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.
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.
Design of workplace for the assembly of monoblock pumpeSAT Journals
Abstract
Productivity is an important aspect of every industrial firm as well as for the economic growth of the country. High productivity means completing a quantum of work with minimum possible time and fewer amounts of resources. Work-study is required for designing the work system, which identifies the effective means of completing the work. Also, it is known that the workers suffer from fatigue and injury during long hours of monotonous work when proper workplace/working environment is absent. This may indirectly contribute to decreased productivity in an industry. Human factor issues arise in simple systems and in consumer products as well. Hence the ergonomic principles are to be considered while designing both consumer and industrial products. One of the most prevalent types of work-related injuries is musculoskeletal disorder. Work-related musculoskeletal disorders (WRMDs) results in continuous pain, functional capability loss and disability to work, but the prevailing disorder diagnosis is difficult because they are mainly based on complaints of pain and other symptoms. Hence a proper workplace is to be designed to overcome the above issues or to reduce them considerably. This research aims at improving the existing and proposed ways of doing work with Ergonomics and Anthropometric considerations, thereby improving the productivity rate. Keywords: Productivity, Work study, Ergonomics, Anthropometry, and Monoblock pump.
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.
Design of workplace for the assembly of monoblock pumpeSAT Journals
Abstract
Productivity is an important aspect of every industrial firm as well as for the economic growth of the country. High productivity means completing a quantum of work with minimum possible time and fewer amounts of resources. Work-study is required for designing the work system, which identifies the effective means of completing the work. Also, it is known that the workers suffer from fatigue and injury during long hours of monotonous work when proper workplace/working environment is absent. This may indirectly contribute to decreased productivity in an industry. Human factor issues arise in simple systems and in consumer products as well. Hence the ergonomic principles are to be considered while designing both consumer and industrial products. One of the most prevalent types of work-related injuries is musculoskeletal disorder. Work-related musculoskeletal disorders (WRMDs) results in continuous pain, functional capability loss and disability to work, but the prevailing disorder diagnosis is difficult because they are mainly based on complaints of pain and other symptoms. Hence a proper workplace is to be designed to overcome the above issues or to reduce them considerably. This research aims at improving the existing and proposed ways of doing work with Ergonomics and Anthropometric considerations, thereby improving the productivity rate. Keywords: Productivity, Work study, Ergonomics, Anthropometry, and Monoblock pump.
Design and fabrication of modular fixture for cmm inspectioneSAT Journals
Abstract This paper is on design and fabrication of modular fixture setup relative to inspection on co-ordinate Measuring Machine proposed and planned to increase the utilization of Co-ordinate Measuring Machine with respect to inspection activity by reducing setup time. The modular fixture design will hold component of different configuration, size and shape without much efforts to locate, align and clamp the components on the fixture. The modular fixture will ensure that even though the component is of different configuration will have one time design and setup configuration which will be standardized by assembly of fixture and then on fixture setup time will be less than a minute on the machine that to only if fixture is disturbed / removed from the Co-ordinate Measuring Machine table. Modular fixture will reduce setup time, hence increase opportunity to utilize the machine for useful value adding inspection purpose rather than setup activity which is noted to be non value adding activity. Along with design of modular fixture standardized method of component setup strategy is provided as work instructions to ensure components are mounted same way each time and every time whenever it is in use irrespective of time and resource.
Interweaving Knowledge Acquisition and Product FunctionalityEditor IJCATR
This research is concerned with the detailed study on Product Functionality and to select a Knowledge Acquisition Method
for Acquiring Knowledge on Product Functionality efficiently. The purpose of this research is to ensure that important aspects of
product data are taken into account in knowledge management projects. The most important venture of this research is to design a
questionnaire for acquiring knowledge on product functionality, and then test the designed questionnaire with certain industrial
product data collection.
Cost Implication of Inventory Management in Organised SystemsDr. Amarjeet Singh
This paper investigates the role of cost implication in
inventory management in order to improve Institutions’
Stores. The study takes a critical look at the costs involved and
the use of economic order quantity as a tool that minimizes the
total inventory costs, the time saved between the manual and
the automated operational system using a Nigerian University
Store, AYZ University (not the real name because of the
ethical issue), as a case study. The study was being guided by
the following objectives; to have stocks available when
required, to maintain accurate stock records and facilities, and
to recommend area improvement of the inventory system at
AYZ University Stores. Findings revealed that the economic
order quantity is seen as a control technique that is attributed
to determine the inventory costs and how it can be minimized.
The data collected from the store were analyzed and the
results obtained shows that the existing system which is
majorly manual based is not effective when it comes to time
management and efficiency. A new automated system,
computerized maintenance store system (CMMS) was
proposed for development and implementation for the AYZ
University Store for her end users of the store and her clients
from within and outside the University system. This would be
greatly improved in terms of both financial and time cost of
inventory management.
