Improving quality of maintenance task for milk powder manufacturing unit through TOPSIS

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nilesh Pancholi ◽  
Hiren Gajera ◽  
Darshit Shah
Keyword(s):  
Failure Analysis ◽  
Milk Powder ◽  
Economic Cost ◽  
Shop Floor ◽  
Critical Component ◽  
Reliability Modeling ◽  
Content Type ◽  
Powder Manufacturing ◽  
Maintenance Plan

PurposeThe purpose of this paper is to explore the possibilities of improving the quality of existing maintenance task of the atomizer of milk powder manufacturing unit of a dairy plant. Looking to the past business volume and expected growth, the milk powder manufacturing unit forms a noticeable sector of processing plant. The lack of quality in maintenance standards leads to reliability losses of about 20–25% with low productivity and profit. Such facts and challenges of keeping the system in ready-state motivate a definite maintenance plan to be modeled based on a live failure analysis to be executed during shutdown or scheduled period.Design/methodology/approachThe deliverables are achieved by collecting the historical failure data i.e. downtime and failure frequencies; from January 2020 to July 2020 at Dudhsagar dairy, Gujarat, India. Reliability modeling is done in a view to understand the failure pattern behavior of the milk powder manufacturing unit. The atomizer is discriminated as a critical component based on these data and their functional failures, failure causes, effects and repercussions of failures with existing control and maintenance practices has been modeled based on live shop-floor study. Scores are assigned on 1 to 10 levels by analyzing attributes effects from lowest to highest concern respectively for every modes of failure through realistic brain-storming among maintenance team by incorporating some advanced attributes like maintainability, economic safety, economic cost and spares with basic criteria in this study. The maintainability criticality index (MCI) is narrated by these score values through multi-attribute decision-making (MADM) based failure analysis models like Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS).FindingsThe primary findings of this research work are to propose improvements in the quality of the maintenance plan of critical component like; atomizer of a milk powder manufacturing unit which is commonly representing critical component in a major range of industrial processes. The case study recommended four silent maintenance strategies i.e. scheduled maintenance scheduled discard, scheduled failure finding and redesign as a qualified maintenance plan for the atomizer based on MCI and rankings of its potential failure causes. The results are helpful in upgrading quality standards for the maintenance activities of a process industry of alike or of dissimilar kinds in accordance with the failure analysis.Originality/valueOriginality mainly consists of investigating the scope of enhancing the existing maintenance practices through actual failure analysis with the help of TOPSIS. The criteria employed in this study are probability of chances of failure, degree of detectability and degree of severity as basic criteria along with some advanced criteria like; maintainability, spare parts, economic cost, economic safety are selected based on the outcome of shop-floor study and reliability modeling. The notable past failure statistics (downtime, frequency of failures) of a milk powder manufacturing unit were recorded and these data are analyzed based on reliability to extract an explicative component i.e. atomizer.

scholarly journals Influence of Cations on Growth of Thermophilic Geobacillus spp. and Anoxybacillus flavithermus in Planktonic Culture

2012 ◽  
Vol 78 (7) ◽  
pp. 2477-2481 ◽  
Author(s):  
Ben Somerton ◽  
Jon Palmer ◽  
John Brooks ◽  
Edward Smolinski ◽  
Denise Lindsay ◽  
...  
Keyword(s):  
Optical Density ◽  
Milk Powder ◽  
Manufacturing Plant ◽  
Planktonic Culture ◽  
Content Type ◽  
Free Ions ◽  
Thermophilic Bacilli ◽  
Anoxybacillus Flavithermus ◽  
Powder Manufacturing

ABSTRACTFree ions of Na+, K+, Ca2+, and Mg2+influenced the optical density of planktonic cultures of thermophilic bacilli.Anoxybacillus flavithermusE16 andGeobacillussp. strain F75 (milk powder manufacturing plant isolates) andA. flavithermusDSM 2641 andG. thermoleovoransDSM 5366 were studied. Ca2+and Mg2+were associated with increases in optical density more so than Na+and K+. Overall, it appeared that Ca2+and/or Mg2+was required for the production of protein in thermophilic bacilli, as shown by results obtained withA. flavithermusE16, which was selected for further study.

