Theory and Practice of Supply Chain Synchronization

In this dissertation, we develop strategies to synchronize component procurement in assemble-to-order (ATO) production and overhaul operations. We focus on the high-tech and mass customization industries which are not only considered to be very important to create or keep U.S. manufacturing jobs, but also suffer most from component inventory burden. In the second chapter, we address the deterministic joint replenishment inventory problem with batch size constraints (JRPB). We characterize system regeneration points, derive a closed-form expression of the average product inventory, and formulate the problem of finding the optimal joint reorder interval to minimize inventory and ordering costs per unit of time. Thereafter, we discuss exact solution approaches and the case of variable reorder intervals. Computational examples demonstrate the power of our methodology. In the third chapter, we incorporate stochastic demand to the JRPB. We propose a joint part replenishment policy that balances inventory and ordering costs while providing a desired service level. A case study and guided computational experiments show the magnitudes of savings that are possible using our methodology. In the fourth chapter, we show how lack of synchronization in assembly systems with long and highly variable component supply lead times can rapidly deteriorate system performance. We develop a full synchronization strategy through time buffering of component orders, which not only guarantees meeting planned production dates but also drastically reduces inventory holding costs. A case study has been carried out to prove the practical relevance, assess potential risks, and evaluate phased implementation policies. The fifth chapter explores the use of condition information from a large number of distributed working units in the field to improve the management of the inventory of spare parts required to maintain those units. Synchronization is again paramount here since spare part inventory needs to adapt to the condition of the engine fleet. All needed parts must be available to complete the overhaul of a unit. We develop a complex simulation environment to assess the performance of different inventory policies and the value of health monitoring. The sixth chapter concludes this dissertation and outlines future research plans as well as opportunities

Developing Leading and Lagging Indicators to Enhance Equipment Reliability in a Lean System

With increasing complexity in equipment, the failure rates are becoming a critical metric due to the unplanned maintenance in a production environment. Unplanned maintenance in manufacturing process is created issues with downtimes and decreasing the reliability of equipment. Failures in equipment have resulted in the loss of revenue to organizations encouraging maintenance practitioners to analyze ways to change unplanned to planned maintenance. Efficient failure prediction models are being developed to learn about the failures in advance. With this information, failures predicted can reduce the downtimes in the system and improve the throughput. The goal of this thesis is to predict failure in centrifugal pumps using various machine learning models like random forest, stochastic gradient boosting, and extreme gradient boosting. For accurate prediction, historical sensor measurements were modified into leading and lagging indicators which explained the failure patterns in the equipment were developed. The best subset of indicators was selected by filtering using random forest and utilized in the developed model. Finally, the models give a probability of failure before the failure occurs. Appropriate evaluation metrics were used to obtain the accurate model. The proposed methodology was illustrated with two case studies: first, to the centrifugal pump asset performance data provided by Meridium, Inc. and second, the data collected from aircraft turbine engine provided in the NASA prognostics data repository. The automated methodology was shown to develop and identify appropriate failure leading and lagging indicators in both cases and facilitate machine learning model development

Management: A continuing literature survey with indexes, March 1974

This special bibliography lists 597 reports, articles, and other documents introduced into the NASA scientific and technical information system in 1973

Innovation for maintenance technology improvements

A group of 34 submitted entries (32 papers and 2 abstracts) from the 33rd meeting of the Mechanical Failures Prevention Group whose subject was maintenance technology improvement through innovation. Areas of special emphasis included maintenance concepts, maintenance analysis systems, improved maintenance processes, innovative maintenance diagnostics and maintenance indicators, and technology improvements for power plant applications

Study of Finite Elements-based reliability and maintenance algorithmic methodologies analysis applied to aircraft structures and design optimization

