Description
Measurement is the assignment of numbers to objects or events. It is a cornerstone of most natural sciences, technology, economics, and quantitative research in other social sciences.
Study on Measurement Techniques Used for Condition Monitoring
Table of contents: page No.
1. Report 1: 1.1. 1.2. Measurement techniques used for condition monitoring 3-5 References 6
2. Report 2: 2.1. 2.2. TPM and RCM References 7-9 10
3. Repot 3: 3.1. Maintenance Strategies utilising Energy Efficient technologies 11 3.2. References 12
4. Report 4: 4.1. Lean Maintenance 15 4.2. References 1316
Word count: 0
REPORT 1: Measurement techniques used for condition monitoring
The different measurement techniques which are used for condition monitoring such techniques are vibration measurement and analysis technique, infrared thermograph, oil analysis techniques, ultrasonic imaging, and power, energy and current monitoring techniques. Also, an explanation on how the equipment is used in measuring condition monitoring the different practical usage and their application. In addition to the measurement techniques equipments and on what application they are used, details of the faults that could be detected and fixed in the machines. So, the basic measurement techniques which will be explained for condition monitoring are: • • • • Vibration analysis/Vibration monitoring Acoustic emission Oil analysis Thermography/thermal imaging
Vibration analysis: Many early failure of machine or plant can be detected using vibration analysis technique. Vibration analysis is the most important and usually the more used technique in prediction and condition monitoring, the data taken from the analysis can be compared to previous analysis that is done on the machine or equipment and then compared to previous data in this way a failure can be detected by comparing the data together so
maintenance can take place. Vibration analysis mainly used and monitored in bearings of an equipment or machine for example inside a shaft, wherever there is a vibration a wave is transmitted and this wave is then measured and compared to previous readings if there is an alteration of the waves then there is a fault in the bearing or shaft. So, this is without doubt one of the important techniques to detect faults in rotating equipment (scheffer and Girdhar, 2004).
Faults • • • • • • • • • • • •
due to vibration that can be detected in machines are: Unbalance of rotating parts Misalignment of couplings and bearings Bent shafts Worn or damaged gears and bearings Bad drive belts and chains Torque variations Electromagnetic forces Aerodynamic forces Hydraulic forces Looseness Rubbing Resonance (scheffer and Girdhar, 2004).
Acoustic emission: Acoustic emission is used to follow and determine where the cracks occur in pipes and machines. Acoustic emission was invented for non-destructive testing of machinery; however, its application has been extended to monitoring of rotating machines and bearings. It offers the advantage of earlier defect detection in comparison to vibration analysis it was noted that signals detected in the AE frequency range represented bearing defects rather than other defects such as; • imbalance • misalignment • looseness • shaft bending (Choudhury and Tandon, 2000).
Oil analysis: In this measurement technique, oil is analysed and the level of lubrication is determined as time passes particles accumulate in the oil and makes the bearings and parts weir (scheffer and Girdhar, 2004). Sometime infrared technologies are used to measure the mass of particles in the oil and by knowing the age of the oil and how long it is been used for the performance level of the machine can be determined.
There are many parameters which affect the condition of the oil and can be measured such as: • the temperature • the amount of water (the color of the oil is an indication of water presence if the oil is brown than water is present) • air in the oil • the particles present in the oil (Raadnui and Kleesuwan, 2005). Thermography/thermal imaging: Thermography or thermal imaging used to detect active electrical and mechanical equipment. The method can detect: • • thermal due to heat and mechanical problems in engines and generators high voltage (HV) lines like electrical power lines and many other defects
the primary thermal analysis techniques and methods are: • temperature differential thermal analysis differential thermometer • heat flow difference by differential scanning calorimetry • magnetic properties by thermoelectric analysis • optical properties, acoustic properties (Brown, 2001).
Condition monitoring is done by using many advanced technologies to determine, predict and fix any equipment condition and avoid failures of equipment. It is extremely important to monitor the condition of equipment because of many factors and the most important factor is cost. If the equipment failed the cost of fixing or maintain the equipment is high so before the equipment can fail we can monitor its condition and fix any problems that will result from running the equipment.
References: Choudhury, A. and Tandon, N (2000), Application of acoustic emission technique for the detection of defects in rolling element bearings, Tribology International, 33, PP.39-45 Cornelius Scheffer Ph.D MEng, Paresh Girdhar B.Eng MechEng (2004). Practical machinery vibration analysis and predictive maintenance, Elsevier: UK. PP.8, 22-23, 168. Michael E. Brown (2001), introduction to thermal analysis: techniques and applications, second edition, Kluwer academic publishers USA. PP.6-8 Surapol Raadnui, Srawut Kleesuwan (2005)," Low-cost condition monitoring sensor for used oil analysis", Wear, 259(7–12), PP. 1502-1506
REPORT 2: TPM and RCM
Bothe Total Productive Maintenance (TPM) and Reliability Centred Maintenance (RCM) are maintenance techniques that evolved and are used by maintenance departments in many countries, both are based on maintenance strategies. When we talk about total productive maintenance we want to achieve maximum equipment effectiveness through involving all employees.
