German Jordanian University

School of Applied Technical Sciences

Mechanical & Maintenance Engineering Department

TME522

Management of Maintenance Systems Project

Study Case : Kawkabuna

Abdalla Zubaidi
20171203033

Page | 1
Abstract

This report presents a case study on the maintenance methods implemented by Kawkubana. The
objective is to analyze the current maintenance practices employed by the company. The study
evaluates the effectiveness and efficiency of these methods, considering factors such as cost, downtime,
and overall equipment performance. The findings of this case study will provide insights into the
strengths and weaknesses of Kawkubana's maintenance approach and suggest potential areas for
improvement.

Page | 2
Table of Contents
Abstract.......................................................................................................................................................2
Introduction.................................................................................................................................................4
Maintenance Department...........................................................................................................................4
Maintenance in Kawkubana........................................................................................................................5
Preventive Maintenance..........................................................................................................................5
Corrective Maintenance..........................................................................................................................7
How to Improve the Maintenance Department?........................................................................................8
Conclusion...................................................................................................................................................9
References.................................................................................................................................................10

Page | 3
Introduction

Kawkabuna for energy solutions was founded in 1953, To develop the Jordanian market by
providing solutions for both Energy efficiency and renewable energy use, and to promote the
importance of good energy management for the economic, social and environmental well-being of the
Jordanian society. This report aims to provide an in-depth analysis of the maintenance methods
currently adopted by Kawkubana, an energy solutions company. Maintenance plays a crucial role in
ensuring the smooth and efficient operation of equipment and systems within the energy sector. As
Kawkubana strives to deliver reliable and sustainable energy solutions to its customers, the effectiveness
and efficiency of their maintenance practices become paramount.

The energy industry is characterized by complex and diverse equipment, ranging from power generation
units to transmission and distribution infrastructure. The reliable performance of these assets is
essential to meet the increasing energy demands and to ensure uninterrupted power supply to
consumers. Effective maintenance practices are vital in preventing equipment failures, minimizing
downtime, and optimizing the lifespan of critical assets.

By reviewing the maintenance methods employed by Kawkubana, this report seeks to evaluate their
approach and identify areas for potential improvement. The study will assess factors such as cost-
effectiveness, maintenance strategies, equipment performance, and the overall impact on the
company's operations. The findings of this case study will not only provide valuable insights into
Kawkubana's current maintenance practices but also offer recommendations for enhancing their
maintenance efficiency and effectiveness.

Understanding the maintenance methods employed by an energy solutions company like Kawkubana
can provide valuable insights and contribute to the industry's knowledge base. This report aims to
contribute to the continuous improvement of maintenance practices in the energy sector, ultimately
leading to enhanced operational reliability, cost savings, and customer satisfaction.

Maintenance Department
Kawkubana's maintenance department comprises a team of skilled professionals dedicated to
ensuring the optimal performance and reliability of the company's energy solutions. With the
recent addition of two maintenance engineers and one electrical expert, the department has
significantly strengthened its technical expertise and capabilities. These professionals bring a
wealth of knowledge and experience to the team, enabling Kawkubana to enhance its
maintenance practices and deliver superior services to its customers.

Page | 4
The maintenance engineers play a vital role in overseeing the day-to-day maintenance
activities, including routine inspections, preventive maintenance tasks, and troubleshooting of
equipment issues. Their expertise in diagnosing and resolving technical problems allows for
efficient and effective maintenance interventions. By implementing proactive maintenance
strategies and leveraging their technical skills, the maintenance engineers contribute to
minimizing downtime, optimizing equipment performance, and extending the lifespan of critical
assets.
The presence of an electrical expert within the maintenance department further enhances
Kawkubana's capabilities in managing electrical systems and equipment. This expert brings
specialized knowledge in electrical maintenance, ensuring that all electrical components,
wiring, and systems are properly inspected, maintained, and repaired. Their expertise is crucial
in maintaining compliance with electrical safety standards, mitigating risks of electrical failures,
and ensuring the overall reliability and safety of the energy solutions provided by Kawkubana.

