711 research outputs found

    An investigation into the improvement of maintenance quality in a production plant through the use of reliability management

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    Abstract: Extensive research has been conducted on plant reliability maintenance. However, getting the maintenance system in place remains the core of maintenance improvement. The purpose of this research dissertation is to investigate the impact reliability management has within production industries and its role in improving the quality of maintenance. This study will assist management to reflect on the costeffectiveness and influence that the maintenance management system has within the organisation. The study will also contribute to existing knowledge in plant reliability maintenance. It is, therefore, significant for an organisation to establish good management practices and set maintenance as an integral part of their overall plant strategy. The approach that was followed by this research is a mixed method – a combination of quantitative and qualitative. Data collection was carried out through a literature review, observations, a questionnaire, a survey, interviews and from company documentation. An employee questionnaire was prepared and distributed to 25 participants to conduct gap analysis and evaluate the maintenance practices within the observed company. A benchmark study was also performed using an online survey, based on 85 responses from employees in other processing plant industries within South Africa. The empirical study conducted with Company A’s employees (mainly from the maintenance and operation departments) identified possible blunders, which transpired during the reliability management system implementation phase. Based on this sample the results obtained indicated that maintenance is done unnecessarily on the plant on average. The study also found issues regarding maintenance financial planning ineffectiveness, unavailability of spares and lack of skillsets to perform jobs. The online survey revealed that organisations do make use of Computerised Maintenance Management System (CMMS) to facilitate their maintenance. CMMS also has a positive impact on the overall maintenance processes and productivity. The study identified the importance of planning and scheduling shutdowns in advance, as a significant part of the maintenance annual budget and cost reduction. ..M.Phil. (Engineering Management

    Heuristic Solution For Separated Manufacturing Process

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    Downtime is a major issue for manufactures. Downtime may occur from breakdowns, quality issues, lack of manpower, lack of materials, or in this case a lack of storage containers. A manufacturing system was studied that consists of an injection machine that supplies two assembly lines. The injection machine suffered from frequent downtime from lack of containers. The process was analyzed for root cause of downtime. After analysis of the system it was found that the injection process had high variability in production quantity and quality. The scheduling scheme called for production until all available containers were full regardless of actual demand. This created times when Injection would have to wait for Assembly to empty containers thus causing downtime. A production model was developed to compare different scheduling schemes for cost effectiveness. An economic order quantity based schedule was found to have least cost

    Impacto de las Herramientas Lean en el consumo de energía

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    Lean principles are mainly used for increasing productivity, reducing lead time, and eliminating waste. Energy impacts can also be assessed by using the lean principles. The objective of this paper is to measure the impact of Lean Manufacturing tools on energy consumption, with the base assumption that they should help decrease it. The methodology assesses and documents the energy utilization as a part of VSM. A pilot application in an industrial setting is presented.  Los principios de Lean Manufacturing se usan principalmente para mejorar la productividad, reducir el tiempo de entrega y eliminar desperdicios. Los impactos en consumo de energía también se pueden estimar usando principios de Lean. El objetivo de este artículo es el de medir el impacto del uso de herramientas de Lean Manufacturing en el consumo de energía, partiendo del supuesto de que su aplicación debería reducirlo. La metodología evalúa y documenta la utilización de la energía como parte de la elaboración de Mapas de la Cadena de Valor. Finalmente se presenta una aplicación piloto en una empresa industrial

    Um estudo exploratório do papel das tecnologias de Internet no campo de manutenção industrial: gestão do conhecimento é o futuro?

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    This is an exploratory study of how Internet technologies are likely to have an impact on a specific industrial activity. Maintenance has long been the poor relation in industry despite being indispensable both in continuous process manufacturing and in discrete production. The research starts from the premise that maintenance has two key functions that can be related to management disciplines. These are the acquisition of spare parts, which is attached to purchasing and the deployment of technicians, engineers and subcontractor personnel which is jointly supervised by production, purchasing and human resource managers. The approach adopted was a review of current practices followed by a key informant study. Experts in several major industrial concerns were interviewed along with an opinion leader from a European maintenance federation were interviewed to analyse to what extent technology take-up is likely to affect both purchasing of spares and information management.Estudo exploratório sobre a possibilidade da tecnologia Internet impactar uma atividade industrial específica. A Manutenção Industrial foi por muito tempo a relação pobre na indústria apesar de ser indispensável tanto no processo contínuo de fabricação como na produção. A pesquisa parte da premissa de que a manutenção tem duas funções-chave que podem ser relacionadas à disciplina de administração. Estas são: a aquisição de peças sobressalente ligadas as compras; e o desenvolvimento dos técnicos, engenheiros e pessoal subcontratado que são supervisionados juntamente por gerentes de produção, compra e de recurso humano. A aproximação adotada foi de uma revisão de práticas atuais seguida por um estudo com um informante chave. Foram entrevistados os peritos em várias áreas industriais principais junto com um líder de opinião de uma Federação de Manutenção Européia para analisar até que ponto a tecnologia é provável de afetar tanto a compra de sobressalentes como a gestão da informação

    The Capacity Efficiency Of Production Machinery And Raw Material Supply Control : Production Process In "Galvanized Steel" Company, Bekasi City