TPM: As introduced earlier TPM is a process that involves all employees from management to operators, technicians and maintenance crew. TPM consists of eight very important pillars that makes a unique and efficient and maintenance and productivity according to (Borris, 2005) are: 1. health and safety; the main aim of health and safety is to train operators not to have accidents during their operation of equipments or machines. 2. Training; in many organizations training is not done properly, training needs to be always updated by new training methods and the operators need to have focused training. Without training TPM well not be useful 3. Autonomous maintenance; to send engineers to do the maintenance will cost the organization plenty, so if operators can perform the maintenance then this will save money and valuable time for the organization by preventing the equipment or machine from failing and waste time on waiting for the engineer to fix it
4. Planned maintenance; basically scheduled and planned proper checks for the machine to prevent the cause of failure. By doing so the machine or equipment usually Overall equipment efficiency (OEE) is used by TPM in planned maintenance 5. Quality maintenance; quality in the product produced is achieved by eliminating the differences between each product. Usually a team focuses on delivering best products through avoiding the machine faults in production 6. Focused improvement; through reducing costs of maintenance 7. Support systems; all the departments in an organization should support by any means the maintenance process from the storage facilities to purchasing and quality control. 8. Initial phase management; in the organization there shoud be a stage where the planning of production is considered in all it's stages from the satge of caring to the customer need to the satge of purchasing raw materials to make the product A key to TPM is restoring the equipment to its original condition (Borris, 2005). By restoring the equipment to its original condition we gain equipment that is brand new as if we have bought new equipment, it won't be necessary to buy new equipment or replace an existing equipment all this is done through TPM. So we don't want to ignore any aspect of maintenance for example if you are driving a car and all the four wheels are running fine then the spare tire would be ignored because it's not needed now! So, through getting the equipment back on its original condition avoid having and encountering future problems. in Reliability centred maintenance RCM this is called function failure according to According to (Moubray,1991). TPM can be used in different industries, one of the main industries it can be used is food industry. In the case study (Tsarouhas, 2007) TPM can be used to increase the production rate and improve quality and provide a safer work environment. the production rate can be measured through the overall equipment effectivnee (OEE). RCM: reliability centred maintenance
•
The definition given by John Moubray of Reliability Centred Maintenance is: the process used to determine the maintenance requirements of any physical asset in its operating context (Moubray, 1991) that means managing the equipment or machine and maintaining it running in accordance to any need that the equipment might require from the operation point of view.
The seven basic questions that should be checked when applying RCM as listed by Moubray taken from SAE standard JA1011 (SAE, 1999) are: 1. 2. 3. 4. 5. 6. 7. What are the Functions and operating standards in the present operation? In what ways does it fail? What are the causes of each failure? What happens when failures occur? How each failure matter? What can be done in case of failure? What should be done if an appropriate task cannot be found?
Fig. 1. Example of RCM logic ( Carretero et al, 2003) As shown in figure 1. An RCM logic is applied schedules of maintenance are done according to the failure. RCM is preventive maintenance strategy used to prevent functional failures rather than protect the equipment so preventive maintenance will avoid the failure before it occurs this is done by frequent oil changes to engines, vibration analysis and other maintenance techniques (Hui et al, 2013). As for the TPM, RCM can be used in different kind of industries. An example would be the textile industry, due to the machines preciseness and accuracy for example the needles which net and all the small components of the machines, all these elements need to be reliable and operate to prevent any failure (Shyjith et al, 2008). The basic goals of TPM are to make a co-operation between all employees and departments to maintain the machines that include involving the operators, technicians and maintenance employees in the process. Management operators and maintenance are all participants in TPM the
key to machine effectiveness and stability is the involvement of all employees. RCM more on keeping the equipment or machine running and on operation, TPM and RCM the management techniques are both maintenance techniques that derive effective fixing and preventing of failure of the equipment.
