Continuous maintenance and the future – Foundations and technological challenges

High value and long life products require continuous maintenance throughout their life cycle to achieve required performance with optimum through-life cost. This paper presents foundations and technologies required to offer the maintenance service. Component and system level degradation science, assessment and modelling along with life cycle ‘big data’ analytics are the two most important knowledge and skill base required for the continuous maintenance. Advanced computing and visualisation technologies will improve efficiency of the maintenance and reduce through-life cost of the product. Future of continuous maintenance within the Industry 4.0 context also identifies the role of IoT, standards and cyber security

Hybrid modeling to support the smart manufacturing: concepts, theoretic contributions and real-case applications about Hybrid and Wisdom-based Systems

L'abstract è presente nell'allegato / the abstract is in the attachmen

A Collection of Technical Papers

Papers presented at the 6th Space Logistics Symposium covered such areas as: The International Space Station; The Hubble Space Telescope; Launch site computer simulation; Integrated logistics support; The Baikonur Cosmodrome; Probabalistic tools for high confidence repair; A simple space station rescue vehicle; Integrated Traffic Model for the International Space Station; Packaging the maintenance shop; Leading edge software support; Storage information management system; Consolidated maintenance inventory logistics planning; Operation concepts for a single stage to orbit vehicle; Mission architecture for human lunar exploration; Logistics of a lunar based solar power satellite scenario; Just in time in space; NASA acquisitions/logistics; Effective transition management; Shuttle logistics; and Revitalized space operations through total quality control management

Urban and extra-urban hybrid vehicles: a technological review

Pollution derived from transportation systems is a worldwide, timelier issue than ever. The abatement actions of harmful substances in the air are on the agenda and they are necessary today to safeguard our welfare and that of the planet. Environmental pollution in large cities is approximately 20% due to the transportation system. In addition, private traffic contributes greatly to city pollution. Further, “vehicle operating life” is most often exceeded and vehicle emissions do not comply with European antipollution standards. It becomes mandatory to find a solution that respects the environment and, realize an appropriate transportation service to the customers. New technologies related to hybrid –electric engines are making great strides in reducing emissions, and the funds allocated by public authorities should be addressed. In addition, the use (implementation) of new technologies is also convenient from an economic point of view. In fact, by implementing the use of hybrid vehicles, fuel consumption can be reduced. The different hybrid configurations presented refer to such a series architecture, developed by the researchers and Research and Development groups. Regarding energy flows, different strategy logic or vehicle management units have been illustrated. Various configurations and vehicles were studied by simulating different driving cycles, both European approval and homologation and customer ones (typically municipal and university). The simulations have provided guidance on the optimal proposed configuration and information on the component to be used

Transferring knowledge of manufacturing techniques within a subsidiary of a multi-national corporation

With the growth of the multi-national corporation (MNCs) has come the need to understand how parent companies transfer knowledge to, and manage the operations of, their subsidiaries. This is of particular interest to manufacturing companies transferring their operations overseas. Japanese companies in particular have been pioneering in the development of techniques such as Kaizen, and elements of the Toyota Production System (TPS) such as Kanban, which can be useful tools for transferring the ethos of Japanese manufacturing and maintaining quality and control in overseas subsidiaries. Much has been written about the process of transferring Japanese manufacturing techniques but much less is understood about how the subsidiaries themselves – which are required to make use of such techniques – actually acquire and incorporate them into their operations. This research therefore takes the perspective of the subsidiary in examining how knowledge of manufacturing techniques is transferred from the parent company within its surrounding (subsidiary). There is clearly a need to take a practice-based view to understanding how the local managers and operatives incorporate this knowledge into their working practices. A particularly relevant theme is how subsidiaries both replicate and adapt knowledge from parents and the circumstances in which replication or adaptation occurs. However, it is shown that there is a lack of research which takes an in-depth look at these processes from the perspective of the participants themselves. This is particularly important as much knowledge literature argues that knowledge is best viewed as enacted and learned in practice – and therefore transferred in person – rather than by the transfer of abstract and de-contextualised information. What is needed, therefore, is further research which makes an in-depth examination of what happens at the subsidiary level for this transfer process to occur. There is clearly a need to take a practice-based view to understanding how the local managers and operatives incorporate knowledge about manufacturing techniques into their working practices. In depth qualitative research was, therefore, conducted in the subsidiary of a Japanese multinational, Gambatte Corporation, involving three main manufacturing initiatives (or philosophies), namely 'TPS‘, 'TPM‘ and 'TS‘. The case data were derived from 52 in-depth interviews with project members, moderate-participant observations, and documentations and presented and analysed in episodes format. This study contributes to our understanding of knowledge transfer in relation to the approaches and circumstances of adaptation and replication of knowledge within the subsidiary, how the whole process is developed, and also how 'innovation‘ takes place. This study further understood that the process of knowledge transfer could be explained as a process of Reciprocal Provider-Learner Exchange that can be linked to the Experiential Learning Theory

Analysis Of An Order Fulfilment Process At A Metalwork Company Using Different Lean Methodologies

This article presents the analysis of a process by using four distinct approaches, each of them recurring to different Lean tools in order to get a detailed and multidimensional overview of the process. The primary objective of this study was to identify activities which add value in the order fulfilment process of a metalwork company. In this context, one also addressed issues such as waste, problems and their causes, in order to define intervention priorities and select actions capable to enhance the performance and efficiency of the process. The secondary objective was to evaluate and compare the results of the analysis made through different mapping techniques. From this study results the proposal of a tool to identify perceived micro-inefficiencies, as well as the impact of these on the production sub-process. Designated as Perceived Waste Mapping (PWM), this method allowed one to estimate that the ratio between the value-added hours and the total number of work hours at the company will be approximately 30%, far from the figure of 84% registered in the existing time and production records.info:eu-repo/semantics/publishedVersio