Impact of total productive maintenance methodology on the performanceeSAT Journals
Abstract These days, the organization and companies meet a lot of challenges(internally: to increase the performance, and externally: market share). This work focuses on the internal challenges: such as performance.The most important pillars of the production operations are employees, machines, equipment's, and etc. Maintenance represents the important activity that makes the machines and equipment's operate efficiently. Companies attempt to increase performance and minimize production costs by using a certain approach such as Total productive maintenance (TPM). This work introduces a methodology to improve the performance (operator and equipment) throughproposed model of TPM. Also, it indicates the importance of maintenance which minimizes or eliminates the production problems and increases the organizational productivity. Keywords:Maintenance, Maintenance Management System (MMS), Maintenance Office (MO), Preventive Maintenance (PM), Total productive maintenance (TPM), andOverall Equipment Effectiveness (OEE).
Study on Factors for Improving The Effectiveness Of ERP Within Korea Agricult...QUESTJOURNAL
ABSTRACT: ERP implementation issues have been given much attention as the size of Agricultural Products Processing Center (APC) in Korea gets bigger and bigger. The goal of this study is to find the factors that influence the effect of Enterprise Resource Planning (ERP) adoption to help improve the business environment of the ERP users, especially in agricultural industry. This study tries to apply traditional IS theory into agricultural industry. By testing multiple aspects in different stages, the study derives more comprehensive factors that positively influence the adoption of ERP. By conducting a survey, the study observed hands-on ERP operators who work at APC which had previously adopted ERP. The study categorizes independent variables into three stages such as pre-adoption, adoption, and post-adoption. Satisfaction, system utility, work efficiency, professionalism, and standardization are examined as dependent variables. Cronbach’s alpha is used to test the reliability of the survey questionnaires in each category and multiple regression analysis is used to derive factors that have an effect on ERP adoption. Discussions on the results of data analysis are made
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
Introduction to Production Engineering DepartmentAmr El-Ganainy
Introductory Session about Production Engineering Department for Preparatory Student, Faculty of Engineering Alexandria University. During a Conference held by SMU | Start Menu Union
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The purpose of this paper is to evaluate the contributions of Total Productive Maintenance (TPM) initiatives in reducing equipment breakdowns, increase equipment reliability and improve productivity. This will result in increased equipment utilization and life, reduced work stoppages and machine slowdowns, closer adherence to production and delivery schedules as well as increased employee morale. The Total Productive Maintenance (TPM) concept addresses these goals. The aim of TPM is to keep the plant and equipment at its highest productive level through the cooperation of all areas of the organization. TPM is a partnership between maintenance and production organization to improve product quality, reduce waste, reduce manufacturing cost and increase equipment availability.
Design and fabrication of modular fixture for cmm inspectioneSAT Journals
Abstract This paper is on design and fabrication of modular fixture setup relative to inspection on co-ordinate Measuring Machine proposed and planned to increase the utilization of Co-ordinate Measuring Machine with respect to inspection activity by reducing setup time. The modular fixture design will hold component of different configuration, size and shape without much efforts to locate, align and clamp the components on the fixture. The modular fixture will ensure that even though the component is of different configuration will have one time design and setup configuration which will be standardized by assembly of fixture and then on fixture setup time will be less than a minute on the machine that to only if fixture is disturbed / removed from the Co-ordinate Measuring Machine table. Modular fixture will reduce setup time, hence increase opportunity to utilize the machine for useful value adding inspection purpose rather than setup activity which is noted to be non value adding activity. Along with design of modular fixture standardized method of component setup strategy is provided as work instructions to ensure components are mounted same way each time and every time whenever it is in use irrespective of time and resource.
Interweaving Knowledge Acquisition and Product FunctionalityEditor IJCATR
This research is concerned with the detailed study on Product Functionality and to select a Knowledge Acquisition Method
for Acquiring Knowledge on Product Functionality efficiently. The purpose of this research is to ensure that important aspects of
product data are taken into account in knowledge management projects. The most important venture of this research is to design a
questionnaire for acquiring knowledge on product functionality, and then test the designed questionnaire with certain industrial
product data collection.
Cost Implication of Inventory Management in Organised SystemsDr. Amarjeet Singh
This paper investigates the role of cost implication in
inventory management in order to improve Institutions’
Stores. The study takes a critical look at the costs involved and
the use of economic order quantity as a tool that minimizes the
total inventory costs, the time saved between the manual and
the automated operational system using a Nigerian University
Store, AYZ University (not the real name because of the
ethical issue), as a case study. The study was being guided by
the following objectives; to have stocks available when
required, to maintain accurate stock records and facilities, and
to recommend area improvement of the inventory system at
AYZ University Stores. Findings revealed that the economic
order quantity is seen as a control technique that is attributed
to determine the inventory costs and how it can be minimized.
