Reliability, availability and maintainability (RAM) analysis for wine packaging production line

2018 ◽  
Vol 35 (3) ◽  
pp. 821-842 ◽  
Author(s):  
Panagiotis Tsarouhas
Keyword(s):  
Production Line ◽  
Failure Modes ◽  
Probability Distributions ◽  
Data Sets ◽  
Effect Analysis ◽  
Content Type ◽  
Factors Affecting ◽  
Potential Factors ◽  
Ram Analysis ◽  
Best Fit

Purpose The purpose of this paper is to provide results for a complete reliability, availability, and maintainability (RAM) analysis utilizing data sets from a production system in a wine packaging line. Through the illustrated case study, the author demonstrates how RAM analysis is very useful for deciding maintenance intervals, and for planning and organizing the adequate maintenance strategy. Design/methodology/approach RAM analysis has been done for each machine by using failures data. The parameters of some common probability distributions, such as Weibull, exponential, lognormal, and normal distributions, have been estimated by using the Minitab software package. An investigation to determine which of these distributions provide the best fit for characterizing the failure pattern at machine and line level has been made. Reliability and maintainability of both wine packaging and its machines has been estimated at different mission times with their best fit distribution. High maintainability issues and potential factors with their potential failure modes were presented, through failure mode and effect analysis process. Findings Analysis of the total downtime, breakdown frequency, reliability, and maintainability characteristics of different machines shows that: first, the availability for the wine packaging line was 91.80 percent, and for the remaining 8.2 percent the line is under repair. Second, about two failures per shift are displayed on the line, whereas for the mean time-to-repair (TTR) a failure is 24 minutes. Third, there is no correlation between the time-between-failures and the TTRs for the wine packaging line. Fourth, the main three factors affecting the maintainability process in the production line are: resources availability, manpower management, and maintenance planning procedures. Originality/value This study is anticipated to serve as an illuminating effort in conducting a complete RAM analysis in the much advertised field of wine packaging production line which on the other hand so little has been published on operational availability and equipment effectiveness. It can also be useful to serve as a valid data source for winery product manufacturers, who wish to improve the design and operation of their production lines.

Reliability block diagram (RBD) and fault tree analysis (FTA) approaches for estimation of system reliability and availability – a case study

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Balaraju Jakkula ◽  
Govinda Raj Mandela ◽  
Murthy Ch S N
Keyword(s):  
Failure Modes ◽  
Block Diagram ◽  
Probability Distributions ◽  
Fault Tree Analysis ◽  
Likelihood Estimation ◽  
Parametric Estimation ◽  
Data Sets ◽  
Content Type ◽  
Best Fit

PurposeIn the present worldwide situation, the survival of a business is a major crucial aspect. The business cannot be succeeded unless it produces the anticipated production levels. Achievement of this can be possible only by maintaining the equipment into an adequate level. Load-Haul-Dumpers (LHDs), as the main workhorse and massive transporting machines, are highly utilized in underground mining operations. Despite the usage of LHDs, these are prone to the uneven and unexpected occurrence of potential failures. These are causes to minimize the production and productivity of capital intensive equipment. To get a good profitability index, it is very necessary to have the required levels of equipment reliability and availability. Estimation of reliabilities and availabilities play a critical role in the performance evaluation of equipment.Design/methodology/approachBy keeping the significance of the present research work in view in this research paper one of the well appropriate techniques such as fault tree analysis (FTA) was utilized to assess the reliability of the LHD system based on the function flow diagram. Best fit distribution of data sets were made by the utilization of Kolmogorov–Smirnov (K-S) test. Parametric estimation of theoretical probability distributions was done by utilizing the maximum likelihood estimation (MLE). Failure rate of each LHD system has computed based on the best fit results from “Isograph Reliability Workbench 13.0”. Reliability configuration of each LHD system has modeled using reliability block diagram (RBD), as well as the FTA.FindingsIndependent and identical distribution (IID) assumption of data sets was validated through statistic U-test (Chi Squared test). On the basis of test results, the data sets are in accordance with IID assumption. Therefore renewal process approach has been utilized for further investigation. Allocations of best fit distribution of data sets were made by the utilization ofK-S test. Parametric estimation of theoretical probability distributions was made by utilizing maximum likelihood estimation (MLE) method. Reliability of each individual subsystem has been computed according to the best fit distribution. The deductive method called RBD was utilized to investigate the given system reliability by analyzing with graphical representations of logic system and observed highest percentage of reliability as 69.44% (LH29). FTA has been utilized to investigate the availability percentage of a system and observed highest percentage value as 79.51% (LH29). This technique also helps to identify the most critical parts/cut sets by using Fussell-Vesely (F-V) importance measure.Research limitations/implicationsAs the reliability analysis is one of the complex techniques, it requires strategic decision-making knowledge for the selection of methodology to be used. As the present case study was from a public sector company, operating under financial constraints the conclusions/findings may not be universally applicable.Originality/valueThe present study throws light on this equipment that need a tailored maintenance schedules, partly due to the peculiar mining conditions, under which they operate. This analysis provides the information on several aspects such as present working condition of the machines, occurrence of various potential failure modes, influence of failure modes on its performance and reliable life aspects etc. Also, these investigations asses the forecasting of necessary managerial practices or control measures like possible design modifications and replacement actions of components to ensure the required levels of availability and utilization of the equipment. Both qualitative and quantitative analysis of FTA has been performed to determine the minimal/most influencing cut sets of the system and to estimate overall system availability within the work environment. Based on the computed results reasons for performance drop of each machine was identified and suitable recommendations were suggested to improve the performance of capital intensive systems.