Designing optimal double sampling plan using the weighted Poisson distribution

2015 ◽  
Vol 33 (1) ◽  
pp. 62-77 ◽  
Author(s):  
Venugopal Haridoss ◽  
Kandasamy Subramani
Keyword(s):  
Poisson Distribution ◽  
Design Methodology ◽  
Sampling Plan ◽  
Shop Floor ◽  
Double Sampling ◽  
Content Type ◽  
Final Inspection ◽  
The Given

Purpose – The purpose of this paper is to present the optimal double sampling attribute plan using the weighted Poisson distribution. Design/methodology/approach – For the given AQL and LQL, sum of producer’s and consumer’s risks have been attained. Based on the weighted Poisson distribution, the sum of these risks has been optimized. Findings – In the final inspection, the producer and the consumer represent the same party. So, the sum these two risks should be minimized. In this paper, the sum of risks has been tabulated using the weighted Poisson distribution for different operating ratios. These tabulated values are comparatively less than the sum of risks derived using Poisson distribution. Originality/value – The sampling plan presented in this paper is particularly useful for testing the quality of finished products in shop floor situations.

scholarly journals Preconditioning with Cations Increases the Attachment of Anoxybacillus flavithermus and Geobacillus Species to Stainless Steel

2013 ◽  
Vol 79 (13) ◽  
pp. 4186-4190 ◽  
Author(s):  
Ben Somerton ◽  
Steve Flint ◽  
Jon Palmer ◽  
John Brooks ◽  
Denise Lindsay
Keyword(s):  
Stainless Steel ◽  
Milk Powder ◽  
Steel Product ◽  
Physiological Factors ◽  
Content Type ◽  
Manufacturing Plants ◽  
Viable Cells ◽  
Anoxybacillus Flavithermus ◽  
Contact Surfaces ◽  
Powder Manufacturing

ABSTRACTPreconditioning ofAnoxybacillus flavithermusE16 andGeobacillussp. strain F75 with cations prior to attachment often significantly increased (P≤ 0.05) the number of viable cells that attached to stainless steel (by up to 1.5 log CFU/cm2) compared with unconditioned bacteria. It is proposed that the transition ofA. flavithermusandGeobacillusspp. from milk formulations to stainless steel product contact surfaces in milk powder manufacturing plants is mediated predominantly by bacterial physiological factors (e.g., surface-exposed adhesins) rather than the concentrations of cations in milk formulations surrounding bacteria.

A conceptual examination of Lean, Six Sigma and Lean Six Sigma models for managing waste in manufacturing SMEs

2020 ◽  
Vol 17 (1) ◽  
pp. 20-32 ◽  
Author(s):  
Harsimran Singh Sodhi ◽  
Doordarshi Singh ◽  
Bikram Jit Singh
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Shop Floor ◽  
Content Type ◽  
Manufactured Products ◽  
Manufacturing Organizations ◽  
Scrap Reduction ◽  
Manufacturing Organization

Purpose The purpose of this paper is to examine and evaluate various Lean, Six Sigma and Lean Six Sigma (LSS) models proposed by various researchers, which have been implemented in manufacturing organizations. Design/methodology/approach The present study has followed three major steps in methodology. In the first step, pooling of various research articles has been done, followed by development of the primary results. At the final step, analysis and development of the LSS model have been performed. Findings This paper evaluated and examined various models of Lean Manufacturing, Six Sigma and LSS and developed an advanced LSS model that can be deployed in any manufacturing organization with the purpose of scrap reduction. Originality/value The findings of this study will assist shop floor managers to implement an LSS model in their organizations, which can effectively reduce the waste and enhance the overall productivity and quality of the manufactured products.

Maintenance programmes for flat roofs in existing buildings

2017 ◽  
Vol 35 (3) ◽  
pp. 339-362 ◽  
Author(s):  
João Morgado ◽  
Inês Flores-Colen ◽  
Jorge de Brito ◽  
Ana Silva
Keyword(s):  
Existing Buildings ◽  
Content Type ◽  
Surrounding Environment ◽  
Service Conditions ◽  
Definition Of ◽  
Flat Roofs ◽  
Maintenance Plan ◽  
Practical Implications ◽  
Proactive Maintenance