This thesis presents the development of a research methodology oriented to the analysis of an aircraft structure in terms of operational reliability and maintainability requirements regarding its airworthiness. The study has been focused on modern commercial aircraft models, carrying out a market research and model selection according to different criteria. The study then develops a practical implementation consisting of the design approach of the aircraft airframe and main structural components for its subsequent numerical analysis and simulation. The numerical simulations will be computed by application of the Finite Elements Method on the main structural systems of the aircraft and establishment of boundary conditions. These simulations will allow the development of a computational study on linear, non-linear, and transient simulations of static loads, buckling, modal analysis, temperature, fatigue and thermal stress of individual structures and full assembly in different conditions. Finally, these results will be assessed and exported to a Matlab code which will compute an algorithmic methodology in order to approach the operational reliability and safety of the aircraft in the studied conditions. The thesis will conclude with a review of airworthiness regulations a proposal of research paths and further development of the methodology implemented

The 2nd International Conference on Advances in Mechanical Engineering

The Second International Conference on Advances in Mechanical Engineering, ICAME-22, was held on 25th August, 2022 at the Mechanical Engineering Department of Capital University of Science and Technology. All articles underwent a rigorous single-blind peer review process. ICAME-22 accepted papers in the disciplines of experimental and computational fluid dynamics, thermodynamics, heat Ttransfer, machine and mechanisms, design, solid mechanics, manufacturing, production and industrial engineering, engineering management, technology management, renewable energy, environmental engineering, bioengineering, materials, failure analysis, and related fields

Lifecycle Prognostics Architecture for Selected High-Cost Active Components

There are an extensive body of knowledge and some commercial products available for calculating prognostics, remaining useful life, and damage index parameters. The application of these technologies within the nuclear power community is still in its infancy. Online monitoring and condition-based maintenance is seeing increasing acceptance and deployment, and these activities provide the technological bases for expanding to add predictive/prognostics capabilities. In looking to deploy prognostics there are three key aspects of systems that are presented and discussed: (1) component/system/structure selection, (2) prognostic algorithms, and (3) prognostics architectures. Criteria are presented for component selection: feasibility, failure probability, consequences of failure, and benefits of the prognostics and health management (PHM) system. The basis and methods commonly used for prognostics algorithms are reviewed and summarized. Criteria for evaluating PHM architectures are presented: open, modular architecture; platform independence; graphical user interface for system development and/or results viewing; web enabled tools; scalability; and standards compatibility. Thirteen software products were identified and discussed in the context of being potentially useful for deployment in a PHM program applied to systems in a nuclear power plant (NPP). These products were evaluated by using information available from company websites, product brochures, fact sheets, scholarly publications, and direct communication with vendors. The thirteen products were classified into four groups of software: (1) research tools, (2) PHM system development tools, (3) deployable architectures, and (4) peripheral tools. Eight software tools fell into the deployable architectures category. Of those eight, only two employ all six modules of a full PHM system. Five systems did not offer prognostic estimates, and one system employed the full health monitoring suite but lacked operations and maintenance support. Each product is briefly described in Appendix A. Selection of the most appropriate software package for a particular application will depend on the chosen component, system, or structure. Ongoing research will determine the most appropriate choices for a successful demonstration of PHM systems in aging NPPs