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    To produce a product that is of good quality with a smooth production process, it is necessary to establish a system of Machine Efficiency Capacity and Raw Material Supplies appropriately, this is intended to make it easier for companies to meet the required quantity of production and efficiency efficiently and certainly affect the smooth production. The purpose of this research is to find out and analyze the Effect of Capacity of Machine Efficiency in Production and Inventory Control of Raw Materials on the Smooth Production Process in Bekasi Branch "Galvanized Steel" Company. The type of research used is observation with a multiple linear regression analysis model with 32 samples. The regression test results show that 58.5%, the smoothness of the production process can be explained by the capacity of machine efficiency, and control of inventory of raw materials, while the remaining 41.5% is explained by other factors not examined in this study. F test results show that simultaneously the efficiency of production machinery and raw material inventory control have a significant effect on the smooth production process. The results of the t test show partially the capacity of machine efficiency has a significant effect on the smoothness of the production process while the control variables for raw material inventory have no significant effect on the smooth production process in the branch company "GALVANIZED STEEL" Bekas

    Identification and characterization of opportunities for improvement in industrial processes by lean automation method

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    Mestrado de dupla diplomação com a UTFPR - Universidade Tecnológica Federal do ParanáConsidering that the need to adapt industries to remain competitive is increasing, this research is being carried out with the objective of identifying and characterizing improvements in industrial processes, in order to improve them through resources and methods widely used in the industry, such as Lean Manufacturing (LM) and Industry 4.0 (I4.0). Therefore, it was necessary to analyze the LM and I4.0 methodology, resulting in Lean Automation tools, the process of a real company was also analyzed as a case study so that improvement suggestions could be provided. In addition, it was important to interpret the biggest losses that happen in industries with the objective of avoiding them. Finally, it was found that the application of Industry 4.0 in lean tools brings convenience and flexibility since the combination of the two methodologies can be done according to the needs of each industry. Regarding the suggestions for improvements found in the process, initially, it was the implementation of a dashboard as an aid to visual management. Furthermore, it is also suggested to apply the OEE together with the production notes, also in the form of a dashboard. The implementations already carried out were satisfactory in terms of facilitating the automated monitoring of the process. Therefore, it is possible to verify that Industry 4.0 helps with lean tools that can facilitate the visualization and monitoring of industrial processes.Considerando que a necessidade de adaptar as indústrias para se manterem competitivas é cada vez maior, esta pesquisa está sendo realizada com o objetivo de identificar e caracterizar melhorias nos processos industriais, a fim de melhora-los por meio de recursos e métodos amplamente utilizados na indústria, como o Lean Manufacturing (LM) e Indústria 4.0 (I4.0). Portanto, foi necessário analisar a metodologia LM e I4.0, resultando em ferramentas de automação enxuta, também foi analisado o processo de uma empresa real como um estudo de caso para que sugestões de melhoria pudessem ser fornecidas. Além disso, foi importante interpretar as maiores perdas que acontecem nas indústrias com o objetivo de evitá-las. Por fim, verificou-se que a aplicação da Indústria 4.0 nas ferramentas enxutas traz comodidade e flexibilidade, visto que a combinação das duas metodologias pode ser feita de acordo com a necessidade de cada indústria. No que diz respeito às sugestões de melhorias encontradas no processo, inicialmente foi a implementação de um dashboard como auxilio de gestão visual. Além disso sugere-se também a aplicação do OEE juntamente com o apontamento de produção também em forma de dashboard. As implementações já realizadas foram satisfatórias em termos de facilitar o monitoramento automatizado do processo. Portanto, é possível verificar que a Indústria 4.0 auxilia nas ferramentas enxutas que podem facilitar a visualização e o monitoramento dos processos industriais

    A strategic plan for incorporating a maintenance strategy to support and sustain maximisation of product volumes.

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    Thesis (MBA)-University of Natal, Duban, 2003.The Acerinox Group has recently acquired Columbus Stainless. With this acquisition, came a dramatic change in operations philosophy. This involves maximisation of product volumes and a low cost strategy throughout the plant. This paper serves to present the management dilemma currently present at Columbus Stainless: Is the current Corporate Maintenance Strategy able to support the manufacturing strategy as laid down by Acerinox? Is there a breakdown in synergy between this corporate maintenance strategy and plant-specific maintenance strategies and why? As part of the research methodology a construct has been developed to perform a gap analysis between World Class/Best Practice maintenance practices and the Columbus Stainless and plant-specific maintenance strategies. A gap analysis is also performed between the Columbus Stainless Maintenance Strategy and the plant-specific maintenance strategies at the Hot End of the organisation. A questionnaire is also used to determine the maturity level of the maintenance management in terms of World Class/Best Practice maintenance theory, the Corporate Maintenance Strategy and plant-specific maintenance strategies. This study has found that the Corporate Maintenance Strategy is able to support the maximisation of volumes and low cost strategy by comparing the World Class/Best Practice maintenance practices found in grounded theory, to the Corporate Strategy and to the plant-specific strategies. The results from this study also find that there is a breakdown in synergy between one plant at the Hot End of the organisation and the Corporate Maintenance Strategy. The reasons for the breakdown in synergy are identified and recommendations are made accordingly
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