The data collected from the store were analyzed and the
results obtained shows that the existing system which is
majorly manual based is not effective when it comes to time
management and efficiency. A new automated system,
computerized maintenance store system (CMMS) was
proposed for development and implementation for the AYZ
University Store for her end users of the store and her clients
from within and outside the University system. This would be
greatly improved in terms of both financial and time cost of
inventory management.
Impact of total productive maintenance methodology on the performanceeSAT Journals
Abstract These days, the organization and companies meet a lot of challenges(internally: to increase the performance, and externally: market share). This work focuses on the internal challenges: such as performance.The most important pillars of the production operations are employees, machines, equipment's, and etc. Maintenance represents the important activity that makes the machines and equipment's operate efficiently. Companies attempt to increase performance and minimize production costs by using a certain approach such as Total productive maintenance (TPM). This work introduces a methodology to improve the performance (operator and equipment) throughproposed model of TPM. Also, it indicates the importance of maintenance which minimizes or eliminates the production problems and increases the organizational productivity. Keywords:Maintenance, Maintenance Management System (MMS), Maintenance Office (MO), Preventive Maintenance (PM), Total productive maintenance (TPM), andOverall Equipment Effectiveness (OEE).
Study on Factors for Improving The Effectiveness Of ERP Within Korea Agricult...QUESTJOURNAL
ABSTRACT: ERP implementation issues have been given much attention as the size of Agricultural Products Processing Center (APC) in Korea gets bigger and bigger. The goal of this study is to find the factors that influence the effect of Enterprise Resource Planning (ERP) adoption to help improve the business environment of the ERP users, especially in agricultural industry. This study tries to apply traditional IS theory into agricultural industry. By testing multiple aspects in different stages, the study derives more comprehensive factors that positively influence the adoption of ERP. By conducting a survey, the study observed hands-on ERP operators who work at APC which had previously adopted ERP. The study categorizes independent variables into three stages such as pre-adoption, adoption, and post-adoption. Satisfaction, system utility, work efficiency, professionalism, and standardization are examined as dependent variables. Cronbach’s alpha is used to test the reliability of the survey questionnaires in each category and multiple regression analysis is used to derive factors that have an effect on ERP adoption. Discussions on the results of data analysis are made
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
Introduction to Production Engineering DepartmentAmr El-Ganainy
Introductory Session about Production Engineering Department for Preparatory Student, Faculty of Engineering Alexandria University. During a Conference held by SMU | Start Menu Union
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The purpose of this paper is to evaluate the contributions of Total Productive Maintenance (TPM) initiatives in reducing equipment breakdowns, increase equipment reliability and improve productivity. This will result in increased equipment utilization and life, reduced work stoppages and machine slowdowns, closer adherence to production and delivery schedules as well as increased employee morale. The Total Productive Maintenance (TPM) concept addresses these goals. The aim of TPM is to keep the plant and equipment at its highest productive level through the cooperation of all areas of the organization. TPM is a partnership between maintenance and production organization to improve product quality, reduce waste, reduce manufacturing cost and increase equipment availability.
Enhancement of the performance of an industry by the application of tqm conceptseSAT Journals
Abstract Nowadays many companies are unable to prove their performance, because they do not practice the TQM concepts in- total. In order to increase the awareness, certain TQM techniques are suggested to enhance overall performance of the organisations. Here an effort is made to apply two important basic concepts of TQM which are i)continuous improvement of production process by applying newer and innovative methods ii)establishing performance measures for the processes .This paper uses the real experimental results of cartons making industry which comprises the four machines such as Printing , Punching , Gluer and Lamination machines. We get all the machines input and output details, and then made certain suggestions based on the input values of all the four machines. Presently the four machines output values such as Availability, Performance, Quality and Overall Equipment Effectiveness are very low compared with the world class industry. In order to increase them it is suggested to reduce the downtime and other non-productive time by adopting certain simple TQM techniques. The new improved values found to be much higher than the existing values. Keywords: Total Quality Management, Availability, Performance, Quality, Overall Equipment Effectiveness, Quality Improvement.
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.
Many students struggle to conduct an effective Ph.D. literature review. To write an effective PhD literature review writing, it is an essential factor to synthesize and evaluate it according to the guiding concept of your dissertation or research question.
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Multi criteria Decision model (MCDM) for the evaluation of maintenance practi...IJERA Editor
The perceptible impact of Total Productive Maintenance (TPM) lies in raising productivity standards, gaining
profitability, and improving the quality besides cutting down the non value added costs greatly. This paper is
an attempt to provide a frame work and pragmatic approach in implementation of TPM. A number of novel
success factors or practices that are responsible for the decisive role to overture the process are identified.
