This document summarizes a case study on improving the availability and maintainability of critical machines at a steel plant through root cause analysis of failures and implementing corrective countermeasures. Data was collected on breakdowns of a housing less mill stand machine and slitting machine before and after implementing countermeasures. Root cause analysis found the main issues for the slitting machine were fire cracks in the reel and improper adjustment. Corrective actions like improved cooling and adjustments increased availability from 94.89% to 97.72%, MTBF from 59 to 82.81 hours, and decreased MTTR from 3.17 to 1.93 hours, demonstrating the effectiveness of the countermeasures at improving performance.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Implementation of a Cellular Manufacturing Tool for Minimization of Non Value...IJERA Editor
The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to reduce wastes in the system; increasing profit and reducing lead-times. Current state and future state of manufacturing of a firm are compared and witnessed: 50 percent reduction in lead time, 4 percent reduction in processing time, 58.5 percent reduction in WIP and 22 percent reduction in manpower required to perform same amount of work.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Implementation of a Cellular Manufacturing Tool for Minimization of Non Value...IJERA Editor
The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to reduce wastes in the system; increasing profit and reducing lead-times. Current state and future state of manufacturing of a firm are compared and witnessed: 50 percent reduction in lead time, 4 percent reduction in processing time, 58.5 percent reduction in WIP and 22 percent reduction in manpower required to perform same amount of work.
Capacity utilization for product mix using operation based time standard eval...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Capacity utilization for product mix using operation based time standard eval...eSAT Journals
Abstract In this paper, a systematic and quantitative view is presented for the application of time study in woodworking furniture industry. The study is done in panel conversion plant on five CNC machines for various operations. For the calculation of cycle time, machining time calculator is developed and the operation research technique of mathematical programming is used for the capacity calculation of product mix. This makes manager to make faster decision in outsourcing problem and to improve the financial performance of the company. Keywords - Capacity utilization, cycle time, linear programming, manufacturing, time study
Any firm typically made a large investment in a piece of capital machinery and, in theory, it could run 24 hour a day for seven days a week at its optimum Speed. If it did this you gain the maximum value from the investment. In reality there is number of element that can affect the value gained from the investment. So that fully utilization of equipment can be done. Hence for fully utilization of any equipment any firm must have to calculate OEE. This paper represents the methodology applied in increasing the OEE of an Organization by exchanging the feed mechanism from Bowl Feeder to a Conveyor.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
Capacity utilization for product mix using operation based time standard eval...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Capacity utilization for product mix using operation based time standard eval...eSAT Journals
Abstract In this paper, a systematic and quantitative view is presented for the application of time study in woodworking furniture industry. The study is done in panel conversion plant on five CNC machines for various operations. For the calculation of cycle time, machining time calculator is developed and the operation research technique of mathematical programming is used for the capacity calculation of product mix. This makes manager to make faster decision in outsourcing problem and to improve the financial performance of the company. Keywords - Capacity utilization, cycle time, linear programming, manufacturing, time study
Any firm typically made a large investment in a piece of capital machinery and, in theory, it could run 24 hour a day for seven days a week at its optimum Speed. If it did this you gain the maximum value from the investment. In reality there is number of element that can affect the value gained from the investment. So that fully utilization of equipment can be done. Hence for fully utilization of any equipment any firm must have to calculate OEE. This paper represents the methodology applied in increasing the OEE of an Organization by exchanging the feed mechanism from Bowl Feeder to a Conveyor.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
Similar to IRJET- Improvement of Availability and Maintainability through Actions based on Root Cause Analysis of Failures: A Case Study of a Critical Machine
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
OVERALL EQUIPMENT EFFECTIVENESS OF CRITICAL MACHINES IN MANUFACTURING INDUSTR...IAEME Publication
Overall Equipment Effectiveness (OEE) is a measure used in Total Productive Maintenance (TPM), a maintenance program which involves a newly defined concept for maintaining plants and equipment, to calculate the percentage of actual effectiveness of the equipment, taking into consideration the availability of the equipment, the performance rate when running and the quality rate of the manufactured product measured over a period of time (days, weeks or months). The equipment criticality is decided by considering how and how much the equipment affects the production volume and quality.
Similar to IRJET- Improvement of Availability and Maintainability through Actions based on Root Cause Analysis of Failures: A Case Study of a Critical Machine (20)
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/