References: J Carretero, JM Pérez, F García-Carballeira, A Calderón, J Fernández, JD García et al (2003). Applying RCM in large scale systems: a case study with railway networks Reliability Engineering and System Safety, pp. 257– 273 J. Moubray (1991), Reliability Centred Maintenance, ButterworthHeinemann, pp.7-9 K. Shyjith, M. Ilangkumaran, S. Kumanan, (2008) "Multi-criteria decisionmaking approach to evaluate optimum maintenance strategy in textile industry", Journal of Quality in Maintenance Engineering, 14(4), pp.375 – 386 Panagiotis Tsarouhas, (2007) "Implementation of total productive maintenance in food industryy: a case study", Journal of Quality in Maintenance Engineering, 13(1), pp.5 – 18 Society of Automotive Engineers Department (1999), SAE Standard JA1011 Evaluation criteria for reliability-centered maintenance (RCM) process International, Commonwealth Drive Warrendale, USA Steve Boris (2005), Total Productive Maintenance, McGraw-Hill USA, pp. 711, 50 Yi, Hui; Ruixin, Zhang; Juntao, Fang; Xin, Yuan (2013), "Research on the Optimal Preventive Maintenance Cost of Electronic Equipments," Fifth International Conference on Measuring Technology and Mechatronics Automation, pp.950-952
REPORT 3: The development of maintenance strategies utilizing Energy Efficient technologies Monitoring the energy usage of machines can significantly improve the manufacturing process, there are many tools and techniques used today to monitor the energy usage within manufacturing and by monitoring the energy used are appropriate maintenance strategies can be selected and executed. Collecting data of energy from machines in manufacturing can be used after it is analyses to perform maintenance. The data which will be collected from monitoring the machines and how much energy they use is very crucial, because in today's world many sources of energy are not renewable such as oil and gas, our planet energy sources are limited and the cost of energy is growing day by day. Also, energy used in manufacturing is very costly for example electricity bills increase the cost of operating which in return increase the cost of the products manufactured. In our current time factories require constant maintenance to reduce the use of energy, one technique in Network Enabled Manufacturing (NEM) which can measure vibration, power used can be monitored through Wireless Sensor Network (WSN), all the data collected can then be sent to the maintenance department for scheduling (Fonda et al, 2008). The manufacturing process consists of different stages, for example when the machine is off, on, or on standby. At the different stages energy can be used at different levels, each level is called an EnergyBlock (Nils Weinert et al, 2011), so at different blocks/levels the energy can be determined and according to the data forecasted (energy used, ex. KWh) then an appropriate maintenance strategy can be assigned to that operating machine, mainly condition based maintenance tools and techniques are used. In the Lif-Cycle Assessment (LCA) of a machine energy usage is monitored, to achieve energy efficiency in the manufacturing process we must collect all the data regarding the energy used, that is Direct-Energy (DE) includes Theoretical Energy (TE), the exact energy used in the manufacturing process and Auxiliary Energy (AE); the energy consumed in the
supporting activities and Indirect-Energy (IE). DE such as casting, spray painting, IE includes heating, lightning. (Rahimifard et al, 2010). By measuring the energy used (DE, IE, TE and AE) a more focused maintenance strategy can be implemented. Carbon emission in the manufacturing process is also an indicator on how energy is used and wither it's used efficiently or not, low carbon emissions in machines are indicators that the machine is running fine if an alteration in carbon emissions are detected that means there is something wrong in the system ( Jeswiet and Kara, 2008) so appropriate action can be taken from the maintenance department.
References: Fonda, J.W.; Zawodniok, M.J.; Jagannathan, S.; Salour, A.; Miller, D. (2008), conference on "Missouri S&T Mote-Based Demonstration of Energy Monitoring Solution for Network Enabled Manufacturing Using Wireless Sensor Networks (WSN), " Information Processing in Sensor Networks", pp.559- 560 J. Jeswiet, S. Kara (2008), Carbon emissions and CES™ in manufacturing, CIRP Annals - Manufacturing Technology, Volume 57(1) Nils Weinert, Stylianos Chiotellis, Günther Seliger(2011), Methodology for planning and operating energy-efficient production systems, CIRP Annals Manufacturing Technology, 60(1), Pages 41-44 S. Rahimifard, Y. Seow, T. Childs (2010), Minimising Embodied Product Energy to support energy efficient manufacturing, CIRP Annals Manufacturing Technology, 59(1), Pages 25-28
REPORT 4: Lean Maintenance (LM): The role of maintenance in the manufacturing process has increased due to the demand to keep the production stable and without any problems, going back to Henry ford and Toyota, lean maintenance aims to eliminate all manufacturing waste and this include all waste in the maintenance operation (Smith and Hawkins, 2004). To improve production and reduce the cost lean maintenance is applied many of the lean maintenance tools and techniques should be applied. Such tools and techniques are: • Proactive maintenance:
Proactive maintenance is maintenance of the equipment through monitoring, to avoid the equipment breakdown it should be monitored and checked for any failure parts or components regularly. Proactive maintenance in clued preventive and predictive Preventive maintenance is taken after the machine has been used and operated for a specific period of time; the maintenance relies that the machine will fail during that period of time, that’s why preventive approach is taken so the machine or the equipment will not fail. Predictive maintenance is taken on the condition of the equipment or machine, where a diagnosis of the machine or equipment will tell what the problem of the machine is and then it can be fixed according to the appropriate maintenance activity (Swanson, 2001). • Planned and scheduled: A planner and aplanning function should be done and the planner should report to the planning management. Planned and scheduled maintenance are of the best maintained strategies. Planning requires more thinking and experience and knowledge of the job than scheduling (Smith and Hawkins, 2004). • Total productive maintenance:
To optimize the reliability of the manufacturing machine and to get the most out of it by making everybody involved in the production process and the maintenance process cooperate. Avoid quality and downtime losses with gaining more efficiency in manufacturing TPM is one of the effective process in lean maintenance and manufacturing scheduling (Smith and Hawkins, 2004). TPM is the corner stone for lean manufacturing; TPM is designed for equipment reliability and more efficiency in the lean manufacturing system. When using TPM we are reducing the manufacturing costs and improving efficiency of production this all contributes to lean maintenance and how lean manufacturing using TPM is increased and manufacturing becomes more and more productive (Ahuja, and Khamba, 2008). • Reliability centred maintenance:
Reliability centered maintenance is one of the effective maintenance tools and strategies for lean maintenance and lean manufacturing system. To get more of the maintenance objectives is one of the goals of lean maintenance and in reliability centred maintenance this is achieved in different ways. Reliability centred maintenance was evolved in the very beginning to improve the aviation industry so it's a pure maintenance strategy when it comes to manufacturing, RCM is defined according to Smith and Hawkins as the maintenance strategy used to maintain the physical state of a machine or equipment.(Smith and Hawkins, 2004). so RCM can be used for many plant and manufacturing systems because it deal with the failure instantly and it avoids the losses that can be done in a manufacturing system. • Empowered (self-directed) action teams:
Self-directed action teams are becoming one of the important factors in many manufacturing industries, self directed teams or SDT are small group or employees who have to manage their daily tasks, Individuals in the manufacturing industry make their own decisions and support each other and the related departments (Clifford and Sohal, 1998). Using self directed teams in lean maintenance is a common practice in combining it with 5-S (Yile et al, 2008).