Purpose The purpose of this paper is to propose a maintenance programme for flat roofs in existing buildings, based on the inspection of 26 buildings in-service conditions, located in the Lisbon region, in Portugal. A proactive maintenance of flat roofs in existing buildings allows reducing their pathology, thus improving their performance and service life. Design/methodology/approach The maintenance plan was established based on the degradation state of the maintenance source elements (MSEs) analysed, the aggressiveness of the surrounding environment and the age of the roofs and maintenance actions carried out during the roofing systems’ life cycle. Findings The maintenance plan proposed in this study includes the prioritization of the interventions, the definition of the required maintenance operations and the definition of the frequency of the intervention, considering the service lives of the MSEs. Research limitations/implications The study addresses only roofs located in the Lisbon area. Even though a relatively large sample of 26 roofs was used, the findings and conclusions can clearly be extrapolated for a much wider scope. Practical implications The maintenance plan proposed in this study considers a planning of proactive maintenance operations to continuously and effectively monitor all the relevant MSE. Originality/value This plan allows minimizing the incidence and spread of defects, thus enabling the optimization of resources, reducing the costs of the entire maintenance system and improving the quality of the built environment.

scholarly journals Influence of Incubation Temperature and Total Dissolved Solids on Biofilm and Spore Formation by Dairy Isolates of Geobacillus stearothermophilus

2021 ◽  
Vol 87 (8) ◽  
Author(s):  
Murali Kumar ◽  
Steve Flint ◽  
Jon Palmer ◽  
Sawatdeenaruenat Chanapha ◽  
Chris Hall
Keyword(s):  
Biofilm Formation ◽  
Milk Powder ◽  
Dairy Industry ◽  
Spore Formation ◽  
Solid Concentration ◽  
Geobacillus Stearothermophilus ◽  
Content Type ◽  
Heat Resistant ◽  
Total Dissolved Solid ◽  
Powder Manufacturing

ABSTRACT Geobacillus species are important contaminants in the dairy industry, and their presence is often considered an indicator of poor plant hygiene with the potential to cause spoilage. They can form heat-resistant spores that adhere to surfaces of processing equipment and germinate to form biofilms. Therefore, strategies aimed toward preventing or controlling biofilm formation in the dairy industry are desirable. In this study, we demonstrated that the preferred temperature for biofilm and spore formation among Geobacillus stearothermophilus A1, D1, P3, and ATCC 12980 was 65°C. Increasing the total dissolved milk solid concentration to 20% (wt/vol) caused an apparent delay in the onset of biofilm and spore formation to detectable concentrations among all the strains at 55°C. Compared to the onset time of the biofilm formation of A1 in 10% (wt/vol) reconstituted skim milk, addition of milk protein (whey protein and sodium caseinate) caused an apparent delay in the onset of biofilm formation to detectable concentrations by an average of 10 h at 55°C. This study proposes that temperature and total dissolved solid concentration have a cumulative effect on biofilm and spore formation by G. stearothermophilus A1, D1, P3, and ATCC 12980. In addition, the findings from this study may indicate that preconditioning of stainless steel surfaces with adsorbed milk proteins may delay the onset of biofilm and spore formation by thermophilic bacteria during milk powder manufacture. IMPORTANCE The thermophilic bacillus Geobacillus stearothermophilus is a predominant spoilage bacterium in milk powder manufacturing plants. If its numbers exceed the accepted levels, financial losses may be incurred because of the need to lower the price of the end product. Furthermore, G. stearothermophilus bacilli can form heat-resistant spores which adhere to processing surfaces and can germinate to form biofilms. Previously conducted research had highlighted the variation in the spore and biofilm formation among three specific strains of G. stearothermophilus isolated from a milk powder manufacturing plant in New Zealand. The significance of our research is in demonstrating the effects of two abiotic factors, namely, temperature and total dissolved solid concentration, on biofilm and spore formation by these three dairy isolates, leading to modifications in the thermal processing steps aimed toward controlling biofilm and spore formation by G. stearothermophilus in the dairy industry.