Maintenance scheduling for modular systems-models and algorithms

Thesis (Ph. D.)--Massachusetts Institute of Technology, Sloan School of Management, Operations Research Center, 2011.Cataloged from PDF version of thesis.Includes bibliographical references (p. 185-188).Maintenance scheduling is an integral part of many complex systems. For instance, without effective maintenance scheduling, the combined effects of preventative and corrective maintenance can have severe impacts on the availability of those systems. Based on current Air Force trends including maintenance manpower, dispersed aircraft basing, and increased complexity, there has been a renewed focus on preventative maintenance. To address these concerns, this thesis develops two models for preventative maintenance scheduling for complex systems, the first of interest in the system concept development and design phase, and the second of interest during operations. Both models are highly complex and intractable to solve in their original forms. For the first model, we develop approximation algorithms that yield high quality and easily implementable solutions. To address the second model, we propose a decomposition strategy that produces submodels that can be solved via existing algorithms or via specialized algorithms we develop. While much of the literature has examined stochastically failing systems, preventative maintenance of usage limited systems has received less attention. Of particular interest is the design of modular systems whose components must be repaired/replaced to prevent a failure. By making cost tradeoffs early in development, program managers, designers, engineers, and test conductors can better balance the up front costs associated with system design and testing with the long term cost of maintenance. To facilitate such a tradeoff, the Modular Maintenance Scheduling Problem provides a framework for design teams to evaluate different design and operations concepts and then evaluate the long term costs. While the general Modular Maintenance Scheduling Problem does not require maintenance schedules with specific structure, operational considerations push us to consider cyclic schedules in which components are maintained at a fixed frequency. In order to efficiently find cyclic schedules, we propose the Cycle Rounding algorithm, which has an approximation guarantee of 2, and a family of Shifted Power-of-Two algorithms, which have an approximation guarantee of 1/ ln(2) ~ 1.4427. Computational results indicate that both algorithms perform much better than their associated performance guarantees providing solutions within 15%-25% of a lower bound. Once a modular system has moved into operations, manpower and transportation scheduling become important considerations when developing maintenance schedules. To address the operations phase, we develop the Modular Maintenance and System Assembly Model to balance the tradeoffs between inventory, maintenance capacity, and transportation resources. This model explicitly captures the risk-pooling effects of a central repair facility while also modeling the interaction between repair actions at such a facility. The full model is intractable for all but the smallest instances. Accordingly, we decompose the problem into two parts, the system assembly portion and module repair portion. Finally, we tie together the Modular Maintenance and System Assembly Model with key concepts from the Modular Maintenance Scheduling Problem to propose an integrated methodology for design and operation.by Eric Jack Zarybnisky.Ph.D

Merging Data Sources to Predict Remaining Useful Life – An Automated Method to Identify Prognostic Parameters

The ultimate goal of most prognostic systems is accurate prediction of the remaining useful life (RUL) of individual systems or components based on their use and performance. This class of prognostic algorithms is termed Degradation-Based, or Type III Prognostics. As equipment degrades, measured parameters of the system tend to change; these sensed measurements, or appropriate transformations thereof, may be used to characterize degradation. Traditionally, individual-based prognostic methods use a measure of degradation to make RUL estimates. Degradation measures may include sensed measurements, such as temperature or vibration level, or inferred measurements, such as model residuals or physics-based model predictions. Often, it is beneficial to combine several measures of degradation into a single parameter. Selection of an appropriate parameter is key for making useful individual-based RUL estimates, but methods to aid in this selection are absent in the literature. This dissertation introduces a set of metrics which characterize the suitability of a prognostic parameter. Parameter features such as trendability, monotonicity, and prognosability can be used to compare candidate prognostic parameters to determine which is most useful for individual-based prognosis. Trendability indicates the degree to which the parameters of a population of systems have the same underlying shape. Monotonicity characterizes the underlying positive or negative trend of the parameter. Finally, prognosability gives a measure of the variance in the critical failure value of a population of systems. By quantifying these features for a given parameter, the metrics can be used with any traditional optimization technique, such as Genetic Algorithms, to identify the optimal parameter for a given system. An appropriate parameter may be used with a General Path Model (GPM) approach to make RUL estimates for specific systems or components. A dynamic Bayesian updating methodology is introduced to incorporate prior information in the GPM methodology. The proposed methods are illustrated with two applications: first, to the simulated turbofan engine data provided in the 2008 Prognostics and Health Management Conference Prognostics Challenge and, second, to data collected in a laboratory milling equipment wear experiment. The automated system was shown to identify appropriate parameters in both situations and facilitate Type III prognostic model development

Aerospace medicine and biology: A continuing bibliography with indexes (supplement 323)

This bibliography lists 125 reports, articles and other documents introduced into the NASA Scientific and Technical Information System during April, 1989. Subject coverage includes; aerospace medicine and psychology, life support systems and controlled environments, safety equipment exobiology and extraterrestrial life, and flight crew behavior and performance