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

Luotettavuustiedon kerääminen palveluorganisaatiossa

Planning and assessing the effectiveness of maintenance operations relies heavily on the reliability data of the examined equipment. This data is readily available for equipment owners, but maintenance service providers struggle with acquiring it in quantity and quality needed for comprehensive analysis. Collecting this data would offer significant possibilities to develop both physical and service products for an original equipment manufacturer that also provides maintenance services for its equipment. In this thesis, a method for constructing and implementing a reliability data collection system is developed. During the thesis work, the current state of reliability data collection in the subject company was assessed, available data sources were identified, appropriate analysis tools were chosen, and data collection method and reporting models structured. The thesis is based on literacy research on the topic and interviews of subject company employees. The constructed method provides an iterative process that initially produces a reporting structure based on qualitative analysis of the product. When adequate amount of reliability data is collected, iteration round provides the organization with maintenance recommendations based on quantitative analysis. Analysis tools used in the process are well established and standardised by international standardization organizations.Huoltotoimintojen suunnittelu ja tehokkuuden arviointi nojaa vahvasti tutkittavasta laitteistosta kerättyyn vikaantumis- ja luotettavuusdataan. Tämä tieto on laitteistojen omistajille helposti saatavilla, mutta huoltopalveluiden toimittajille sen kerääminen analyysien vaatimassa laajuudessa on haasteellista. Luotettavuusdatan kerääminen tarjoaa laitteiden ja palveluiden toimittajalle merkittäviä mahdollisuuksia sekä laitteiden että palveluiden tuotekehityksessä. Tässä diplomityössä esitellään luotettavuusdatan keräämisjärjestelmän muodostamiseen ja käyttöönottoon tarkoitetun metodin kehitys. Diplomityön aikana määritettiin datankeräyksen tämänhetkinen tila kohde yrityksessä, tunnistettiin mahdolliset datalähteet, sopivat analysointimenetelmät valittiin ja mallit tiedonkeruuprosessiksi ja raportointi malleiksi kehitettiin. Diplomityö perustuu kirjallisuustutkimukseen ja kohdeyhtiön työntekijöiden haastatteluihin. Muodostettu metodi tarjoaa iteratiivisen prosessin joka tuottaa aluksi kvalitatiiviseen systeemianalyysiin perustuvan raportointi rakenteen. Kun luotettavuusdataan on kerätty tarvittava määrä, seuraava iteraatiokierros tuottaa kvantitatiiviseen analyysiin perustuvan huoltosuosituksen. Prosessissa käytetyt analysointi menetelmät ovat hyvin tunnettuja ja ne on standardoitu kansainvälisten standardointiorganisaatioiden toimesta

An Integrated Fuzzy Inference Based Monitoring, Diagnostic, and Prognostic System

To date the majority of the research related to the development and application of monitoring, diagnostic, and prognostic systems has been exclusive in the sense that only one of the three areas is the focus of the work. While previous research progresses each of the respective fields, the end result is a variable grab bag of techniques that address each problem independently. Also, the new field of prognostics is lacking in the sense that few methods have been proposed that produce estimates of the remaining useful life (RUL) of a device or can be realistically applied to real-world systems. This work addresses both problems by developing the nonparametric fuzzy inference system (NFIS) which is adapted for monitoring, diagnosis, and prognosis and then proposing the path classification and estimation (PACE) model that can be used to predict the RUL of a device that does or does not have a well defined failure threshold. To test and evaluate the proposed methods, they were applied to detect, diagnose, and prognose faults and failures in the hydraulic steering system of a deep oil exploration drill. The monitoring system implementing an NFIS predictor and sequential probability ratio test (SPRT) detector produced comparable detection rates to a monitoring system implementing an autoassociative kernel regression (AAKR) predictor and SPRT detector, specifically 80% vs. 85% for the NFIS and AAKR monitor respectively. It was also found that the NFIS monitor produced fewer false alarms. Next, the monitoring system outputs were used to generate symptom patterns for k-nearest neighbor (kNN) and NFIS classifiers that were trained to diagnose different fault classes. The NFIS diagnoser was shown to significantly outperform the kNN diagnoser, with overall accuracies of 96% vs. 89% respectively. Finally, the PACE implementing the NFIS was used to predict the RUL for different failure modes. The errors of the RUL estimates produced by the PACE-NFIS prognosers ranged from 1.2-11.4 hours with 95% confidence intervals (CI) from 0.67-32.02 hours, which are significantly better than the population based prognoser estimates with errors of ~45 hours and 95% CIs of ~162 hours

