process. A method designed to model the decisions, actions, and activities of an organization or system. IDEF0 is useful in establishing the scope of an analysis, especially for a functional analysis. The "box and arrow" graphics of an IDEF0 diagram show the function as a box and the interfaces to or from the function as arrows entering or leaving the box. To express functions, boxes operate simultaneously with other boxes, with the interface arrows "constraining" when and how operations are triggered and controlled. The basic syntax for an IDEF0 model is shown in the figure below 3.9. Figure 3.9 IDEF0 Box and Arrow Graphics
  • 26. 26 MODULE IN METHODS OF RESEARCH Video links: Literature review Keywords and Search strategy • https://m.youtube.com/watch?v=LxkN5mM3--I How to write literature review? • https://m.youtube.com/watch?v=rnHvO5aRXq0 Refference • https://shodhganga.inflibnet.ac.in/bitstream/10 603/291359/7/chapter%20%202.pdf • https://study.sagepub.com/sites/default/files/O nwuegbuzie%20%26%20Frels.pdf • https://www.quora.com/What-is-the-difference- between-a-literature-review-and-a-review-of- studies