•
5S:
5S focuses on the work environment, it reduces cost and reduce waste by organising and putting things in order it's about keeping everything in place and in order. There are 5 basic rules(Moriones et al, 2010: 1. Sort; keep things separated and where they belong 2. Straighten; to find in particular what you need in less than 30 minutes 3. Shine; have you equipment always ready to use
4. Standardize; each one should do his/her job in the same way and improve it. 5. Sustain; every employee should do hi/her part in the work place This help in the lean manufacturing system by organising all employees and all material). • Kaizen improvement events:
Kaizen means continues improvement, as its integrated into the lean manufacturing system and maintenance it's always important to continually improve the maintenance process of a manufacturing system listed by Smith and Hawkins, 5S is one of Kaizen improvement and eliminating wastes such as production and inventory wastes, standardized work flow, process mapping and JIT (just in time) supply for the manufacturing system scheduling (Smith and Hawkins, 2004). • Autonomous maintenance:
Production line operators should be assigned to maintenance teams where each team is responsible for the manufacture maintenance system scheduling this is AM or routine maintenance performed by the production line employees. So in-operation maintenance can be performed. (Smith and Hawkins, 2004) • Multi skilled, maintenance technician:
In lean manufacturing it's very crucial to have a skilled technician on the job. So training to do the job instead of highly paid engineers will reduce the cost and is implemented in many modern manufacturing systems. • Work order system:
Managing labor and measuring the manufacturing department effectiveness in lean manufacturing Smith and Hawkins (Smith and Hawkins, 2004) describe it as counting the hours 8 hours of work order, will equal 8 hours of production. • Computer managed maintenance system:
In many computerised systems companies aim to solve maintenance problems addressed to the maintenance department, it helps in work order, planning spare management Key Performance Indicators (KPI).
•
Root cause analysis:
Root analysis will prevent the occurrence of the event if addressed properly. By eliminating the root cause in a maintenance strategy an efficient and more reliable system is created.
•
FMECA:
Failure mode effects critical analysis is basically Preventing failure by prediction have been applied in many manufacturing industries as a lean technique, Nissan used it in it's production line as an effective maintenance technique (Herronand Braiden 2006).
References: Alberto Bayo-Moriones, Alejandro Bello-Pintado, Javier Merino-Díaz de Cerio, (2010) "5S use in manufacturing plants: contextual factors and impact on operating performance", International Journal of Quality & Reliability Management, 27(2), pp.217 – 230 Colin Herron, Paul M. Braiden (2006), A methodology for developing sustainable quantifiable productivity improvement in manufacturing companies, International Journal of Production Economics, 104(1) pp. 143153 Gavin P. Clifford, Amrik S. Sohal, (1998) "Developing self-directed work teams", Management Decision, 36(2), pp.77 – 84 I.P.S. Ahuja, J.S. Khamba, (2008) "Total productive maintenance: literature review and directions", International Journal of Quality & Reliability Management, 25(7), pp.709 – 756 Laura Swanson (2001), Linking maintenance strategies to performance, International Journal of Production Economics, 70(3), Pages 237-244 Liu Yile; Xu Xue Hang; Zou Lei (2008), International Conference on "Lean Maintenance Framework and Its Application in Clutch Maintenance," Information Management, Innovation Management and Industrial Engineering, pp.230-232
Ricky smith, Bruce Hawkins (2004) Lean Maintenance: Reduce Costs, Improve Quality, and Increase Market Share (Life Cycle Engineering Series, Butterworth-Heinemann; 1 edition, pp.6, 9, 55-59, 77, 92, 145, 227
doc_384882593.doc
Measurement is the assignment of numbers to objects or events. It is a cornerstone of most natural sciences, technology, economics, and quantitative research in other social sciences.