These practices are interchangeably called as sub-attributes. These practices must have evolved from different
strategies. The sub-attributes are quantified using least square multi attribute decision model (LSMADM) for
three alternatives strategies viz. corrective maintenance, reliability centered maintenance(RCM), and TPM. Any
sub-attribute irrespective of its own high or low relative score among the number of sub attributes is evaluated
over three alternative strategies. To implement any sub-attribute, an investigation of its highest relative score
for given alternatives will guide the managers to opt the best alternative. The best practices must come from
different strategies to get most optimal results. The priorities established using LSMADM will act as base line
to implement the industrial activities in a more systematic and balanced way to gain far-reaching optimized
productivity and quality standards. The higher priority task will be given higher consideration in terms of
committing the resources vis a vis less priority task. This will aid in orienting the collective efforts for optimal
outcomes.
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
EMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influenci
Failure Mode Effect Analysis and Total Productive Maintenance: A ReviewAM Publications
The goal of quality and reliability systems is the same-to achieve customer satisfaction. Quality and reliability are
synonymous. A system cannot be reliable if it does not have high quality. Likewise, a system cannot be of high quality if it is not
reliable. The quality performance of a firm is often assessed by the reliability of the firm's equipment or machinery. If a system is
unreliable, it is unpredictable and if it is unpredictable, it is not of high quality. FMEA is a one of the most important quality
management Techniques. Total Productive Maintenance is useful technique to increase the productivity of plant and equipment
with a modest investment in maintenance. The paper reviews various approaches of Failure Mode Effect Analysis and Total
Productive Maintenance has been developed so far and discussion about use of FMEA-TPM in integrated approach.
Maintenance Leading and Lagging Key Performance Indicators (KPIs)Ricky Smith CMRP
“It is not possible to manage what you cannot control and you cannot control what you cannot measure!” (Peter Drucker)
Performance measurement is a fundamental principle of management. The measurement of performance is important because it identifies current performance gaps between current and desired performance and provides indication of progress towards closing the gaps. Carefully selected key performance indicators identify precisely where to take action to improve performance.
This paper deals with the identification of key performance indicators for the maintenance function, by first looking at the ways that maintenance performance metrics relate to manufacturing metrics. Since performance measurements for maintenance must include both results metrics and metrics for the process that produces the results, this document presents a representation for the business process for maintenance. The document then identifies typical business process and results metrics that can be used as key performance indicators for the maintenance function.
Development Of An Effective Industrial Maintenance Practice For Plant Optimum...IJERA Editor
Plant optimization is a sound fiscal decision and this is a key attribute of good operational management. The
decision to adhere strictly to the maintenance measurements, controls and efficiencies necessary for optimum
performance not only enhances the plant operations, it quite often produces a safer operating facility and
protects plant asset or investment. Plant operations rely on dependable acquired knowledge, skills, equipment
and maintenance programs for an assured performance whiles strategies are required to be in place for
equipment optimum availability to ensure system operational integrity in order to reduce costs which affect
production. This optimized system would ideally give meaning to effective maintenance practice of plant
equipment and accepted best maintenance management system. This paper presents a comprehensive review of
characteristics of plant equipment and maintenance strategies and proposes sustainable maintenance
management performance criteria. Thereby improving business, safety, equipment efficiency and sustain the
environment. The goal is to achieve optimum availability and optimum operating condition of the equipment
life cycle in a cost optimized approach.
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.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
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/
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.
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.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
block diagram and signal flow graph representation
Maintenance performance metrics for manufacturing industry
1. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
__________________________________________________________________________________________
Volume: 02 Issue: 02 | Feb-2013, Available @ http://www.ijret.org 136
MAINTENANCE PERFORMANCE METRICS FOR MANUFACTURING
INDUSTRY
Jitendra Kumar1
, V.K. Soni2
, Geeta Agnihotri3
1
PhD Scholar, Dept. of Mechanical Engineering, MANIT, Bhopal, jitendra.me@gmail.com
2
Asst. Professor, Dept. of Mechanical Engineering, MANIT, Bhopal, soni_vk@rediffmail.com
3
Professor, Dept. of Mechanical Engineering, MANIT, Bhopal, dr.gagnihotri@gmail.com
Abstract
The purpose of this paper is to demonstrate various maintenance performance indicators (MPIs) within the perspective of
maintenance metrics conducted by the managerial personnel for achieving the specified production target. In this paper, a conceptual
framework has been developed, that provides guideline for choosing maintenance performance metrics for a typical manufacturing
industry. It seeks to align maintenance objective with the performance indicators and provides a link between the two. Operations and
maintenance of manufacturing system are of great economic importance. The review of literature on maintenance performance
indicators and their measurement has been summarized under the five categories of metrics; functional metrics, equipment
performance metrics, maintenance process metrics, periodicity metrics and OEE metrics. The review indicates that quantitative
metrics for measuring maintenance performance are lacking. To address this gap, maintenance performance metrics has been
proposed.