Maintenance in Kawkubana

In the PV systems department at Kawkubana, a comprehensive maintenance approach is

employed, combining both corrective and preventive maintenance strategies. This integrated
approach ensures the efficient operation and longevity of the photovoltaic systems deployed by
the company.

Preventive Maintenance

The preventive maintenance approach implemented by the PV systems department at

Kawkubana aims to proactively identify and address potential issues before they lead to system
failures. This approach focuses on regular inspections, performance assessments, and
scheduled maintenance tasks to ensure the optimal performance and longevity of the
photovoltaic systems.
Regular inspections are conducted to assess the condition of the PV system components and identify
any signs of wear, degradation, or potential failures. These inspections involve visual checks,
thermographic imaging, and electrical measurements to detect anomalies or deviations from expected
performance. By regularly monitoring the system's health, the maintenance team can identify early
warning signs and take preventive actions.

Page | 5
Performance assessments are also carried out to evaluate the energy generation efficiency of the PV
systems. Data analysis and performance metrics are used to track the system's output over time and
compare it against expected performance levels. Any significant deviations or declines in performance
can indicate underlying issues that require attention. By proactively addressing performance deviations,
the maintenance team can prevent potential failures and optimize the energy production of the PV
systems.

Scheduled maintenance tasks are an integral part of the preventive maintenance program. These tasks
involve routine maintenance activities such as cleaning solar panels, tightening connections, lubricating
moving parts, and inspecting electrical wirings. By performing these tasks on a regular basis, the
maintenance team ensures that the PV system operates at its peak efficiency, reducing the likelihood of
unexpected failures and optimizing the system's lifespan.

The preventive maintenance approach followed by Kawkubana's PV systems department helps to

maximize the reliability, performance, and lifespan of the photovoltaic systems. By proactively
addressing minor issues before they escalate, the department minimizes system downtime, reduces
repair costs, and enhances customer satisfaction. Moreover, the regular monitoring and assessment of
system performance enable them to identify potential efficiency improvements or upgrades to further
optimize the energy generation capacity of the PV systems.

Estimated annual cost: $50,000

• Frequency: Conducted every three months (4 times per year)
• Tasks included: Cleaning solar panels, inspecting electrical connections, lubricating moving parts,
conducting performance assessments, and reviewing system logs.
• Benefits: Proactive identification and resolution of potential issues, optimized system
performance, increased equipment lifespan, and reduced likelihood of unexpected failures.

Corrective Maintenance

Corrective maintenance in the PV systems department at Kawkubana is an essential component

of their maintenance strategy. This approach focuses on addressing equipment failures or
malfunctions as they happen, aiming to minimize system downtime and swiftly restore normal
operation.
When a PV system component or subsystem encounters an issue, the maintenance team responds
promptly to diagnose the problem. This involves conducting thorough inspections, utilizing diagnostic
tools, and analyzing system data to identify the root cause of the failure. Once the cause is determined,
the team takes appropriate actions to rectify the issue and restore the system to optimal functionality.

Page | 6
Corrective maintenance activities may involve repairing or replacing faulty components, reconfiguring
system settings, or resolving any technical issues affecting the performance of the PV system. The
maintenance team utilizes their technical expertise and knowledge of PV systems to implement effective
solutions efficiently. They ensure that the corrective measures align with industry best practices and
adhere to the manufacturer's recommendations for the specific equipment being serviced.

By promptly addressing equipment failures through corrective maintenance, Kawkubana's PV systems

department minimizes the impact of system downtime and maximizes the overall operational efficiency.
This approach enables them to swiftly restore energy generation capacity, ensuring uninterrupted
power supply to customers and minimizing any potential revenue loss. Furthermore, by analyzing the
root causes of failures encountered, the department can identify patterns or trends that may indicate
larger systemic issues, allowing for proactive measures to be taken to prevent similar failures in the
future.

Estimated annual cost: $30,000

• Frequency: On-demand basis as equipment failures or malfunctions occur.

• Tasks included: Diagnosing equipment failures, repairing or replacing faulty components,
reconfiguring system settings, and restoring normal operation.
• Benefits: Swift response to equipment failures, minimized system downtime, restoration of
energy generation capacity, and prevention of potential revenue loss.

