Reliability assessment of manufacturing systems: A comprehensive overview, challenges and opportunities

Reliability assessment refers to the process of evaluating reliability of components or systems during their lifespan or prior to their implementation. In the manufacturing industry, the reliability of systems is directly linked to production efficiency, product quality, energy consumption, and other crucial performance indicators. Therefore, reliability plays a critical role in every aspect of manufacturing. In this review, we provide a comprehensive overview of the most significant advancements and trends in the assessment of manufacturing system reliability. For this, we also consider the three main facets of reliability analysis of cyber–physical systems, i.e., hardware, software, and human-related reliability. Beyond the overview of literature, we derive challenges and opportunities for reliability assessment of manufacturing systems based on the reviewed literature. Identified challenges encompass aspects like failure data availability and quality, fast-paced technological advancements, and the increasing complexity of manufacturing systems. In turn, the opportunities include the potential for integrating various assessment methods, and leveraging data to automate the assessment process and to increase accuracy of derived reliability models

AI and OR in management of operations: history and trends

The last decade has seen a considerable growth in the use of Artificial Intelligence (AI) for operations management with the aim of finding solutions to problems that are increasing in complexity and scale. This paper begins by setting the context for the survey through a historical perspective of OR and AI. An extensive survey of applications of AI techniques for operations management, covering a total of over 1200 papers published from 1995 to 2004 is then presented. The survey utilizes Elsevier's ScienceDirect database as a source. Hence, the survey may not cover all the relevant journals but includes a sufficiently wide range of publications to make it representative of the research in the field. The papers are categorized into four areas of operations management: (a) design, (b) scheduling, (c) process planning and control and (d) quality, maintenance and fault diagnosis. Each of the four areas is categorized in terms of the AI techniques used: genetic algorithms, case-based reasoning, knowledge-based systems, fuzzy logic and hybrid techniques. The trends over the last decade are identified, discussed with respect to expected trends and directions for future work suggested

A Process to Implement an Artificial Neural Network and Association Rules Techniques to Improve Asset Performance and Energy Efficiency

In this paper, we address the problem of asset performance monitoring, with the intention of both detecting any potential reliability problem and predicting any loss of energy consumption e ciency. This is an important concern for many industries and utilities with very intensive capitalization in very long-lasting assets. To overcome this problem, in this paper we propose an approach to combine an Artificial Neural Network (ANN) with Data Mining (DM) tools, specifically with Association Rule (AR) Mining. The combination of these two techniques can now be done using software which can handle large volumes of data (big data), but the process still needs to ensure that the required amount of data will be available during the assets’ life cycle and that its quality is acceptable. The combination of these two techniques in the proposed sequence di ers from previous works found in the literature, giving researchers new options to face the problem. Practical implementation of the proposed approach may lead to novel predictive maintenance models (emerging predictive analytics) that may detect with unprecedented precision any asset’s lack of performance and help manage assets’ O&M accordingly. The approach is illustrated using specific examples where asset performance monitoring is rather complex under normal operational conditions.Ministerio de Economía y Competitividad DPI2015-70842-

Customized Pull Systems for Single-Product Flow Lines

Traditionally pull production systems are managed through classic control systems such as Kanban, Conwip, or Base stock, but this paper proposes ‘customized’ pull control. Customization means that a given production line is managed through a pull control system that in principle connects each stage of that line with each preceding stage; optimization of the corresponding simulation model, however, shows which of these potential control loops are actually implemented. This novel approach may result in one of the classic systems, but it may also be another type: (1) the total line may be decomposed into several segments, each with its own classic control system (e.g., segment 1 with Kanban, segment 2 with Conwip); (2) the total line or segments may combine different classic systems; (3) the line may be controlled through a new type of system. These different pull systems are found when applying the new approach to a set of twelve production lines. These lines are configured through the application of a statistical (Plackett-Burman) design with ten factors that characterize production lines (such as line length, demand variability, and machine breakdowns).Pull production / inventory;sampling;optimization;evolutionary algorithm

A contribution to supply chain design under uncertainty

Dans le contexte actuel des chaînes logistiques, des processus d'affaires complexes et des partenaires étendus, plusieurs facteurs peuvent augmenter les chances de perturbations dans les chaînes logistiques, telles que les pertes de clients en raison de l'intensification de la concurrence, la pénurie de l'offre en raison de l'incertitude des approvisionnements, la gestion d'un grand nombre de partenaires, les défaillances et les pannes imprévisibles, etc. Prévoir et répondre aux changements qui touchent les chaînes logistiques exigent parfois de composer avec des incertitudes et des informations incomplètes. Chaque entité de la chaîne doit être choisie de façon efficace afin de réduire autant que possible les facteurs de perturbations. Configurer des chaînes logistiques efficientes peut garantir la continuité des activités de la chaîne en dépit de la présence d'événements perturbateurs. L'objectif principal de cette thèse est la conception de chaînes logistiques qui résistent aux perturbations par le biais de modèles de sélection d'acteurs fiables. Les modèles proposés permettent de réduire la vulnérabilité aux perturbations qui peuvent aV, oir un impact sur la continuité des opérations des entités de la chaîne, soient les fournisseurs, les sites de production et les sites de distribution. Le manuscrit de cette thèse s'articule autour de trois principaux chapitres: 1 - Construction d'un modèle multi-objectifs de sélection d'acteurs fiables pour la conception de chaînes logistiques en mesure de résister aux perturbations. 2 - Examen des différents concepts et des types de risques liés aux chaînes logistiques ainsi qu'une présentation d'une approche pour quantifier le risque. 3 - Développement d'un modèle d'optimisation de la fiabilité afin de réduire la vulnérabilité aux perturbations des chaînes logistiques sous l'incertitude de la sollicitation et de l'offre