Keywords: Maintenance performance indicators, Performance metrics, Reactive Maintenance, Periodic maintenance,
OEE
---------------------------------------------------------------------***----------------------------------------------------------------------
1. INTRODUCTION
Effective maintenance is critical to many operations. It extends
equipment life, improves equipment availability and retains
equipment in proper condition without delay of production
schedules. The Maintenance Engineering Society of Australia
(MESA) indicates that maintenance is about achieving the
required asset capabilities within an economic or business
context (MESA, 1995). They define maintenance as the
engineering decision and associated actions, necessary and
sufficient for optimization of specified equipment „capability‟.
The term “capability” indicates the ability to perform a
specified function within a range of performance levels that
may relate to capacity, rate, quality and responsiveness (Tsang,
1998).
The four major factors (Karim, 2011) that cause defects in the
product quality are human negligence, bad quality of raw
material, machine that need maintenance and work procedure.
After analysis it has been concluded that the machine
maintenance from time to time is an important issue in quality
control. To optimize and reduce defects & occurring of
machine damage, the plant managers should focus on the
maintenance of machinery to ensure quality production at a
satisfactory level.
A number of methods have been expressed by Antero Ollila
and Markku (1999) like reactive maintenance, preventive
maintenance, predictive maintenance and proactive
maintenance. Reactive maintenance can be minimized by using
methods like JIT (Just-In-Time), TQM (Total Quality
Maintenance) to repair the machine & to reduce the defects in
produced products. Further, for achieving zero defects, JIT and
TQM method can be used in conjunction with the DPM
(Downtime Due to Preventive Maintenance) methods. While
the methods for preventive maintenance is a routine
maintenance that has been set. Campbell (1995) proposed the
implementation of two highly successful methods for the
continuous improvement – RCM (Reliability centered
Maintenance) and TPM (Total Productive Maintenance).
Pintelon and Van Wassenhove (1992) have provided a
maintenance management tool to evaluate maintenance
performance. The tool consists of a control board and a set of
reports to analyze certain ratios. This tool is applied in five
different domains falling under the control of the maintenance
manager: cost/budget, equipment performance, personnel
performance, material management and work order control.
The outline of this article is as follows. Section 2 treats the
possibility of performance metrics in achieving higher
improvement. Section 3 gives an overview of the maintenance
performance metrics and explains the importance of metrics.
Section 4 describes the different maintenance performance
metrics including functional metrics, equipment performance
metrics, maintenance process metrics, periodicity metrics and
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OEE metrics. Conclusion and future research scope are
formulated in section 5.
2. PERFORMANCE METRICS
Performance metric is the fundamental instrument of the
management which provides essential link between strategies,
execution and ultimate value creation. Performance metric is a
standard definition of a measurable quantity that indicates some
aspect of performance and it is often viewed as being part of
the infrastructure or environment in which manufacturing
operation must operate. In other words a metric is nothing more
than a standard measure to assess the performance in a
particular area. Manufacturing and management consultant
Oliver Wight almost 40 years ago offered the often repeated
maxim, “you get what you inspect, not what you expect”. All
type of firms, activity, and worker needs metrics to evaluate
fundamental activities of measuring, educating, and directing
the gap for improvement. For the continuous improvement of
plant, it is very essential to evaluate the present status of
maintenance performance with respect to the fundamental,
strategic and maintenance objectives defined by the corporate,
plant and maintenance management. While making
maintenance objectives, performance indicators and key
performance indicators can be defined (Liyange, 2003) in the
manner of either measure past or predict future performance.
Operational performance indicators related to the maintenance
are referred to as maintenance performance indicators (MPIs).
MPIs are evaluated against goals coupled with the objectives by
the company and the plant managers, respectively. Familiar
maintenance metrics can be developed for measuring
performance along the dimension of maintenance function,
process, and equipment at the plant level maintenance activities
which is untouched by the researcher.
3. MAINTENANCE PERFORMANCE METRICS
The European standard for maintenance key performance
indicators (EN: 15341, 2007) provides three main categories of
indicators namely economic indicators, technical indicators and
organizational indicators. A hierarchical manner of key figures
of industrial maintenance has been developed by Komonen
(2002) like external, internal and intermediate objective
variable including the business-oriented indicators.