Study on Measurement Techniques Used for Condition Monitoring
Table of contents: page No.
1. Report 1: 1.1. 1.2. Measurement techniques used for condition monitoring 3-5 References 6
2. Report 2: 2.1. 2.2. TPM and RCM References 7-9 10
3. Repot 3: 3.1. Maintenance Strategies utilising Energy Efficient technologies 11 3.2. References 12
4. Report 4: 4.1. Lean Maintenance 15 4.2. References 1316
Word count: 0
REPORT 1: Measurement techniques used for condition monitoring
The different measurement techniques which are used for condition monitoring such techniques are vibration measurement and analysis technique, infrared thermograph, oil analysis techniques, ultrasonic imaging, and power, energy and current monitoring techniques. Also, an explanation on how the equipment is used in measuring condition monitoring the different practical usage and their application. In addition to the measurement techniques equipments and on what application they are used, details of the faults that could be detected and fixed in the machines. So, the basic measurement techniques which will be explained for condition monitoring are: • • • • Vibration analysis/Vibration monitoring Acoustic emission Oil analysis Thermography/thermal imaging
Vibration analysis: Many early failure of machine or plant can be detected using vibration analysis technique. Vibration analysis is the most important and usually the more used technique in prediction and condition monitoring, the data taken from the analysis can be compared to previous analysis that is done on the machine or equipment and then compared to previous data in this way a failure can be detected by comparing the data together so
maintenance can take place. Vibration analysis mainly used and monitored in bearings of an equipment or machine for example inside a shaft, wherever there is a vibration a wave is transmitted and this wave is then measured and compared to previous readings if there is an alteration of the waves then there is a fault in the bearing or shaft. So, this is without doubt one of the important techniques to detect faults in rotating equipment (scheffer and Girdhar, 2004).
Faults • • • • • • • • • • • •
due to vibration that can be detected in machines are: Unbalance of rotating parts Misalignment of couplings and bearings Bent shafts Worn or damaged gears and bearings Bad drive belts and chains Torque variations Electromagnetic forces Aerodynamic forces Hydraulic forces Looseness Rubbing Resonance (scheffer and Girdhar, 2004).
Acoustic emission: Acoustic emission is used to follow and determine where the cracks occur in pipes and machines. Acoustic emission was invented for non-destructive testing of machinery; however, its application has been extended to monitoring of rotating machines and bearings. It offers the advantage of earlier defect detection in comparison to vibration analysis it was noted that signals detected in the AE frequency range represented bearing defects rather than other defects such as; • imbalance • misalignment • looseness • shaft bending (Choudhury and Tandon, 2000).
Oil analysis: In this measurement technique, oil is analysed and the level of lubrication is determined as time passes particles accumulate in the oil and makes the bearings and parts weir (scheffer and Girdhar, 2004). Sometime infrared technologies are used to measure the mass of particles in the oil and by knowing the age of the oil and how long it is been used for the performance level of the machine can be determined.
There are many parameters which affect the condition of the oil and can be measured such as: • the temperature • the amount of water (the color of the oil is an indication of water presence if the oil is brown than water is present) • air in the oil • the particles present in the oil (Raadnui and Kleesuwan, 2005). Thermography/thermal imaging: Thermography or thermal imaging used to detect active electrical and mechanical equipment. The method can detect: • • thermal due to heat and mechanical problems in engines and generators high voltage (HV) lines like electrical power lines and many other defects
the primary thermal analysis techniques and methods are: • temperature differential thermal analysis differential thermometer • heat flow difference by differential scanning calorimetry • magnetic properties by thermoelectric analysis • optical properties, acoustic properties (Brown, 2001).
Condition monitoring is done by using many advanced technologies to determine, predict and fix any equipment condition and avoid failures of equipment. It is extremely important to monitor the condition of equipment because of many factors and the most important factor is cost. If the equipment failed the cost of fixing or maintain the equipment is high so before the equipment can fail we can monitor its condition and fix any problems that will result from running the equipment.
References: Choudhury, A. and Tandon, N (2000), Application of acoustic emission technique for the detection of defects in rolling element bearings, Tribology International, 33, PP.39-45 Cornelius Scheffer Ph.D MEng, Paresh Girdhar B.Eng MechEng (2004). Practical machinery vibration analysis and predictive maintenance, Elsevier: UK. PP.8, 22-23, 168. Michael E. Brown (2001), introduction to thermal analysis: techniques and applications, second edition, Kluwer academic publishers USA. PP.6-8 Surapol Raadnui, Srawut Kleesuwan (2005)," Low-cost condition monitoring sensor for used oil analysis", Wear, 259(7–12), PP. 1502-1506
REPORT 2: TPM and RCM
Bothe Total Productive Maintenance (TPM) and Reliability Centred Maintenance (RCM) are maintenance techniques that evolved and are used by maintenance departments in many countries, both are based on maintenance strategies. When we talk about total productive maintenance we want to achieve maximum equipment effectiveness through involving all employees.