Maintenance management of load haul dumper using reliability analysis

2019 ◽  
Vol 26 (2) ◽  
pp. 290-310 ◽  
Author(s):  
Balaraju Jakkula ◽  
Govinda Raj M. ◽  
Murthy Ch.S.N.
Keyword(s):  
Reliability Analysis ◽  
Probability Distributions ◽  
Parametric Estimation ◽  
Maintenance Management ◽  
Data Sets ◽  
Content Type ◽  
Theoretical Probability ◽  
Reliability Level ◽  
Kolmogorov Smirnov ◽  
Best Fit

Purpose Load haul dumper (LHD) is one of the main ore transporting machineries used in underground mining industry. Reliability of LHD is very significant to achieve the expected targets of production. The performance of the equipment should be maintained at its highest level to fulfill the targets. This can be accomplished only by reducing the sudden breakdowns of component/subsystems in a complex system. The identification of defective component/subsystems can be possible by performing the downtime analysis. Hence, it is very important to develop the proper maintenance strategies for replacement or repair actions of the defective ones. Suitable maintenance management actions improve the performance of the equipment. This paper aims to discuss this issue. Design/methodology/approach Reliability analysis (renewal approach) has been used to analyze the performance of LHD machine. Allocations of best-fit distribution of data sets were made by the utilization of Kolmogorov–Smirnov (K–S) test. Parametric estimation of theoretical probability distributions was made by utilizing the maximum likelihood estimate (MLE) method. Findings Independent and identical distribution (IID) assumption of data sets was validated through trend and serial correlation tests. On the basis of test results, the data sets are in accordance with IID assumption. Therefore, renewal process approach has been utilized for further investigation. Allocations of best-fit distribution of data sets were made by the utilization of Kolmogorov–Smirnov (K–S) test. Parametric estimation of theoretical probability distributions was made by utilizing the MLE method. Reliability of each individual subsystem has been computed according to the best-fit distribution. In respect of obtained reliability results, the reliability-based preventive maintenance (PM) time schedules were calculated for the expected 90 percent reliability level. Research limitations/implications As the reliability analysis is one of the complex techniques, it requires strategic decision making knowledge for the selection of methodology to be used. As the present case study was from a public sector company, operating under financial constraints the conclusions/findings may not be universally applicable. Originality/value The present study throws light on this equipment that need a tailored maintenance schedule, partly due to the peculiar mining conditions, under which they operate. This study mainly focuses on estimating the performance of four numbers of well-mechanized LHD systems with reliability, availability and maintainability (RAM) modeling. Based on the drawn results, reasons for performance drop of each machine were identified. Suitable recommendations were suggested for the enhancement of performance of capital intensive production equipment. As the maintenance management is only the means for performance improvement of the machinery, PM time intervals were estimated with respect to the expected rate of reliability level.