The managerial aim of indicators is to guide plant operations
and maintenance performance specifically. The different
category of measure shows different areas of interest in
maintenance performance in both literature and practice. The
importance of maintenance performance measurements have
extensively been discussed by many authors (Arts 1998; Tsang
1999; Visser 2003; Weber 2006; Parida 2007). Maintenance
managers require performance information to monitor and
control maintenance processes and results, which provide
indication towards improvement. The measure of maintenance
effectiveness is defined in terms of maintenance performance
indicators (MPIs) for the plant. While, metrics are needed to
evaluate the effectiveness of maintenance strategies and
decisions regarding designing a new maintenance policy or
redesigning an existing one. Such metrics should be simple to
use to facilitate their application in today‟s changeable and
reconfigurable manufacturing environment (wiendahl, 2007). In
other words, there should be a strong dependency between
maintenance performance metrics (MPMs) and the MPIs.
Based on data analysis, this dependency should be reflected in a
strong correlation between the MPMs and MPIs. Parida and
Kumar (2006) identified the various issues and challenges
associated with development and implementation of a
maintenance performance measurement (MPM) system. The
study finds that for successful implementation of MPM, all
employees should be involved and all relevant issues need to be
considered.
A huge numbers of indicators are used in the industrial
maintenance but literature does not provide any methodology
for selection of key performance indicators and usually it has
been derived by the need and experience felt by the industry to
industry. The similar type of indicators can be grouped within a
performance metrics which can evaluate the performance of
maintenance and such type of metrics is a great challenge for
the researcher. In consequence a similar attempt has been made
to develop maintenance performance metrics in the next
section.
4. DEVELOPING A BASIS OF MAINTENANCE
PERFORMANCE METRICS
As explained in previous section it is necessary to identify the
needs of advance in order to maintain the normal functioning of
production systems. Further the analysis of maintenance
function is needed to implement better maintenance policy. For
the same the performance of maintenance must be analyzed
through performance indicators. The similar type of indicators
can be grouped within a metrics for measuring maintenance
performance according to the maintenance function. Moya
(2004) developed a system composed of indicators to control
the setting up predictive maintenance programs which should
facilitate the early detection of anomalies which can appear
during setting up to avoid the failure of maintenance program.
The procedure for detailed metrics development is shown as
follows:
(A). Metrics Collection and Definition: A comprehensive list
of maintenance performance indicators is put together through
extensive literature review including web based information
sources. Each indicator is defined within their metric so that it‟s
meaning and measures are clearly understood.
(B). Metrics Evaluation and Categorization: Each metric is
evaluated based on its characteristics and maintenance work
relevant to it, such as maintenance objective, strategies,
process, and maintenance cost is involved.
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(C). Relevancy and Repetition Check: Each category is
reviewed to ensure that all the metrics are relevant. Redundant
ones are eliminated.
4.1 FUNCTIONAL METRICS
To ensure that plant operates at the required condition while
meeting its production targets at an optimal cost, maintenance
management has to make conscious decisions regarding the
maintenance objective and strategies that need to be pursued. It
is evident that (Kelly 1989; MESA 1995; Tsang 1999; Visser
2003), maintenance objectives are related to attainment of
production target (through high equipment availability) at
required quality within the constraints of the system condition
and safety, utilizing optimum available maintenance resources
so that the plant achieves its design life, the safety standard are
met, the energy use and raw material consumption are
optimized among the other factors (Dekker, 1996).
Maintenance objective has been summarized under the
following five headings (as shown in Fig. 1): ensuring the
functionality of plant so that plant achieves its design life
within the environmental safety and cost effectiveness with
effective use of resources. It is assumed that the maintenance
objectives pursued at a given plant influences the kind of
performance metrics or indicators used.
Once the maintenance objectives are outlined, maintenance
strategy formulation is necessary to decide which type of
maintenance needs to be done, when to do it and how often it
can be done. According to Pintelon (2006) maintenance
decision making can be broadly explained in terms of
maintenance action, maintenance policies and maintenance
concepts. Maintenance policies are the rules or set of rules
describing the triggering mechanism for the different
maintenance actions. Example of these policies are Failure
based maintenance (FBM), use based or time based
maintenance (UBM/TBM), condition based maintenance
(CBM), design out maintenance (DOM) (Madu, 2000; Pintelon,
2002; savsar, 2006).
When maintenance objectives and strategies have been
established, the success of functional metrics is dependent on
the maintenance work management cycle, as outlined by
Campbell (1995), consists of work identification, planning,
scheduling, execution and closing the job. At the heart of the
maintenance, functions are work planning and scheduling,
which defines what gets done and when.