Review of recent research towards power cable life cycle management

Power cables are integral to modern urban power transmission and distribution systems. For power cable asset managers worldwide, a major challenge is how to manage effectively the expensive and vast network of cables, many of which are approaching, or have past, their design life. This study provides an in-depth review of recent research and development in cable failure analysis, condition monitoring and diagnosis, life assessment methods, fault location, and optimisation of maintenance and replacement strategies. These topics are essential to cable life cycle management (LCM), which aims to maximise the operational value of cable assets and is now being implemented in many power utility companies. The review expands on material presented at the 2015 JiCable conference and incorporates other recent publications. The review concludes that the full potential of cable condition monitoring, condition and life assessment has not fully realised. It is proposed that a combination of physics-based life modelling and statistical approaches, giving consideration to practical condition monitoring results and insulation response to in-service stress factors and short term stresses, such as water ingress, mechanical damage and imperfections left from manufacturing and installation processes, will be key to success in improved LCM of the vast amount of cable assets around the world

Supplier Ranking System and Its Effect on the Reliability of the Supply Chain

Today, due to the growing use of social media and an increase in the number of A HITS with a solution in PageRank (Massimo, 2011) sharing their opinions globally, customers can review products and services in many novel ways. However, since most reviewers lack in-depth technical knowledge, the true picture concerning product quality remains unclear. Furthermore, although product defects may come from the supplier side, making it responsible for repair cost, it is ultimately the manufacturer whose name is damaged when such defects are revealed. In this context, we need to revisit the cost vs. quality equations. Observations of customer behavior towards brand name and reputation suggest that, contrary to the currently dominant model in production where manufacturers are expected to control only Tier 1 supplier and make it responsible for all higher tiers, manufacturers should also have a better hold on the entire supply chain. Said differently, while the current system considers all parts in Tier 1 as equally important, it underestimates the importance of the impact of each piece on the final product. Another flaw of the current system is that, by commonizing the pieces in several different products, such as different care models of the same manufacturer to reduce the cost, only the supplier of the most common parts will be considered essential and thus get the most attention during quality control. To address the aforementioned concerns, in the present study, we created a parts/supplier ranking algorithm and implemented it into our supply chain system. Upon ranking all suppliers and parts, we calculated the minimum number of the elements, from Tier 1 to Tier 4, that have to be checked in our supply chain. In doing so, we prioritized keeping the cost as low as possible with most inferior possible defects

A survey of AI in operations management from 2005 to 2009

Purpose: the use of AI for operations management, with its ability to evolve solutions, handle uncertainty and perform optimisation continues to be a major field of research. The growing body of publications over the last two decades means that it can be difficult to keep track of what has been done previously, what has worked, and what really needs to be addressed. Hence this paper presents a survey of the use of AI in operations management aimed at presenting the key research themes, trends and directions of research. Design/methodology/approach: the paper builds upon our previous survey of this field which was carried out for the ten-year period 1995-2004. Like the previous survey, it uses Elsevier’s Science Direct database as a source. The framework and methodology adopted for the survey is kept as similar as possible to enable continuity and comparison of trends. Thus, the application categories adopted are: design; scheduling; process planning and control; and quality, maintenance and fault diagnosis. Research on utilising neural networks, case-based reasoning (CBR), fuzzy logic (FL), knowledge-Based systems (KBS), data mining, and hybrid AI in the four application areas are identified. Findings: the survey categorises over 1,400 papers, identifying the uses of AI in the four categories of operations management and concludes with an analysis of the trends, gaps and directions for future research. The findings include: the trends for design and scheduling show a dramatic increase in the use of genetic algorithms since 2003 that reflect recognition of their success in these areas; there is a significant decline in research on use of KBS, reflecting their transition into practice; there is an increasing trend in the use of FL in quality, maintenance and fault diagnosis; and there are surprising gaps in the use of CBR and hybrid methods in operations management that offer opportunities for future research. Design/methodology/approach: the paper builds upon our previous survey of this field which was carried out for the 10 year period 1995 to 2004 (Kobbacy et al. 2007). Like the previous survey, it uses the Elsevier’s ScienceDirect database as a source. The framework and methodology adopted for the survey is kept as similar as possible to enable continuity and comparison of trends. Thus the application categories adopted are: (a) design, (b) scheduling, (c) process planning and control and (d) quality, maintenance and fault diagnosis. Research on utilising neural networks, case based reasoning, fuzzy logic, knowledge based systems, data mining, and hybrid AI in the four application areas are identified. Findings: The survey categorises over 1400 papers, identifying the uses of AI in the four categories of operations management and concludes with an analysis of the trends, gaps and directions for future research. The findings include: (a) The trends for Design and Scheduling show a dramatic increase in the use of GAs since 2003-04 that reflect recognition of their success in these areas, (b) A significant decline in research on use of KBS, reflecting their transition into practice, (c) an increasing trend in the use of fuzzy logic in Quality, Maintenance and Fault Diagnosis, (d) surprising gaps in the use of CBR and hybrid methods in operations management that offer opportunities for future research. Originality/value: This is the largest and most comprehensive study to classify research on the use of AI in operations management to date. The survey and trends identified provide a useful reference point and directions for future research