Evaluation Of Fuzzy Methods To Determine Probability Of Failure Compared With Rbi Analysis For Pressure Vessel In Oil And Gas Company

Maintenance activities conduct to manage and preserve assets integrity. Risk assessment is used to develop interval inspection hence, maintenance strategy can arrange perfectly. On the other hand, prescriptive inspection is still used as the main consideration to determine the inspection schedule. The consequence is an ineffective inspection activity. Past expert judgement was a major consideration in resulting prescriptive schedule which probably has not been reassessed and updated at present. A quantitative assessment can cover the probability and consequence of failure through a detailed assessment. The assessment takes time to be developed which complex systems and formulas are adjusted to the actual condition. Somehow, this task might be conducted by an external party who has expert knowledge. Therefore, within this schedule vacancy, any deterioration might occur in the system. A qualitative assessment can be done to estimate risk. Local engineers, who have basic knowledge of corrosion and other damage factors, can do the qualitative assessment. The result shall update the previous prescriptive methods. In processing qualitative assessment, fuzzy methods are chosen due to their ability to cover linguistic tasks and numerical value. In this paper, fuzzy logic was used to determine the probability of failure of equipment. The result was compared to API 581 RBI assessment. At the latter, risk value from both methods was evaluated to determine the inspection interval. Both types of equipment have close results from inspection interval calculation. Mostly, the inspection interval from the fuzzy method was earlier than RBI methods. From this calculation, the fuzzy results can be used as an estimation for the local engineer's consideration to determine any inspection based on qualitative assessment. If the result compared with an 8-years prescriptive inspection interval, inspection interval from qualitative assessment earlier conducted. It means asset integrity could be maintained more precisely. The equipment is pressure vessels in the utility area to support the boiler system from an Indonesian oil and gas company

Integrative risk-based assessment modelling of safety-critical marine and offshore applications

This research has first reviewed the current status and future aspects of marine and offshore safety assessment. The major problems identified in marine and offshore safety assessment in this research are associated with inappropriate treatment of uncertainty in data and human error issues during the modelling process. Following the identification of the research needs, this thesis has developed several analytical models for the safety assessment of marine and offshore systems/units. Such models can be effectively integrated into a risk-based framework using the marine formal safety assessment and offshore safety case concepts. Bayesian network (BN) and fuzzy logic (FL) approaches applicable to marine and offshore safety assessment have been proposed for systematically and effectively addressing uncertainty due to randomness and vagueness in data respectively. BN test cases for both a ship evacuation process and a collision scenario between the shuttle tanker and Floating, Production, Storage and Offloading unit (FPSO) have been produced within a cause-effect domain in which Bayes' theorem is the focal mechanism of inference processing. The proposed FL model incorporating fuzzy set theory and an evidential reasoning synthesis has been demonstrated on the FPSO-shuttle tanker collision scenario. The FL and BN models have been combined via mass assignment theory into a fuzzy-Bayesian network (FBN) in which the advantages of both are incorporated. This FBN model has then been demonstrated by addressing human error issues in a ship evacuation study using performance-shaping factors. It is concluded that the developed FL, BN and FBN models provide a flexible and transparent way of improving safety knowledge, assessments and practices in the marine and offshore applications. The outcomes have the potential to facilitate the decision-making process in a risk-based framework. Finally, the results of the research are summarised and areas where further research is required to improve the developed methodologies are outline