How to Improve the Maintenance Department?

To enhance their maintenance approach, Kawkubana can consider implementing the following
strategies:
1. Implement Condition-Based Maintenance: Instead of relying solely on fixed maintenance
schedules, Kawkubana can adopt a condition-based maintenance approach. This involves using
real-time data from sensors and monitoring systems to assess the health and performance of
equipment. By analyzing the condition of assets, maintenance activities can be scheduled based
on actual need, optimizing resource allocation and minimizing unnecessary maintenance tasks.

2. Embrace Predictive Maintenance: Predictive maintenance leverages data analytics, machine

learning, and AI algorithms to forecast equipment failures before they occur. By analyzing
historical data and patterns, Kawkubana can identify early warning signs and indicators of
potential failures. This enables proactive maintenance interventions, reducing downtime, and
preventing costly breakdowns. Implementing predictive maintenance can lead to significant cost
savings and increased equipment reliability.

Page | 7
 3. Invest in Training and Skills Development: Providing regular training and skills development
opportunities for maintenance personnel can enhance their technical expertise and keep them
updated on the latest industry trends and advancements. Training programs can cover topics
such as new equipment technologies, emerging maintenance methodologies, safety practices,
and troubleshooting techniques. Well-trained maintenance staff can improve the accuracy and
effectiveness of maintenance tasks, leading to enhanced equipment performance and reduced
downtime.

4. Foster Collaboration and Communication: Promoting collaboration and communication between

the maintenance department and other relevant departments within Kawkubana can improve
overall maintenance effectiveness. Sharing knowledge, insights, and feedback across
departments can lead to a holistic understanding of maintenance requirements and enable the
development of comprehensive maintenance strategies. Collaboration can also help identify
potential improvements in equipment design, installation practices, or operational procedures.

5. Implement Remote Monitoring and IoT: By utilizing remote monitoring systems and
Internet of Things (IoT) devices, Kawkubana can gather real-time data from equipment and
systems remotely. This allows for continuous monitoring of key performance indicators,
early fault detection, and predictive analytics. Remote monitoring enables proactive
maintenance actions, reduces the need for physical inspections, and improves response
times to equipment anomalies or failures.

Conclusion

In conclusion, the maintenance approach of Kawkubana, an energy solutions company, plays a

vital role in ensuring the optimal performance, reliability, and longevity of their equipment and
systems. By reviewing their current maintenance methods, this report has identified several
opportunities for improvement.
Implementing strategies such as condition-based maintenance and predictive maintenance can enable
Kawkubana to transition from reactive to proactive maintenance practices. By leveraging real-time data,
advanced analytics, and machine learning algorithms, the company can anticipate and prevent
equipment failures, reducing downtime and optimizing resource allocation.

Investing in training and skills development for maintenance personnel fosters a culture of continuous
improvement, empowering them to adopt the latest industry best practices and technologies.
Emphasizing collaboration and communication between departments facilitates knowledge sharing and
drives comprehensive maintenance strategies.

Page | 8
Leveraging technology solutions such as remote monitoring, IoT, big data analytics, augmented reality,
and mobile applications can revolutionize the maintenance approach of Kawkubana. These technologies
enable real-time data insights, remote diagnostics, interactive instructions, and efficient communication,
leading to improved maintenance efficiency and effectiveness.

By embracing these strategies and leveraging technological advancements, Kawkubana can enhance its
maintenance approach, ultimately leading to increased equipment reliability, minimized downtime,
optimized performance, and improved customer satisfaction. Continuous improvement, data-driven
decision-making, and the adoption of emerging technologies will position Kawkubana at the forefront of
the energy solutions industry, ensuring their ability to deliver reliable and sustainable energy solutions
to their customers.

References

1- Smeirat, S. Photo Voltaic System, Kawkabuna For Energy Solutions. Available at:
http://www.kawkabuna.com/Default.aspx

2- Infinity, A. (2022a) 6 tips to enhance your maintenance management strategy, Asset Infinity. Available
at: https://www.assetinfinity.com/blog/tips-to-enhance-maintenance-management-strategy

Page | 9