Knowledge Management and Experience Transfer in Major Maintenance Activities: A Practitioner’s Perspective

Abstract

Major overhauls, outages, shutdowns and turnarounds (MoOSTs) are significant maintenance interventions needed on a periodic basis to optimise the performance of physical industrial assets (PIAs). However, uncertainties in the forms of emergent and discovery work which sometimes cause delays and cost overruns are quite common partly because, MoOSTs are characterised by inherent challenges such as, but not limited to, short execution spans, volatility in ever-evolving schedules, task complexities as well as huge offline production and/or operation costs etc. Furthermore, in the literature, other complex elements which further constrains decision-makers in MoOSTs from satisfactorily achieving predetermined objectives have been identified, one of which is the lack of a formalised approach for capturing tacit knowledge from experienced practitioners. Consequently, because MoOSTs is an applied discipline, significant human endeavours are required in the planning and management, which makes it pertinent to examine and obtain the perspectives of experienced MoOSTs practitioners. Therefore, the aims of this study are two folds; firstly, to examine the extent of alignment between findings from literature as it relates to the challenges encountered during MoOSTs, as well as probe their underlying causes in practice. Secondly, to show how relevant the findings from this study would be in providing a baseline for establishing a proposal for capturing MoOSTs knowledge and the transfer of experience. The research approach adopted; thematic synthesis of themes which emerged from knowledge management challenges in MoOSTs identified via an earlier systematic literature review (SLR); and then, the identified challenges were validated through conducting interviews with practitioners. Demography analysis as well as specific MoOSTs related questions were administered via questionnaires, which were then analysed using frequency analysis method. Additionally, semi-structured interviews were conducted to investigate the perceptions of practitioners on pertinent MoOSTs issues. Both questionnaires and interview questions were formulated by findings obtained from the SLR, so as to examine whether the knowledge management challenges identified in the literature exist in practice, and if they do to what extent. In total, the selected responses of 49 practitioners, with origin across five industries were examined to determine the extent of alignment between literature and the practice-based perspectives. Based on the results, nine challenges were identified as critical themes, six of which were associated with managing knowledge. The study identified not only known constraints from literature but also their underlying causes based on the perspective of practitioners involved in multiple MoOSTs, which is crucial for developing sustainable mitigation. A unique contribution of this research is the mapping of demographic information such as industry, country, job class, years of experience, MoOSTs organization size, frequency for performing MoOSTs, etc., to responses obtained from participants, which has not been shown in literature prior to now. The importance of such rigorous efforts in the research design, is crucial for enabling the adoption of holistic approaches to eliminating the underlying causes of challenges encountered in MoOSTs, based on first hand reporting of people involved. In addition, the relevance of such first-hand analyses of responses obtained from this study; serve as baseline for the introduction of the proposal to adequately manage knowledge management issues in this discipline.

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