Organizational
strategies
Manufacturing
Strategies
Maintenance Objective
Be able to operate as & when
required
Operate efficiently, accurately at
the required level
Operate without unscheduled
stoppage
Operate within safety &
environmental limit
1. Operate at minimum maintenance cost
2. Operate at designed speed
3. Product Quality
4. Reliability
Fig. 1 Maintenance Objective for Maintenance Department
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4.2 EQUIPMENT PERFORMANCE METRICS
The role of the equipment condition in controlling quality and
quantity is well known in the manufacturing industry (Daya,
1995). Equipment must be maintained in top operating
conditions through adequate maintenance activities. From the
analysis of the manufacturing and maintenance environment, it
was found that equipment breakdown is the most important
cause of production disruption among other causes of
disruptions (quality, feedstock, logistics etc). Saxena (2008)
developed algorithmic performance metrics to plan
maintenance in advance to reduce downtime and maximize
availability. Ollila and Malmipuro (1999) observed that the
equipment availability has a major impact on efficiency and
quality of production. An integrated maintenance model using
statistical process control for monitoring quality of product has
been developed by Noorossana (2011) and found that the
quality of product is synonymous to monitoring status of
equipment and as the result an out-of-control signal would
indicate deterioration of the equipment. Huang et al. (2006)
considered a further extension using a preventive maintenance
(PM) that either brings the system to the „as good as new‟
condition or the system will fail immediately because of faulty
maintenance. Equipment performance (Rosqvist et al., 2009)
can be analyzed through proactivity of maintenance task of
equipment (Preventive tasks and actions/Maintenance tasks),
equipment reliability (Number of functional
failures/Operational cycles of equipment) and equipment
availability (Downtime/Operational period of equipment).
Planning of preventive maintenance of technical system is
assessed by the RCM (Reliability centered maintenance)
analysis and it is gaining a solid reputation for successful
method (Selvik, 2011). The analysis of RCM includes all
historical records such as the list of functionality significant
items (FSIA), the failure mode and effect analysis (FMEA),
case based reasoning (CBR) and the basic reliability data
(Cheng et al., 2008).
4.3 MAINTENANCE PROCESS METRICS
Marquez (2006) have defined maintenance process as the series
of action at different stages which need to follow. The
maintenance Process include assessing the feasibility and effort
required to fulfill the need of maintenance for system change
and scoping the work accordingly; planning, designing and
implementing the changes to the system and accompanying
documentation; testing the amended system at the unit, system,
integration, and acceptance levels; and transitioning the
amended system into production with minimal disruption of
normal production level. At large the assessment of
maintenance process has two parts effective analysis and
efficiency analysis. The first part helps to detect the most
important problems and locate their potential solution. The
second part identifies the suitable procedure. The researcher
define eight phases to accomplish this comprehensive
assessment as: (1) determination of current factory performance
(2) quality and downtime (3) effectiveness analysis of
alternative solution (4) efficiency analysis of maintenance
procedure (5) plan action (6) implementing action and
gathering of data (7) monitoring action and processing data (8)
adaption of plans.
Lam (2007) introduced a special monotone process applied to a
replacement model in which the operating times of system from
a non-increasing geometric process and consecutive repair
times constitute a non-decreasing geometric process. Chen
(2010) identified Geometric process modeling as a useful tool
to study repairable deteriorating system in maintenance
problems. While maintenance Error Decision Aid (MEDA)
process was developed (Rankin, 2000) based on the philosophy
that maintenance technician do not make errors on the purpose,
that errors result from a series of related contributing factors,
and that these factors are largely under management control
and, therefore, can be changed. The process was tested by the
employees of airline and one repair centre. Grall (2010)
discussed maintenance policies for stochastically deteriorating
systems which are subject to sudden change in their
degradation processes. From a maintenance decision making
point of view two condition based maintenance policies are
considered and compared through a numerical example and
show that the time distribution of the change of deterioration
rate and the difference between the two possible deterioration
rates strongly influence the choice of the best decision rule
structure.
4.3.1 PLANNED MAINTENANCE PROCESS
Planned Maintenance has two loops: Planning, scheduling,
Execution and Follow up make up the first loop while second
loop consists of work identification and performance analysis
elements. Planned maintenance process is measured by
schedule compliance i.e. the percentage of work orders
completed during the scheduled period before the late finish or
required by date. World class maintenance should achieve more
than 90% during execution. An integrated model developed by
Daya (2002) for the joint determination of economic production
quantity and preventive maintenance (PM) level for an
imperfect process having a general deterioration distribution
with increasing hazard rate.
4.3.2 ASSET RELIABILITY PROCESS
The analysis of typical asset could include costs of planning,
research and development, production, operation, maintenance
and disposal. So a life cycle cost analysis calculates the cost of
an asset for its entire life span whereas reliability analysis such
as failure rate cost of spares, repair times, and component costs.
In many maintenance problems, it is convenient to assume that
repairs are either equivalent or less beneficial than the
replacement and the system are brought back into an as good as
new state after each repair and for the same Kallen (2011) used
to model the effect of imperfect maintenance through the use of
superposition of renewal process. This model can be
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extensively used to determine an approximate probability
distribution of the time between repairs. Failed component are
not repaired until a predefined fraction of the total number has
failed.