Statistical analysis of failure data for estimating reliability, availability and maintainability of an automated croissant production line

2019 ◽  
Vol 25 (3) ◽  
pp. 452-475 ◽  
Author(s):  
Panagiotis Tsarouhas
Keyword(s):  
Production Line ◽  
Continuous Monitoring ◽  
Maintenance Strategy ◽  
Content Type ◽  
Failure Patterns ◽  
Failure Data ◽  
Correlation Tests ◽  
Line Level ◽  
Ram Analysis ◽  
Best Fit

Purpose The purpose of this paper is to compute reliability, availability and maintainability (RAM) indices to measure and improve the performance of an automated croissant production line under real working conditions. Based on this study, the authors demonstrate how RAM analysis is very useful for deciding maintenance intervals and for planning and organizing the adequate maintenance strategy. Design/methodology/approach The present work is carried out by analyzing failure and repair data based on statistical techniques. Descriptive statistics of the failure and repair data at workstation and line level were carried out. Trend and serial correlation tests validated the assumption of independence and identical distribution of the failure data were conducted. Moreover, the reliability and maintainability of both the croissant production line and its workstations have been estimated at different mission times with their best fit distribution. Findings The main objectives of the applied method are to understand the nature of the failure patterns, and to estimate the reliability and maintainability characteristics of the croissant production system in precise quantitative terms. The analysis identifies the critical points of the production line that require further improvement through effective maintenance strategy. Originality/value This study is anticipated to serve as an illuminating effort in conducting a complete RAM analysis and its effect on the performance of the system that works under real conditions. The advantage of the methodology is the continuous monitoring of the production process through appropriate indices, the utilization of which leads to a continuous cycle of improvement.

Fuzzy risk assessment for electro-optical target tracker

2016 ◽  
Vol 33 (6) ◽  
pp. 830-851 ◽  
Author(s):  
Soumen Kumar Roy ◽  
A K Sarkar ◽  
Biswajit Mahanty
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Linear Equations ◽  
Mode Analysis ◽  
Failure Behavior ◽  
Membership Functions ◽  
Design And Development ◽  
Effect Analysis ◽  
Content Type ◽  
Criticality Analysis

Purpose – The purpose of this paper is to evolve a guideline for scientists and development engineers to the failure behavior of electro-optical target tracker system (EOTTS) using fuzzy methodology leading to success of short-range homing guided missile (SRHGM) in which this critical subsystems is exploited. Design/methodology/approach – Technology index (TI) and fuzzy failure mode effect analysis (FMEA) are used to build an integrated framework to facilitate the system technology assessment and failure modes. Failure mode analysis is carried out for the system using data gathered from technical experts involved in design and realization of the EOTTS. In order to circumvent the limitations of the traditional failure mode effects and criticality analysis (FMECA), fuzzy FMCEA is adopted for the prioritization of the risks. FMEA parameters – severity, occurrence and detection are fuzzifed with suitable membership functions. These membership functions are used to define failure modes. Open source linear programming solver is used to solve linear equations. Findings – It is found that EOTTS has the highest TI among the major technologies used in the SRHGM. Fuzzy risk priority numbers (FRPN) for all important failure modes of the EOTTS are calculated and the failure modes are ranked to arrive at important monitoring points during design and development of the weapon system. Originality/value – This paper integrates the use of TI, fuzzy logic and experts’ database with FMEA toward assisting the scientists and engineers while conducting failure mode and effect analysis to prioritize failures toward taking corrective measure during the design and development of EOTTS.

VIKOR power law-based customer-oriented FMEA with complete unique risk priority numbers

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Randula L. Hettiarachchi ◽  
Pisut Koomsap ◽  
Panarpa Ardneam
Keyword(s):  
Case Studies ◽  
Power Law ◽  
Design Methodology ◽  
Service Sector ◽  
Failure Modes ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Content Type ◽  
Industrial Sectors ◽  
Inherent Problem

PurposeAn inherent problem on risk priority number (RPN) value duplication of traditional failure modes and effect analysis (FMEA) also exists in two customer-oriented FMEAs. One has no unique value, and another has 1% unique values out of 4,000 possible values. The RPN value duplication has motivated the development of a new customer-oriented FMEA presented in this paper to achieve practically all 4,000 unique values and delivering reliable prioritization.Design/methodology/approachThe drastic improvement is the result of power-law and VlseKriterijumska Optimizacija I Kompromisno Resenje (VIKOR). By having all three risk factors in a power-law form, all unique values can be obtained, and by applying VIKOR to these power-law terms, the prioritization is more practical and reliable.FindingsThe proposed VIKOR power law-based customer-oriented FMEA can achieve practically all 4,000 unique values and is tested with two case studies. The results are more logical than the results from the other two customer-oriented FMEAs.Research limitations/implicationsThe evaluation has been done on two case studies for the service sector. Therefore, additional case studies in other industrial sectors will be required to confirm the effectiveness of this new customer-oriented RPN calculation.Originality/valueAchieving all 1,000 unique values could only be done by having experts tabulate all possible combinations for the traditional FMEA. Therefore, achieving all 4,000 unique values will be much more challenging. A customer-oriented FMEA has been developed to achieve practically all 4,000 unique risk priority numbers, and that the prioritization is more practical and reliable. Furthermore, it has a connection to the traditional FMEA, which helps explain the traditional one from a broader perspective.