TPM: As introduced earlier TPM is a process that involves all employees from management to operators, technicians and maintenance crew. TPM consists of eight very important pillars that makes a unique and efficient and maintenance and productivity according to (Borris, 2005) are: 1. health and safety; the main aim of health and safety is to train operators not to have accidents during their operation of equipments or machines. 2. Training; in many organizations training is not done properly, training needs to be always updated by new training methods and the operators need to have focused training. Without training TPM well not be useful 3. Autonomous maintenance; to send engineers to do the maintenance will cost the organization plenty, so if operators can perform the maintenance then this will save money and valuable time for the organization by preventing the equipment or machine from failing and waste time on waiting for the engineer to fix it
4. Planned maintenance; basically scheduled and planned proper checks for the machine to prevent the cause of failure. By doing so the machine or equipment usually Overall equipment efficiency (OEE) is used by TPM in planned maintenance 5. Quality maintenance; quality in the product produced is achieved by eliminating the differences between each product. Usually a team focuses on delivering best products through avoiding the machine faults in production 6. Focused improvement; through reducing costs of maintenance 7. Support systems; all the departments in an organization should support by any means the maintenance process from the storage facilities to purchasing and quality control. 8. Initial phase management; in the organization there shoud be a stage where the planning of production is considered in all it's stages from the satge of caring to the customer need to the satge of purchasing raw materials to make the product A key to TPM is restoring the equipment to its original condition (Borris, 2005). By restoring the equipment to its original condition we gain equipment that is brand new as if we have bought new equipment, it won't be necessary to buy new equipment or replace an existing equipment all this is done through TPM. So we don't want to ignore any aspect of maintenance for example if you are driving a car and all the four wheels are running fine then the spare tire would be ignored because it's not needed now! So, through getting the equipment back on its original condition avoid having and encountering future problems. in Reliability centred maintenance RCM this is called function failure according to According to (Moubray,1991). TPM can be used in different industries, one of the main industries it can be used is food industry. In the case study (Tsarouhas, 2007) TPM can be used to increase the production rate and improve quality and provide a safer work environment. the production rate can be measured through the overall equipment effectivnee (OEE). RCM: reliability centred maintenance
•
The definition given by John Moubray of Reliability Centred Maintenance is: the process used to determine the maintenance requirements of any physical asset in its operating context (Moubray, 1991) that means managing the equipment or machine and maintaining it running in accordance to any need that the equipment might require from the operation point of view.
The seven basic questions that should be checked when applying RCM as listed by Moubray taken from SAE standard JA1011 (SAE, 1999) are: 1. 2. 3. 4. 5. 6. 7. What are the Functions and operating standards in the present operation? In what ways does it fail? What are the causes of each failure? What happens when failures occur? How each failure matter? What can be done in case of failure? What should be done if an appropriate task cannot be found?
Fig. 1. Example of RCM logic ( Carretero et al, 2003) As shown in figure 1. An RCM logic is applied schedules of maintenance are done according to the failure. RCM is preventive maintenance strategy used to prevent functional failures rather than protect the equipment so preventive maintenance will avoid the failure before it occurs this is done by frequent oil changes to engines, vibration analysis and other maintenance techniques (Hui et al, 2013). As for the TPM, RCM can be used in different kind of industries. An example would be the textile industry, due to the machines preciseness and accuracy for example the needles which net and all the small components of the machines, all these elements need to be reliable and operate to prevent any failure (Shyjith et al, 2008). The basic goals of TPM are to make a co-operation between all employees and departments to maintain the machines that include involving the operators, technicians and maintenance employees in the process. Management operators and maintenance are all participants in TPM the
key to machine effectiveness and stability is the involvement of all employees. RCM more on keeping the equipment or machine running and on operation, TPM and RCM the management techniques are both maintenance techniques that derive effective fixing and preventing of failure of the equipment.