Joint application of AI techniques, PRA and disturbance analysis methodology to problems in the maintenance and design of nuclear power plants. Final report

This final report summarizes the accomplishments of a two year research project entitled ``Joint Application of Artificial Intelligence Techniques, Probabilistic Risk Analysis, and Disturbance Analysis Methodology to Problems in the Maintenance and Design of Nuclear Power Plants. The objective of this project is to develop and apply appropriate combinations of techniques from artificial intelligence, (AI), reliability and risk analysis and disturbance analysis to well-defined programmatic problems of nuclear power plants. Reactor operations issues were added to those of design and maintenance as the project progressed

Generic nuclear safety issues : methods of analysis

"Prepared for: Nuclear Safety Analysis Center."Includes bibliographical references (leaves 223-231

Risk-based maintenance of critical and complex systems

Tableau d’honneur de la Faculté des études supérieures et postdoctorales, 2016-2017.De nos jours, la plupart des systèmes dans divers secteurs critiques tels que l'aviation, le pétrole et les soins de santé sont devenus très complexes et dynamiques, et par conséquent peuvent à tout moment s'arrêter de fonctionner. Pour éviter que cela ne se reproduise et ne devienne incontrôlable ce qui engagera des pertes énormes en matière de coûts et d'indisponibilité; l'adoption de stratégies de contrôle et de maintenance s'avèrent plus que nécessaire et même vitale. Dans le génie des procédés, les stratégies optimales de maintenance pour ces systèmes pourraient avoir un impact significatif sur la réduction des coûts et sur les temps d'arrêt, sur la maximisation de la fiabilité et de la productivité, sur l'amélioration de la qualité et enfin pour atteindre les objectifs souhaités des compagnies. En outre, les risques et les incertitudes associés à ces systèmes sont souvent composés de plusieurs relations de cause à effet de façon extrêmement complexe. Cela pourrait mener à une augmentation du nombre de défaillances de ces systèmes. Par conséquent, un outil d'analyse de défaillance avancée est nécessaire pour considérer les interactions complexes de défaillance des composants dans les différentes phases du cycle de vie du produit pour assurer les niveaux élevés de sécurité et de fiabilité. Dans cette thèse, on aborde dans un premier temps les lacunes des méthodes d'analyse des risques/échec et celles qui permettent la sélection d'une classe de stratégie de maintenance à adopter. Nous développons ensuite des approches globales pour la maintenance et l'analyse du processus de défaillance fondée sur les risques des systèmes et machines complexes connus pour être utilisées dans toutes les industries. Les recherches menées pour la concrétisation de cette thèse ont donné lieu à douze contributions importantes qui se résument comme suit: Dans la première contribution, on aborde les insuffisances des méthodes en cours de sélection de la stratégie de maintenance et on développe un cadre fondé sur les risques en utilisant des méthodes dites du processus de hiérarchie analytique (Analytical Hierarchy Process (AHP), de cartes cognitives floues (Fuzzy Cognitive Maps (FCM)), et la théorie des ensembles flous (Fuzzy Soft Sets (FSS)) pour sélectionner la meilleure politique de maintenance tout en considérant les incertitudes. La deuxième contribution aborde les insuffisances de la méthode de l'analyse des modes de défaillance, de leurs effets et de leur criticité (AMDEC) et son amélioration en utilisant un modèle AMDEC basée sur les FCM. Les contributions 3 et 4, proposent deux outils de modélisation dynamique des risques et d'évaluation à l'aide de la FCM pour faire face aux risques de l'externalisation de la maintenance et des réseaux de collaboration. Ensuite, on étend les outils développés et nous proposons un outil d'aide à la décision avancée pour prédire l'impact de chaque risque sur les autres risques ou sur la performance du système en utilisant la FCM (contribution 5).Dans la sixième contribution, on aborde les risques associés à la maintenance dans le cadre des ERP (Enterprise Resource Planning (ERP)) et on propose une autre approche intégrée basée sur la méthode AMDEC floue pour la priorisation des risques. Dans les contributions 7, 8, 9 et 10, on effectue une revue de la littérature concernant la maintenance basée sur les risques des dispositifs médicaux, puisque ces appareils sont devenus très complexes et sophistiqués et l'application de modèles de maintenance et d'optimisation pour eux est assez nouvelle. Ensuite, on développe trois cadres intégrés pour la planification de la maintenance et le remplacement de dispositifs médicaux axée sur les risques. Outre les contributions ci-dessus, et comme étude de cas, nous avons réalisé un projet intitulé “Mise à jour de guide de pratique clinique (GPC) qui est un cadre axé sur les priorités pour la mise à jour des guides de pratique cliniques existantes” au centre interdisciplinaire de recherche en