Implementation of lean principles for performance improvement: Use of VSM+WID for waste identification

This article demonstrates the implementation of lean principles for performance improvement in a manufacturing firm. Value stream mapping and waste identification diagrams (VSM+WID) are integrated to assess the level of currently existing waste and the overall current status of the manufacturing flow. The VSM+WID enables an increase in the awareness of relative waste distribution among different processes in the selected case study manufacturing unit. This manuscript demonstrates how to use VSM+WID to understand the current status of the manufacturing flow related challenges such as: overproduction, work-in-process, inefficient use of man-hours (e.g. unbalanced work distribution), etc. It also demonstrates the effectiveness of visualization of the performance gap between the current and future state. The aforementioned type of performance assessment enables effective identification of waste present in a manufacturing flow in order for future improvement initiatives to be taken.This work has been supported by COMPETE: POCI-01-0145-FEDER-007043 and FCT – Fundação para a Ciência e Tecnologia within the Project Scope: UID/CEC/00319/2013

Digitization Methods of Grinding Pins for Technological Process Planning

The paper presents different techniques for digitizing grinding pins and discusses the use of digitalized pins and the results of measurements in technological process planning (TPP), focusing on the challenges of the digital era. It describes the potential of different measuring devices, taking into account the digitization of a real tool shape into virtual 2D and 3D models. The following methods for measuring grinding pins are presented in the study: contact and non-contact coordinate measurements – performed on coordinate measuring machines (CMM); optical measurements on microscopes (i.e. focus-variation technique); optical measurements using tool presetters; optical measurements with measuring arm; laser micrometer measurements; and laser triangulation sensor measurements. Moreover, the use of testers which are applied in contour measurements is analyzed. On the basis of the presented methods, taking into account their possibilities and limitations, we discuss how the obtained digital data can be used in the planning of technological processes.publishedVersio

A Decision Model for Executing Plant Strategy: Maintaining the Technical Integrity of Petroleum Flowlines

Copyright © 2012 Inderscience Enterprises Ltd.The ‘strategic’ management of technical integrity has become a high profile subject matter over recent years within inspection and maintenance of assets in the process industry. The assets such as production and process facilities require being optimised, prioritised and cost-effective inspection and maintenance, depending on whether they are at the beginning or end of their design life. In both cases, it is vital to ensure that sufficient condition monitoring data from all relevant sources are collated and analysed as a part in a planned scheme of inspection and maintenance. This is largely driven by certifying authority requirements, sound mechanical and corrosion engineering principles as well as inspection and maintenance approaches, indicated in a plant strategy. This manuscript suggests a model to execute plant strategy using analytic hierarchy process method. The model indicates the incorporation of requirements specified in a plant strategy for reaching optimised, prioritised and cost-effective outcome

Risk-based maintenance assessment in the manufacturing industry: minimisation of suboptimal prioritisation

Manufacturing firms continuously strive to increase the efficiency and effectiveness in the maintenance management processes. Focus is placed on eliminating the unexpected failures which cause unnecessary costs and the production losses. Risk-based maintenance (RBM) strategies enable to address the above through the identification of probability and consequences of potential failures whilst providing a way for prioritisation of maintenance actions based on the risk of possible failures. Such prioritisations enable to identify the optimal maintenance strategy, intervals of maintenance tasks, and optimal level of spare parts inventory. However, the risk assessment activities are performed with the support of a risk matrix. Suboptimal classifications and/or prioritisations arise due to the inherent nature of the risk matrix. This is caused by the fact that there are no means to incorporate actual circumstances at the boundary of the input ranges or at the levels of linguistic data and risk categories. In this paper, a risk matrix is first developed in collaboration with one of the manufacturing firms in Poland. Then, it illustrates the use of fuzzy logic for minimisation of suboptimal prioritisation and/or classifications using a fuzzy inference system (FIS) together with illustrative membership functions and a rule base. Finally, an illustrative risk assessment is also demonstrated to illustrate the methodology

Management of Tags and Tag-related Technical Information in Small and Large Scale Modifications: An Application for a Drilling Rig