References: J Carretero, JM Pérez, F García-Carballeira, A Calderón, J Fernández, JD García et al (2003). Applying RCM in large scale systems: a case study with railway networks Reliability Engineering and System Safety, pp. 257– 273 J. Moubray (1991), Reliability Centred Maintenance, ButterworthHeinemann, pp.7-9 K. Shyjith, M. Ilangkumaran, S. Kumanan, (2008) "Multi-criteria decisionmaking approach to evaluate optimum maintenance strategy in textile industry", Journal of Quality in Maintenance Engineering, 14(4), pp.375 – 386 Panagiotis Tsarouhas, (2007) "Implementation of total productive maintenance in food industryy: a case study", Journal of Quality in Maintenance Engineering, 13(1), pp.5 – 18 Society of Automotive Engineers Department (1999), SAE Standard JA1011 Evaluation criteria for reliability-centered maintenance (RCM) process International, Commonwealth Drive Warrendale, USA Steve Boris (2005), Total Productive Maintenance, McGraw-Hill USA, pp. 711, 50 Yi, Hui; Ruixin, Zhang; Juntao, Fang; Xin, Yuan (2013), "Research on the Optimal Preventive Maintenance Cost of Electronic Equipments," Fifth International Conference on Measuring Technology and Mechatronics Automation, pp.950-952
REPORT 3: The development of maintenance strategies utilizing Energy Efficient technologies Monitoring the energy usage of machines can significantly improve the manufacturing process, there are many tools and techniques used today to monitor the energy usage within manufacturing and by monitoring the energy used are appropriate maintenance strategies can be selected and executed. Collecting data of energy from machines in manufacturing can be used after it is analyses to perform maintenance. The data which will be collected from monitoring the machines and how much energy they use is very crucial, because in today's world many sources of energy are not renewable such as oil and gas, our planet energy sources are limited and the cost of energy is growing day by day. Also, energy used in manufacturing is very costly for example electricity bills increase the cost of operating which in return increase the cost of the products manufactured. In our current time factories require constant maintenance to reduce the use of energy, one technique in Network Enabled Manufacturing (NEM) which can measure vibration, power used can be monitored through Wireless Sensor Network (WSN), all the data collected can then be sent to the maintenance department for scheduling (Fonda et al, 2008). The manufacturing process consists of different stages, for example when the machine is off, on, or on standby. At the different stages energy can be used at different levels, each level is called an EnergyBlock (Nils Weinert et al, 2011), so at different blocks/levels the energy can be determined and according to the data forecasted (energy used, ex. KWh) then an appropriate maintenance strategy can be assigned to that operating machine, mainly condition based maintenance tools and techniques are used. In the Lif-Cycle Assessment (LCA) of a machine energy usage is monitored, to achieve energy efficiency in the manufacturing process we must collect all the data regarding the energy used, that is Direct-Energy (DE) includes Theoretical Energy (TE), the exact energy used in the manufacturing process and Auxiliary Energy (AE); the energy consumed in the
supporting activities and Indirect-Energy (IE). DE such as casting, spray painting, IE includes heating, lightning. (Rahimifard et al, 2010). By measuring the energy used (DE, IE, TE and AE) a more focused maintenance strategy can be implemented. Carbon emission in the manufacturing process is also an indicator on how energy is used and wither it's used efficiently or not, low carbon emissions in machines are indicators that the machine is running fine if an alteration in carbon emissions are detected that means there is something wrong in the system ( Jeswiet and Kara, 2008) so appropriate action can be taken from the maintenance department.
References: Fonda, J.W.; Zawodniok, M.J.; Jagannathan, S.; Salour, A.; Miller, D. (2008), conference on "Missouri S&T Mote-Based Demonstration of Energy Monitoring Solution for Network Enabled Manufacturing Using Wireless Sensor Networks (WSN), " Information Processing in Sensor Networks", pp.559- 560 J. Jeswiet, S. Kara (2008), Carbon emissions and CES™ in manufacturing, CIRP Annals - Manufacturing Technology, Volume 57(1) Nils Weinert, Stylianos Chiotellis, Günther Seliger(2011), Methodology for planning and operating energy-efficient production systems, CIRP Annals Manufacturing Technology, 60(1), Pages 41-44 S. Rahimifard, Y. Seow, T. Childs (2010), Minimising Embodied Product Energy to support energy efficient manufacturing, CIRP Annals Manufacturing Technology, 59(1), Pages 25-28
REPORT 4: Lean Maintenance (LM): The role of maintenance in the manufacturing process has increased due to the demand to keep the production stable and without any problems, going back to Henry ford and Toyota, lean maintenance aims to eliminate all manufacturing waste and this include all waste in the maintenance operation (Smith and Hawkins, 2004). To improve production and reduce the cost lean maintenance is applied many of the lean maintenance tools and techniques should be applied. Such tools and techniques are: • Proactive maintenance:
Proactive maintenance is maintenance of the equipment through monitoring, to avoid the equipment breakdown it should be monitored and checked for any failure parts or components regularly. Proactive maintenance in clued preventive and predictive Preventive maintenance is taken after the machine has been used and operated for a specific period of time; the maintenance relies that the machine will fail during that period of time, that’s why preventive approach is taken so the machine or the equipment will not fail. Predictive maintenance is taken on the condition of the equipment or machine, where a diagnosis of the machine or equipment will tell what the problem of the machine is and then it can be fixed according to the appropriate maintenance activity (Swanson, 2001). • Planned and scheduled: A planner and aplanning function should be done and the planner should report to the planning management. Planned and scheduled maintenance are of the best maintained strategies. Planning requires more thinking and experience and knowledge of the job than scheduling (Smith and Hawkins, 2004). • Total productive maintenance:
To optimize the reliability of the manufacturing machine and to get the most out of it by making everybody involved in the production process and the maintenance process cooperate. Avoid quality and downtime losses with gaining more efficiency in manufacturing TPM is one of the effective process in lean maintenance and manufacturing scheduling (Smith and Hawkins, 2004). TPM is the corner stone for lean manufacturing; TPM is designed for equipment reliability and more efficiency in the lean manufacturing system. When using TPM we are reducing the manufacturing costs and improving efficiency of production this all contributes to lean maintenance and how lean manufacturing using TPM is increased and manufacturing becomes more and more productive (Ahuja, and Khamba, 2008). • Reliability centred maintenance:
Reliability centered maintenance is one of the effective maintenance tools and strategies for lean maintenance and lean manufacturing system. To get more of the maintenance objectives is one of the goals of lean maintenance and in reliability centred maintenance this is achieved in different ways. Reliability centred maintenance was evolved in the very beginning to improve the aviation industry so it's a pure maintenance strategy when it comes to manufacturing, RCM is defined according to Smith and Hawkins as the maintenance strategy used to maintain the physical state of a machine or equipment.(Smith and Hawkins, 2004). so RCM can be used for many plant and manufacturing systems because it deal with the failure instantly and it avoids the losses that can be done in a manufacturing system. • Empowered (self-directed) action teams:
Self-directed action teams are becoming one of the important factors in many manufacturing industries, self directed teams or SDT are small group or employees who have to manage their daily tasks, Individuals in the manufacturing industry make their own decisions and support each other and the related departments (Clifford and Sohal, 1998). Using self directed teams in lean maintenance is a common practice in combining it with 5-S (Yile et al, 2008).