Interval type-2 fuzzy inference-based failure mode and effect analysis model in a group decision-making setting

Kybernetes ◽  
2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
İlker Gölcük
Keyword(s):  
Failure Modes ◽  
Fuzzy Inference ◽  
Real Life ◽  
Effect Analysis ◽  
Inference System ◽  
Content Type ◽  
Proposed Model ◽  
Interval Type

PurposeThis paper proposes an integrated IT2F-FMEA model under a group decision-making setting. In risk assessment models, experts' evaluations are often aggregated beforehand, and necessary computations are performed, which in turn, may cause a loss of information and valuable individual opinions. The proposed integrated IT2F-FMEA model aims to calculate risk priority numbers from the experts' evaluations and then fuse experts' judgments using a novel integrated model.Design/methodology/approachThis paper presents a novel failure mode and effect analysis (FMEA) model by integrating the fuzzy inference system, best-worst method (BWM) and weighted aggregated sum-product assessment (WASPAS) methods under interval type-2 fuzzy (IT2F) environment. The proposed FMEA approach utilizes the Mamdani-type IT2F inference system to calculate risk priority numbers. The individual FMEA results are combined by using integrated IT2F-BWM and IT2F-WASPAS methods.FindingsThe proposed model is implemented in a real-life case study in the furniture industry. According to the case study, fifteen failure modes are considered, and the proposed integrated method is used to prioritize the failure modes.Originality/valueMamdani-type singleton IT2F inference model is employed in the FMEA. Additionally, the proposed model allows experts to construct their membership functions and fuzzy rules to capitalize on the experience and knowledge of the experts. The proposed group FMEA model aggregates experts' judgments by using IT2F-BWM and IT2F-WASPAS methods. The proposed model is implemented in a real-life case study in the furniture company.

Capture and evaluation of innovative ideas in early stages of product development

2019 ◽  
Vol 31 (6) ◽  
pp. 908-927 ◽  
Author(s):  
Peter Madzík
Keyword(s):  
Product Development ◽  
Innovation Process ◽  
Kano Model ◽  
Effect Analysis ◽  
Content Type ◽  
Factors Affecting ◽  
Early Stages ◽  
Structured Analysis ◽  
Idea Evaluation

Purpose The purpose of this paper is to propose a structured procedure for the capture and evaluation of innovative ideas in the early stages of product development. The procedure is designed to take account of internal and external factors affecting the value of innovative ideas. Design/methodology/approach The proposed procedure is based on divergent and convergent approaches to innovation. Ideas are generated and captured using targeted questions and subsequently evaluated using modifications of the Kano model and failure mode and effect analysis (FMEA). Idea evaluation considers four criteria – delight, originality, market share potential and simplicity – which are used to compute an “idea priority number”. Findings A case study looking at innovations in swimming goggles verified the validity of the proposed procedure. The procedure also supports fact-based decision making and applies a structured perspective to the innovation process that makes it easier to manage. Research limitations/implications The case study made use of a pilot survey in which 32 customers participated. Although the case study was only intended as a demonstration of the method’s use, such a sample size could lead to unreliable results in certain cases. Originality/value Applications of standard or expanded FMEA do not add value to a product because the main purpose of the approach is to prevent failure. The proposed inversion of FMEA logic combined with customer view via the Kano model offers a method for the structured analysis of product innovations. No similar approach to the evaluation of innovations has so far appeared in the literature.

Digital transformation: setting the pace

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ari Margiono
Keyword(s):  
Research Work ◽  
Digital Transformation ◽  
Content Type ◽  
Factors Affecting ◽  
Rapid Acquisition ◽  
Organic Growth ◽  
Conceptual Paper ◽  
Potential Factors ◽  
Strategic Paths ◽  
Practical Implications

Purpose This paper aims to identify the paths of digital transformation followed by companies facing disruption and offer recommendations for executives for choosing the appropriate path. Design/methodology/approach This is a conceptual paper. Findings This paper identifies two paths of digital transformation. The offensive path is aggressive and involves the rapid acquisition of digital resources through portfolio investment and merger and acquisition tactics. The defensive path is relatively slow and relies on the organic growth of the digital capabilities of the incumbent companies over time. Research limitations/implications This paper identifies a number of potential factors affecting the choice of the transformation path taken by companies. Further studies can be conducted to investigate these contingent factors. Practical implications This study describes the strategic paths available in a digital transformation and identifies the conditions that might justify a particular approach. Originality/value This paper identifies two types of paths that are generally followed by companies aiming digital transformation – offensive and defensive. This aspect has not been studied in any other research work.