4.4 PERIODICITY METRICS
The planned maintenance process is targeted to achieve
required performance asset performance. For the better periodic
maintenance activities, must be a better planning and
scheduling. As planning develops procedure for maintenance
work while scheduling evaluates the availability of all
resources required for maintenance work “due” in a specified
time frame.
Maintenance strategy is a structured combination of two
maintenance action (Dekker, 1996) corrective and preventive
which describes the events (e.g. failure, machine condition,
etc.) and the type of action they trigger (i.e. inspection, repair,
maintenance or replacement). Corrective maintenance which
includes all actions performed as a result of a failure to restore
an item to a specified working condition, while preventive
maintenance includes all actions performed on operating
equipment to restore them to a better condition.
Meselhy (2010) introduced two independent source of
periodicity due to maintenance programs; the failure repair and
pre-planned Preventive maintenance. Therefore, for the given
maintenance policy parameter repair level (RL), periodicity
extent expressed by the level of PM (PMLi), preventive
maintenance frequency (PMFi) and the machine failure rate E
(λ), the total system periodicity can be expressed as:
Periodicity =
E(λ)
2
RL
− 1
+
PMFi
2
PMLi
− 1
n
i=1
The above calculated periodicity is a measure of the relative
ability of the maintenance strategy to resets the machine‟s
functionality.
We may conclude that equipment performance are measured on
a shorter time interval (daily and weekly basis), probably to
facilitate quicker corrective actions. Rosqvist et al. (2009)
discussed Periodic preventive maintenance task related to
preventive maintenance strategies which are either condition-
based (periodic functional testing, periodic inspection,
condition monitoring, operation supervision) or predetermined
(periodic restoration, periodic servicing, Modification work).
4.5 OEE METRICS
The total productive maintenance (TPM) concept launched by
Nakajima (1988) provides a quantitative metric called Overall
Equipment Effectiveness (OEE) for measuring productivity of
manufacturing equipments. OEE metric and its variants came
out as the most popular equipment performance indicator
capable of measuring different production losses, of which
maintenance related losses are important. The important
maintenance indicators in the OEE have shown in the fig 2.
OEE
Availability
Rate
Performance
Rate
Quality Rate
Planned
Downtime
Unplanned
Downtime
1. Preventive Maintenance time
2. No. f preventive Maintenance
1. Failure (MTBF)
2. Failure Frequency
3. Mean Time To Repair
Fig. 2 Maintenance Indicator in the OEE Metrics
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The OEE concept has become increasingly popular and has
been widely used as a quantitative tool essential for
measurement equipments‟ performance in industries (Huang
2003; Muchiri 2008).
OEE = Availability A X Performance P X Quality (Q)
A =
calender time − Downtime
calender time
X 100
P =
Processed amount
operating time
X100
Q =
processed amount − Defective amount
processed amount
X100
This metric has become widely accepted as a quantitative tool
essential for measurement of productivity in manufacturing
operations (Samuel et al., 2002). One of the most critical
success factors influencing survival, profitability, and
competitive advantage of manufacturing organization is to
select proper maintenance policy. OEE is mostly used in one of
the policies, i.e. total productive maintenance and it helps in
decision making (Shahin, 2011) to improve the overall
performance of organizations.
Using OEE metrics and establishing a disciplined reporting
system help an organization to focus on the parameters critical
to its success. Analyzing OEE categories can reveal the greatest
limits to success.
CONCLUSIONS
In this paper, a conceptual framework has been developed that
provide the overview of maintenance performance metrics
aligning various maintenance performance indicators according
to the maintenance objective of the plant. The maintenance
performance metrics are summarized under the five categories:
functional metrics, equipment performance metrics,
maintenance process metrics, periodicity metrics and OEE
metrics. The aim is to ensure that the key indicators must be
measured within the metrics to evaluate the maintenance
performance.
This research demonstrates that the performance indicators can
be grouped within a metric so that the maintenance
performance analysis will be easy to review. Further research
work is recommended on the maintenance diagnostic metrics
and maintenance cost metrics which plays key role in the
operation and maintenance department to evaluate the
performance and further improvement. Since the availability of
maintenance metrics may not necessarily guarantee low
maintenance cost, hence a maintenance cost metrics may be
derived for the low cost repair, replacement and maintenance in
practice.
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BIOGRAPHIES:
Jitendra Kumar holds a Bachelor‟s
Degree in Mechanical Engineering and M.
Tech in Industrial Design from LNCT,
Bhopal. Presently, he is pursuing PhD in
the Dept. of Mechanical Engineering,
M.A.National Institute of Technology,
Bhopal. His main research area is
Industrial Engineering & Management.
Jitendra Kumar is the corresponding author and can be
contacted at: jitendra.me@gmail.com