Analysis of Operational Readiness and Reliability of the Paper Machine System after Implementation of Model of Influence (original) (raw)
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The South African Journal of Industrial Engineering, 2012
Maintenance is an important process in a manufacturing system. Thus it should be conducted and measured effectively to ensure performance efficiency. A variety of studies have been conducted on maintenance as affected by factors such as productivity, cost, employee skills, resource utilisation, equipment, processes, and maintenance task planning and scheduling [1,2]. According to Coetzee [3], equipment is the most significant factor affecting maintenance performance because it is directly influenced by maintenance activities. This paper proposes an equipment performance and reliability (EPR) model for measuring maintenance performance based on machine effectiveness. The model is developed in four phases, using Pareto analysis for machine selection, and failure mode and effect analysis (FMEA) for failure analysis processes. Machine effectiveness is measured using the integration of overall equipment effectiveness and the reliability principle. The result is interpreted in terms of maintenance effectiveness, using five health index levels as bases. The model is implemented in a semiconductor company, and the outcomes confirm the practicality of the EPR model as it helps companies to measure maintenance effectiveness.
Istraživanja i projektovanja za privredu, 2022
Maintenance performance level (MPL) is an important part of the key performance indicator (KPI) to improve the effectiveness of machine maintenance which includes factors of overall equipment effectiveness-machine effectiveness (OEE-ME) and machine reliability (MR). The purpose of this paper is to optimize the value of the maintenance performance level (MPL) through the collaboration of overall equipment effectiveness-machine effectiveness (OEE-ME) and machine reliability (MR). The study began with collecting research data, namely machine operation, preventive maintenance, and corrective maintenance. The data is processed using the Pareto principle to determine the critical system based on failure frequency. The selected critical system is tested for probability distribution and machine reliability (MR) assessment with several predetermined maintenance time interval scenarios. The main result of this research is the optimal maintenance time interval is a better criterion than other criteria. The optimal maintenance time interval was chosen because it can meet the requirements of overall equipment effectiveness-machine effectiveness (OEE-ME) at a world-class maintenance performance level (MPL) with a value of 90.43%, and the proposed machine reliability (MR) is better than the initial machine reliability (MR) based on the failure ratio value. Therefore, it can be boldly stated that the collaboration of overall equipment effectiveness-machine effectiveness (OEE-ME) and machine reliability (MR) can influence and optimize the value of maintenance performance level (MPL), which has a strong correlation and significant impact.
Improving on Machine Reliability and Productivity Through Data Analysis
2022
The objective of the manufacturing industry is to produce quality and quantity of goods to satisfy existing customer base, expand market sphare, remain competitive and profitable. However, achieving these ideals depend largely on the reliability of the machines in the production line. Therefore, it is necessary to explore the impact of machine reliability on production and profiability in a manufacturing industry by analysing and interpreting the operational information in the computerised maintenance management system (CMMS) database.This research adopted the principle of action research, involving a two-year longitudinal analysis of the operational information in the database of the machines in the production line of Adcock Ingram Critical Care (AICC) and benchmarking the same with that of Adcock Ingram Health Care (AIHC), a similar pharmaceutical industry. It focused on how AIHC used the factors of total breakdowns, total down time, mean time between failure (MTBF) and the mean time to repair (MTTR) to improve on the reliability of machines in their production network. The analysis was complemented with interviews of participants from interrelated units of the same industry. The findings revealed that in all the areas of measurement in 2017, the machines in the production line of AICC performed below the benchmark of AIHC. However, in 2018, there were appreciable improvements, due to the practice of preventive maintenance. Therefore, the introduction of appropriate CMMS in maintenance operations, including the detailed analysis of operational information and benchmarking, provides a useful learning curve to improve on the reliability of machines in the production line of manufacturing industries.