Abstract: Considerable amount of Oil and Gas (O&G) production and process installations operating in the North Sea are getting aged and requiring continuous modifications. Nature of such contractual jobs is relatively short term with demanding deliverables. Hence, the engineering contractors require excellent coordination and seamless communication during all phases of a project. For any contractor/supplier, it is of utmost importance to ensure that equipment related technical information is made available at the right time to avoid any unexpected project delays. Experience shows that poor coordination among project participants can result in failing to comply with regulatory and governing requirements. Also, there are other challenges to managing tags, databases and tag history as well as keeping technical information integrity. This manuscript illustrates role of a tag management system developed by an engineering contractor company which provides services to operators in NCS. The particular system is developed and customized to meet a drilling rig client's specification

Development of a Procedure for Risk-Based Qualification of Additively Manufactured Components: Adopting to Oil and Gas Industrial Applications

Recent advances in additive manufacturing (AM) technology provide the potential for on-demand and rapid production of spare parts during urgent repair times. Recently, big oil and gas companies have shown early progress in using additive technology in manufacturing specific heat exchangers, downhole cleanout tool nozzles, offshore risers, gas turbine nozzles, and subsea chemical stick injection tools. Despite the mentioned progress, the current adoption level of additive technology for the offshore oil and gas industry is very limited. Non-destructive and destructive evaluation methods of additively manufactured metallic components have been studied extensively. However, the technique selection procedure and scope of the required test methods have not been studied sufficiently. This paper discusses various elements related to the qualification of additively manufactured components for application in the oil and gas industry. A risk-based qualification method for identifying the scopes of required non-destructive and destructive tests and the resulting qualification procedure for additively manufactured spare components in offshore oil and gas applications is suggested

Development of a Procedure for Risk-Based Qualification of Additively Manufactured Components: Adopting to Oil and Gas Industrial Applications

Recent advances in additive manufacturing (AM) technology provide the potential for on-demand and rapid production of spare parts during urgent repair times. Recently, big oil and gas companies have shown early progress in using additive technology in manufacturing specific heat exchangers, downhole cleanout tool nozzles, offshore risers, gas turbine nozzles, and subsea chemical stick injection tools. Despite the mentioned progress, the current adoption level of additive technology for the offshore oil and gas industry is very limited. Non-destructive and destructive evaluation methods of additively manufactured metallic components have been studied extensively. However, the technique selection procedure and scope of the required test methods have not been studied sufficiently. This paper discusses various elements related to the qualification of additively manufactured components for application in the oil and gas industry. A risk-based qualification method for identifying the scopes of required non-destructive and destructive tests and the resulting qualification procedure for additively manufactured spare components in offshore oil and gas applications is suggested

Finite Element Analysis of Steel Plates with Rectangular Openings Subjected to Axial Stress

Steel plates with openings are among the important ship structural components used in the ship’s hull to withstand the hydrostatic forces of the ocean, which cause sagging and hogging moments at the ship’s bottom. The existence of openings on plates can cause structural rupture, stress concentration and a decrease in ultimate strength. This research is aimed at investigating the influence of selected parameters on the ultimate capacity of steel plates with rectangular holes subjected to axial stress, using ANSYS finite element analysis (FEA) under its non-linear static structural programme. The main parameters investigated in this paper are the plate thickness, opening aspect ratio, number of openings, position of openings, and the boundary condition of the plate. The influence of these parameters on the stress of plates and their deformation was evaluated. The comparison of the numerical simulation with the well-established analytical method using the Navier solution and Roark’s Formulas showed a good agreement

Thin-Walled Cylindrical Shell Storage Tank under Blast Impacts: Finite Element Analysis

Thin-walled cylindrical shell storage tanks are pressure vessels in which the walls of the vessel have a thickness that is much smaller than the overall size of the vessel. These types of structures have global applications in various industries, including oil refineries and petrochemical plants. However, these storage tanks are vulnerable to fire and explosions. Therefore, a parametric study using numerical simulation was carried out, considering the internal liquid level, wall thickness, material yield strength, constraint conditions, and blast intensity, with a diameter of 100 m and height of 22.5 m under different blast loads using the finite element analysis method. The thickness of the tank wall is varied as 10 mm, 20 mm, 30 mm, and 40 mm, while the fill level of internal fluid is varied as 25, 50, 75, and 100%. The blast simulation was conducted using LS-DYNA software. The numerical results are then compared with analytical results. The effects of blast intensity, standoff distance, wall thickness, and fill level of internal fluid on the structural behaviour of the storage tank were investigated and discussed