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5S:
5S focuses on the work environment, it reduces cost and reduce waste by organising and putting things in order it's about keeping everything in place and in order. There are 5 basic rules(Moriones et al, 2010: 1. Sort; keep things separated and where they belong 2. Straighten; to find in particular what you need in less than 30 minutes 3. Shine; have you equipment always ready to use
4. Standardize; each one should do his/her job in the same way and improve it. 5. Sustain; every employee should do hi/her part in the work place This help in the lean manufacturing system by organising all employees and all material). • Kaizen improvement events:
Kaizen means continues improvement, as its integrated into the lean manufacturing system and maintenance it's always important to continually improve the maintenance process of a manufacturing system listed by Smith and Hawkins, 5S is one of Kaizen improvement and eliminating wastes such as production and inventory wastes, standardized work flow, process mapping and JIT (just in time) supply for the manufacturing system scheduling (Smith and Hawkins, 2004). • Autonomous maintenance:
Production line operators should be assigned to maintenance teams where each team is responsible for the manufacture maintenance system scheduling this is AM or routine maintenance performed by the production line employees. So in-operation maintenance can be performed. (Smith and Hawkins, 2004) • Multi skilled, maintenance technician:
In lean manufacturing it's very crucial to have a skilled technician on the job. So training to do the job instead of highly paid engineers will reduce the cost and is implemented in many modern manufacturing systems. • Work order system:
Managing labor and measuring the manufacturing department effectiveness in lean manufacturing Smith and Hawkins (Smith and Hawkins, 2004) describe it as counting the hours 8 hours of work order, will equal 8 hours of production. • Computer managed maintenance system:
In many computerised systems companies aim to solve maintenance problems addressed to the maintenance department, it helps in work order, planning spare management Key Performance Indicators (KPI).
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Root cause analysis:
Root analysis will prevent the occurrence of the event if addressed properly. By eliminating the root cause in a maintenance strategy an efficient and more reliable system is created.
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FMECA:
Failure mode effects critical analysis is basically Preventing failure by prediction have been applied in many manufacturing industries as a lean technique, Nissan used it in it's production line as an effective maintenance technique (Herronand Braiden 2006).
References: Alberto Bayo-Moriones, Alejandro Bello-Pintado, Javier Merino-Díaz de Cerio, (2010) "5S use in manufacturing plants: contextual factors and impact on operating performance", International Journal of Quality & Reliability Management, 27(2), pp.217 – 230 Colin Herron, Paul M. Braiden (2006), A methodology for developing sustainable quantifiable productivity improvement in manufacturing companies, International Journal of Production Economics, 104(1) pp. 143153 Gavin P. Clifford, Amrik S. Sohal, (1998) "Developing self-directed work teams", Management Decision, 36(2), pp.77 – 84 I.P.S. Ahuja, J.S. Khamba, (2008) "Total productive maintenance: literature review and directions", International Journal of Quality & Reliability Management, 25(7), pp.709 – 756 Laura Swanson (2001), Linking maintenance strategies to performance, International Journal of Production Economics, 70(3), Pages 237-244 Liu Yile; Xu Xue Hang; Zou Lei (2008), International Conference on "Lean Maintenance Framework and Its Application in Clutch Maintenance," Information Management, Innovation Management and Industrial Engineering, pp.230-232
Ricky smith, Bruce Hawkins (2004) Lean Maintenance: Reduce Costs, Improve Quality, and Increase Market Share (Life Cycle Engineering Series, Butterworth-Heinemann; 1 edition, pp.6, 9, 55-59, 77, 92, 145, 227
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