Performance Optimizing of a Sanitary Towel Production Plant Using Reliability Model
Nigerian Journal of Technology, 2013
The study was conducted in a rm that manufactures sanitary pads and babies disposable towels which production is below the installed capacity as a result of high production downtime that resulted from incessant breakdown of the subsystems of the production system. The aim of the study was to reduce the production downtime signi cantly, thereby optimizing the machine time, and consequently, raising the reliability of the production system. The research work obtained machine breakdown records from the production unit and used the data to estimate the reliability of the production system to be 0.708. This showed that the production system was idle for about 30% of the total machine time, thereby incurring a huge production loss. The hazard rates of vital subsystems obtained, as well as the provision of redundancy for some subsystem as appropriate helped to determine the improved reliability of the production system to be 0.862. The study concludes that reliability model could be an e e...
International Journal of Innovation in Enterprise System, 2017
The development of science and technology that has been developed more rapidly at this time, along with the increasing need for information itself. By producing a newspaper every day then the states forced PT Pikiran Rakyat to further improve the smoothness, the effectiveness and efficiency of the printing. One way to measure the performance of machines in general by using OEE and to minimize the possibility of losses to be borne by the company is improving the Reliability, Availability and Maintainability (RAM). By using the data in the form of MTTF (Main Time to Failure) and MTTR (Main Time To Repair) of each subsystem of the printing press. Based on calculations using the method of Overall Equipment Effectiveness, by performing calculations based on three main parameters with a study for eight months or 5760 hours, show that the value of the Availability of 75%, the value of the Performance of 97%, and the value of Quality by 98%, then the system has OEE values of 71.60%. The sys...
Total productive maintenance is practical technique aimed at maximizing the effectiveness of facility that we use within our organization. Total productive maintenance establishes a system of productive maintenance, covering the entire life cycle of equipment, covers all departments, involves participation of all employees from top to bottom and promotes small group autonomous activities. During high growth era companies make technical progress in automation and centralization of the plants, which needs large amount of manual work to maintain the automation systems. The strategy of maintaining the equipment of a plant is crucial for the effectiveness of manufacturing. And, as the competitive environment in the world continues to increase the pace, our project work intends to help companies to develop new strategies to reduce costs, develop employees to face future challenges and bring about a new culture at work place. To carry out successful implementation of our work, firstly, literature review was done thoroughly to understand the underlying concepts of TPM. Further, empirical study was conducted based on real time data and analysis was done to obtain achievable results. Finally questionnaires were distributed to assess information on successful implementa-tion of TPM in the industry. Results obtained through the empirical study revealed the varying trends in the Overall Equipment Effectiveness (OEE) and Total Productivity of the machines taken up for the study. The average values of OEE were found to lay between the ranges of 63% to 71% against world class standards of 85%. The results highlighted the major causes resulting in the downtime and decrease in the productivity. A comparative study between World Class industries where TPM has been implemented and industries which do not follow TPM identifies the various problems leading to decrease in the overall efficiency of the industry and provides valuable suggestions focusing on the benefits and methodology for implementing TPM in industries. Total productive maintenance has proved the capacity for helping companies set up their operations through outlining feasible aims and objectives, structures and guidelines. These improve the production of companies, increase their market share and help them achieve high performance using minimum costs. Companies that have used TPM have realized immense performance growth levels.
Planning and optimizing the maintenance of paper production systems in a paper plant
Computers & Industrial Engineering, 2008
Manufacturing and production plants operate physical assets that deteriorate with usage and time, thus, maintenance actions are required to restore the assets back to their original predetermined operational conditions. But since, organizational resources are limited and scarce. The objective of an effective maintenance program is to minimize total cost of inspection and repair, and equipment downtime. In this paper, we describe a new multicriteria optimization framework for deriving optimal maintenance schedules for preventive maintenance which considers availability, maintenance cost and life cycle costs as the criteria for optimization. The Simulink toolbox of the Matlab has been interfaced with Genetic algorithm for optimization. After getting solution, Stochastic Petri nets has been used to model the system and find out the effect of optimized maintenance schedules on system performance. The application of the proposed framework has been discussed on a practical case of a paper plant.