Modelo de apoio à decisão para a manutenção condicionada de equipamentos produtivos

Doctoral Thesis for PhD degree in Industrial and Systems EngineeringIntroduction: This thesis describes a methodology to combine Bayesian control chart and CBM (Condition-Based Maintenance) for developing a new integrated model. In maintenance management, it is a challenging task for decision-maker to conduct an appropriate and accurate decision. Proper and well-performed CBM models are beneficial for maintenance decision making. The integration of Bayesian control chart and CBM is considered as an intelligent model and a suitable strategy for forecasting items failures as well as allow providing an effectiveness maintenance cost. CBM models provides lower inventory costs for spare parts, reduces unplanned outage, and minimize the risk of catastrophic failure, avoiding high penalties associated with losses of production or delays, increasing availability. However, CBM models need new aspects and the integration of new type of information in maintenance modeling that can improve the results. Objective: The thesis aims to develop a new methodology based on Bayesian control chart for predicting failures of item incorporating simultaneously two types of data: key quality control measurement and equipment condition parameters. In other words, the project research questions are directed to give the lower maintenance costs for real process control. Method: The mathematical approach carried out in this study for developing an optimal Condition Based Maintenance policy included the Weibull analysis for verifying the Markov property, Delay time concept used for deterioration modeling and PSO and Monte Carlo simulation. These models are used for finding the upper control limit and the interval monitoring that minimizes the (maintenance) cost function. Result: The main contribution of this thesis is that the proposed model performs better than previous models in which the hypothesis of using simultaneously data about condition equipment parameters and quality control measurements improve the effectiveness of integrated model Bayesian control chart for Condition Based Maintenance.Introdução: Esta tese descreve uma metodologia para combinar Bayesian control chart e CBM (Condition- Based Maintenance) para desenvolver um novo modelo integrado. Na gestão da manutenção, é importante que o decisor possa tomar decisões apropriadas e corretas. Modelos CBM bem concebidos serão muito benéficos nas tomadas de decisão sobre manutenção. A integração dos gráficos de controlo Bayesian e CBM é considerada um modelo inteligente e uma estratégica adequada para prever as falhas de componentes bem como produzir um controlo de custos de manutenção. Os modelos CBM conseguem definir custos de inventário mais baixos para as partes de substituição, reduzem interrupções não planeadas e minimizam o risco de falhas catastróficas, evitando elevadas penalizações associadas a perdas de produção ou atrasos, aumentando a disponibilidade. Contudo, os modelos CBM precisam de alterações e a integração de novos tipos de informação na modelação de manutenção que permitam melhorar os resultados.Objetivos: Esta tese pretende desenvolver uma nova metodologia baseada Bayesian control chart para prever as falhas de partes, incorporando dois tipos de dados: medições-chave de controlo de qualidade e parâmetros de condição do equipamento. Por outras palavras, as questões de investigação são direcionadas para diminuir custos de manutenção no processo de controlo.Métodos: Os modelos matemáticos implementados neste estudo para desenvolver uma política ótima de CBM incluíram a análise de Weibull para verificação da propriedade de Markov, conceito de atraso de tempo para a modelação da deterioração, PSO e simulação de Monte Carlo. Estes modelos são usados para encontrar o limite superior de controlo e o intervalo de monotorização para minimizar a função de custos de manutenção.Resultados: A principal contribuição desta tese é que o modelo proposto melhora os resultados dos modelos anteriores, baseando-se na hipótese de que, usando simultaneamente dados dos parâmetros dos equipamentos e medições de controlo de qualidade. Assim obtém-se uma melhoria a eficácia do modelo integrado de Bayesian control chart para a manutenção condicionada

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

Industry 4.0 (also referred to as digitization of manufacturing) is characterized by cyber physical systems, automation, and data exchange. It is no longer a future trend and is being employed worldwide by manufacturing organizations, to gain benefits of improved performance, reduced inefficiencies, and lower costs, while improving flexibility. However, the implementation of Industry 4.0 enabling technologies is a difficult task and becomes even more challenging without any standardized approach. The barriers include, but are not limited to, lack of knowledge, inability to realistically quantify the return on investment, and lack of a skilled workforce. This study presents a systematic and content-centric literature review of Industry 4.0 enabling technologies, to highlight their impact on the manufacturing industry. It also provides a strategic roadmap for the implementation of Industry 4.0, based on lean six sigma approaches. The basis of the roadmap is the design for six sigma approach for the development of a new process chain, followed by a continuous improvement plan. The reason for choosing lean six sigma is to provide manufacturers with a sense of familiarity, as they have been employing these principles for removing waste and reducing variability. Major reasons for the rejection of Industry 4.0 implementation methodologies by manufactures are fear of the unknown and resistance to change, whereas the use of lean six sigma can mitigate them. The strategic roadmap presented in this paper can offer a holistic view of phases that manufacturers should undertake and the challenges they might face in their journey toward Industry 4.0 transition

Analysis and improvement of a bottling line using a simulation modelling approach

This project thesis is focused on the study of a bottling production line using a modelling simulation method, through which we analyse the inefficiencies and then improve their performance. Moreover, the line is also analysed thorugh an analytic approach applying a formula to optimize the buffer sizing. The two approachs are compared to highlight the differences