réadaptation et intégration sociale du Québec (CIRRIS). Nos travaux au sein du CIRRIS ont amené à deux importantes contributions. Dans ces deux contributions (11e et 12e) nous avons effectué un examen systématique de la littérature pour identifier les critères potentiels de mise à jour des GPCs. Nous avons validé et pondéré les critères identifiés par un sondage international. Puis, sur la base des résultats de la onzième contribution, nous avons développé un cadre global axé sur les priorités pour les GPCs. Ceci est la première fois qu'une telle méthode quantitative a été proposée dans la littérature des guides de pratiques cliniques. L'évaluation et la priorisation des GPCs existants sur la base des critères validés peuvent favoriser l'acheminement des ressources limitées dans la mise à jour de GPCs qui sont les plus sensibles au changement, améliorant ainsi la qualité et la fiabilité des décisions de santé.Today, most systems in various critical sectors such as aviation, oil and health care have become very complex and dynamic, and consequently can at any time stop working. To prevent this from reoccurring and getting out of control which incur huge losses in terms of costs and downtime; the adoption of control and maintenance strategies are more than necessary and even vital. In process engineering, optimal maintenance strategies for these systems could have a significant impact on reducing costs and downtime, maximizing reliability and productivity, improving the quality and finally achieving the desired objectives of the companies. In addition, the risks and uncertainties associated with these systems are often composed of several extremely complex cause and effect relationships. This could lead to an increase in the number of failures of such systems. Therefore, an advanced failure analysis tool is needed to consider the complex interactions of components’ failures in the different phases of the product life cycle to ensure high levels of safety and reliability. In this thesis, we address the shortcomings of current failure/risk analysis and maintenance policy selection methods in the literature. Then, we develop comprehensive approaches to maintenance and failure analysis process based on the risks of complex systems and equipment which are applicable in all industries. The research conducted for the realization of this thesis has resulted in twelve important contributions, as follows: In the first contribution, we address the shortcomings of the current methods in selecting the optimum maintenance strategy and develop an integrated risk-based framework using Analytical Hierarchy Process (AHP), fuzzy Cognitive Maps (FCM), and fuzzy Soft set (FSS) tools to select the best maintenance policy by considering the uncertainties.The second contribution aims to address the shortcomings of traditional failure mode and effect analysis (FMEA) method and enhance it using a FCM-based FMEA model. Contributions 3 and 4, present two dynamic risk modeling and assessment tools using FCM for dealing with risks of outsourcing maintenance and collaborative networks. Then, we extend the developed tools and propose an advanced decision support tool for predicting the impact of each risk on the other risks or on the performance of system using FCM (contribution 5). In the sixth contribution, we address the associated risks in Enterprise Resource Planning (ERP) maintenance and we propose another integrated approach using fuzzy FMEA method for prioritizing the risks. In the contributions 7, 8, 9, and 10, we perform a literature review regarding the risk-based maintenance of medical devices, since these devices have become very complex and sophisticated and the application of maintenance and optimization models to them is fairly new. Then, we develop three integrated frameworks for risk-based maintenance and replacement planning of medical devices. In addition to above contributions, as a case study, we performed a project titled “Updating Clinical Practice Guidelines; a priority-based framework for updating existing guidelines” in CIRRIS which led to the two important contributions. In these two contributions (11th and 12th) we first performed a systematic literature review to identify potential criteria in updating CPGs. We validated and weighted the identified criteria through an international survey. Then, based on the results of the eleventh contribution, we developed a comprehensive priority-based framework for updating CPGs based on the approaches that we had already developed and applied success fully in other industries. This is the first time that such a quantitative method has been proposed in the literature of guidelines. Evaluation and prioritization of existing CPGs based on the validated criteria can promote channelling limited resources into updating CPGs that are most sensitive to change, thus improving the quality and reliability of healthcare decisions made based on current CPGs. Keywords: Risk-based maintenance, Maintenance strategy selection, FMEA, FCM, Medical devices, Clinical practice guidelines