2018
This article is the research of object that engaged in printing (advertising) industry company, the product is a printed item in the form of textbooks, magazines, brochures, catalogs, and others. During production runs there are often problems occur causing inhibition of production so the results are not maximum, such problems include machines that always a lot of time wasted (downtime), breakdown time, also the preparation of equipment (setup and adjustment) resulting in a less productivity in the production. For this research, the data used is observation result on Yoshino I machine from March to May 2015 and March to May 2016. Data processing is done by calculating the value of Overall Equipment Effectiveness (OEE) seen from Availability, Performance, and Quality. After the calculation using this Overall Equipment Effectiveness method, the OEE achievement was significantly increased every month, but yet has not reached the World Class OEE standard. The OEE value becomes low on th...
To implement the TPM tools and techniques a particular unit of machine shop in the Manufacturing Industry is considered in order to evaluate the contributions of total productive maintenance (TPM) initiatives to improve manufacturing performance in machine shop. Due to frequent failures and breakdowns occurred in machine shop, it requires more effort on maintenance due to which increased in maintenance cost and this results into different losses at work place which cause low availability, poor performance and low quality of the output ultimately cause low overall equipment effectiveness (OEE) of the machine. The correlations between various TPM implementation dimensions and manufacturing performance improvements have been evaluated and validated by employing OEE in machine shop. The purpose of this paper is to evaluate the contributions of TPM initiatives through Work sampling to achieve the World class OEE which raise the Quality excellence. Hence in sampling study has been conducted to compute the downtime and utilization of the machines and to improve OEE. The study establishes that focused TPM implementation over a reasonable time period can strategically contribute towards utilization of significant manufacturing performance enhancements. Keywords: Total Productive Maintenance, Overall Equipment Effectiveness, Work Sampling and Utilization ________________________________________________________________________________________________________ I. INTRO DUCTIO N Total Productive Maintenance play an important role due to it control over the various factors Overall equipment effectiveness such as performance, quality, and availability of the machine in the industries. In today's situation, the importance of the keeping good condition of equipment has its own importance since the condition and performance of the equipment have large role in the quality and availability of the products. Many developing countries have liberalized their economies by adopting the TPM and its pillars to remain in the competition but due to the complexity and rapid demand make the organization difficult to follow the TPM. If we focuses of the present status of Indian industries through the literature survey no one industries has OEE equal to the world class OEE, it just about average of 50%-70% of OEE which is comparatively low as world class OEE. Some of the industries trying to achieve the OEE to make the plant in good condition or it also take the place in the market as a leader or competitor. Continuous analysis of the plant by the help of TPM pillar can reduce the trouble up to some extent. II. CO NTRIBUTIO NS TOWARDS TPM PRACTICES IMPROVING MANUFACTURING PERFO RMANCE The advancement in technology had lead to the industrial revolution and higher level competition for survival. PDCA approach is one of the TPM tool which help to plan the activity within the organization [1]. The author (Abhishek Jain et al. [2]) explained that by adopting many improvement strategies to enhance their performance as TPM, Kaizen or Continuous improveme nt (CI), and pillar of TPM model, is a good concept for small continuous improvements. S.Nakajima (Author) has described about challenging limits for TPM, method for calculation of OEE & its comparison with world class manufacturing, possible areas of wastage of resources which may occur losses [3]. The objective of TPM is maximizing of equipment effectiveness by maximization of machine utilization and machine availability. As one of the pillars of TPM activities, Kaizen pursues efficie nt equipment, operator and material and energy utilization that is extremes of productivity and aims at achieving substantial effects. Kaizen activities try to thoroughly eliminate losses in which six major losses that were identified [4]. Frequent machine breakdowns, low plant availability, increased rejection are a great threat to increase operating cost and lower productivity. The company has to suffer due to lower availability of machines and performance rate also decreases as a result of breakdowns which may leads to possess extra cost during the production [5]. The author (Paropate and Sambhe [6]) explained that world-class manufacturing which has been recognized as one of the significant operation strategy to regain the production losses due to equipment inefficiency. Fishbone diagram is one of the seven basic Quality Control tools used for