Cost consequence of failure in failure mode and effect analysis

2017 ◽  
Vol 34 (8) ◽  
pp. 1318-1342 ◽  
Author(s):  
Jeff Guinot ◽  
John W. Sinn ◽  
M. Affan Badar ◽  
Jeffrey M. Ulmer
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Cost Data ◽  
Ordinal Scale ◽  
Automotive Application ◽  
Manufacturing Cost ◽  
Potential Cost ◽  
Effect Analysis ◽  
Content Type ◽  
Cost Consequence

Purpose The purpose of this paper is to investigate the possibility of including the cost consequence of failure in the a priori risk assessment methodology known as failure mode and effect analysis (FMEA). Design/methodology/approach A model of the standard costs that are incurred when an electronic control module in an automotive application fails in service was developed. These costs were related to the Design FMEA ranking of the level of severity of the failure mode and the probability of its occurrence. Monte Carlo simulations were conducted to establish the average costs expected for each level of severity at each level of occurrence. The results were aggregated using fuzzy utility sets into a nine-point ordinal scale of cost consequence. The criterion validity of this scale was assessed with warranty cost data derived from a case study. Findings It was found that the model slightly underestimated the warranty costs that accrued, but the fit could be improved with adjustments dictated by actual usage conditions. Research limitations/implications Cost data used in the simulations were derived from government and academic surveys, analyses, and estimates of the manufacturing cost structure; and nominal costs for various quality issues experienced by Tier 2 automotive electronics supplier. Specificity is lacking. The sample size and the type of the failure modes used to validate the model are constrained by the number and type of products which have had demonstrable performance concerns over the past three years, with cost data available to the authors. The power of the validation is limited. The validation is considered a screening assessment. Practical implications This work relates the characterization of risk with its potential cost and develops a scaling instrument to allow the incorporation of cost consequence into an FMEA. Originality/value A ranking scale was developed that related severity and occurrence rank scores to a cost consequence rank that keys to a cost of quality figure (given as percent of sales) that would accompany a realization of the failure mode.

Improving risk evaluation in FMEA with a hybrid multiple criteria decision making method

2015 ◽  
Vol 32 (7) ◽  
pp. 763-782 ◽  
Author(s):  
Hu-Chen Liu ◽  
Jian-Xin You ◽  
Xue-Feng Ding ◽  
Qiang Su
Keyword(s):  
Decision Making ◽  
Failure Modes ◽  
Multiple Criteria Decision Making ◽  
Multiple Criteria ◽  
Analytic Hierarchy ◽  
Effect Analysis ◽  
Maintenance Strategies ◽  
Content Type ◽  
Safety And Reliability ◽  
Hierarchy Process

Purpose – The purpose of this paper is to develop a new failure mode and effect analysis (FMEA) framework for evaluation, prioritization and improvement of failure modes. Design/methodology/approach – A hybrid multiple criteria decision-making method combining VIKOR, decision-making trial and evaluation laboratory (DEMATEL) and analytic hierarchy process (AHP) is used to rank the risk of the failure modes identified in FMEA. The modified VIKOR method is employed to determine the effects of failure modes on together. Then the DEMATEL technique is used to construct the influential relation map among the failure modes and causes of failures. Finally, the AHP approach based on the DEMATEL is utilized to obtain the influential weights and give the prioritization levels for the failure modes. Findings – A case study of diesel engine’s turbocharger system is provided to illustrate the potential application and benefits of the proposed FMEA approach. Results show that the new risk priority model can be effective in helping analysts find the high risky failure modes and create suitable maintenance strategies. Practical implications – The proposed FMEA can overcome the shortcomings and improve the effectiveness of the traditional FMEA. Particularly, the dependence and interactions between different failure modes and effects have been addressed by the new failure analysis method. Originality/value – This paper presents a systemic analytical model for FMEA. It is able to capture the complex interrelationships among various failure modes and effects and provide guidance to analysts by setting the suitable maintenance strategies to improve the safety and reliability of complex systems.

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