Establishment of a novel predictive reliability assessment strategy for ship machinery

There is no doubt that recent years, maritime industry is moving forward to novel and sophisticated inspection and maintenance practices. Nowadays maintenance is encountered as an operational method, which can be employed both as a profit generating process and a cost reduction budget centre through an enhanced Operation and Maintenance (O&M) strategy. In the first place, a flexible framework to be applicable on complex system level of machinery can be introduced towards ship maintenance scheduling of systems, subsystems and components.;This holistic inspection and maintenance notion should be implemented by integrating different strategies, methodologies, technologies and tools, suitably selected by fulfilling the requirements of the selected ship systems. In this thesis, an innovative maintenance strategy for ship machinery is proposed, namely the Probabilistic Machinery Reliability Assessment (PMRA) strategy focusing towards the reliability and safety enhancement of main systems, subsystems and maintainable units and components.;In this respect, the combination of a data mining method (k-means), the manufacturer safety aspects, the dynamic state modelling (Markov Chains), the probabilistic predictive reliability assessment (Bayesian Belief Networks) and the qualitative decision making (Failure Modes and Effects Analysis) is employed encompassing the benefits of qualitative and quantitative reliability assessment. PMRA has been clearly demonstrated in two case studies applied on offshore platform oil and gas and selected ship machinery.;The results are used to identify the most unreliability systems, subsystems and components, while advising suitable practical inspection and maintenance activities. The proposed PMRA strategy is also tested in a flexible sensitivity analysis scheme.There is no doubt that recent years, maritime industry is moving forward to novel and sophisticated inspection and maintenance practices. Nowadays maintenance is encountered as an operational method, which can be employed both as a profit generating process and a cost reduction budget centre through an enhanced Operation and Maintenance (O&M) strategy. In the first place, a flexible framework to be applicable on complex system level of machinery can be introduced towards ship maintenance scheduling of systems, subsystems and components.;This holistic inspection and maintenance notion should be implemented by integrating different strategies, methodologies, technologies and tools, suitably selected by fulfilling the requirements of the selected ship systems. In this thesis, an innovative maintenance strategy for ship machinery is proposed, namely the Probabilistic Machinery Reliability Assessment (PMRA) strategy focusing towards the reliability and safety enhancement of main systems, subsystems and maintainable units and components.;In this respect, the combination of a data mining method (k-means), the manufacturer safety aspects, the dynamic state modelling (Markov Chains), the probabilistic predictive reliability assessment (Bayesian Belief Networks) and the qualitative decision making (Failure Modes and Effects Analysis) is employed encompassing the benefits of qualitative and quantitative reliability assessment. PMRA has been clearly demonstrated in two case studies applied on offshore platform oil and gas and selected ship machinery.;The results are used to identify the most unreliability systems, subsystems and components, while advising suitable practical inspection and maintenance activities. The proposed PMRA strategy is also tested in a flexible sensitivity analysis scheme