A Sample Preparation on Decapsulation Methodology for Effective Failure Analysis on Thin Small Leadless (TSLP) Flip Chip Package with Copper Pillar (CuP) Bump Interconnect Technology

2014 ◽  
Author(s):  
Gwee Hoon Yen ◽  
Ng Kiong Kay
Keyword(s):  
Sample Preparation ◽  
Failure Analysis ◽  
Flip Chip ◽  
Fault Localization ◽  
Cost Effective ◽  
Fault Isolation ◽  
Voltage Contrast ◽  
Interconnect Technology

Abstract Today, failure analysis involving flip chip [1] with copper pillar bump packaging technologies would be the major challenges faced by analysts. Most often, handling on the chips after destructive chemical decapsulation is extremely critical as there are several failure analysis steps to be continued such as chip level fault localization, chip micro probing for fault isolation, parallel lapping [2, 3, 4] and passive voltage contrast. Therefore, quality of sample preparation is critical. This paper discussed and demonstrated a quick, reliable and cost effective methodology to decapsulate the thin small leadless (TSLP) flip chip package with copper pillar (CuP) bump interconnect technology.

scholarly journals Chazuta: subnational governments and internationalization of the agro-industrial value chain

2019 ◽  
Vol 26 (4) ◽  
pp. 340-351
Author(s):  
Alberto Carlo Cajavilca ◽  
Marta Tostes
Keyword(s):  
Value Chain ◽  
Qualitative Approach ◽  
Value Chains ◽  
Public Officials ◽  
Extension Services ◽  
Content Type ◽  
Alternative Crop ◽  
San Martín ◽  
Subnational Governments

Purpose The purpose of this paper is to examine the role and contribution of San Martin and Chazuta subnational governments in promoting development and internationalization of the cocoa and chocolate value chain from the stakeholders’ perceptions. This work was based on a qualitative approach in which information triangulation method, information processing with evaluation rubric and WebQDA software were used. The results showed that stakeholders of both value chains perceive that the subnational government’s actions taken to develop and internationalize these value chains are poorly valued and insufficient. Likewise, six internationalization barriers were identified in which two are perceived as the main limitations: low productivity levels and access to innovations and technology. These results contribute to enrich the decision-making process of political authorities and public officials from the San Martin subnational governments. Moreover, they provide information, according to the Peruvian national requirements, on the perceptions needed to rethink and improve the governmental services available, especially productive activities in the rainforest area (Presidencia del Consejo de Ministros, 2015; Wiener Fresco, 2010). This can improve or create new extension services to increase the quality of the Chazuta’s cocoa and chocolate products and to facilitate their entry into more demanding and profitable markets (Shapira, y otros, 2015). Design/methodology/approach This paper has been developed by using a qualitative approach with an exploratory and descriptive scope. The objective was to examine a study case of how subnational governments contribute in the promotion of development and internationalization of agro-industrial value chains as alternatives to illicit crops (Hernandez, Fernandez, & Baptista, 2010). The Chazuta case was selected because it is representative of the region in terms of coca eradication and is located between two regions of high biodiversity – Cordillera Escalera Regional Conservation Area and Cordillera Azul National Park. Findings One of the issues hindering the ability of the Chazuta cocoa and chocolate producers is based on their perception that the subnational governments’ efforts are focused on meeting already-established goals and little emphasis is placed on solving productive problems. On the other hand, at an articulation level, the most relevant efforts have been connecting the cocoa and chocolate customers to Chazuta producers through events. In spite of this, such events are not considered a permanent activity and the producers do not perceive that these mechanisms enable them to maintain these long-term trade relationships. This can be explained by the fact that Chazuta cocoa and chocolate organizations recognize that they still have incipient productive capacities to meet the foreign market’s demand. Furthermore, associations, cooperatives and SMEs are not able to maintain constant levels of production quality, except the family-based business. Knowledge and techniques provided by subnational governments and private organizations are not fully used or implemented by the associations’ members. This low level of knowledge application can be explained by cultural factors and also because the producers receive multiple and sometimes contradictory information from various providers of technology extension services. This leads to inadequate use or non-implementation of productivity improvements, thus generating a virtuous circle in which production and quality of the goods remain at low levels, which hinders their entry into demanding and profitable markets. Research limitations/implications This paper has been developed with a qualitative approach considering an exploratory and descriptive scope. Chazuta case was selected because it is representative of the region in terms of eradication achievements and it is located between two regions of high biodiversity. A rubric is an evaluation method of individuals or organizations performance, taking into consideration the evaluator’s pre-established criteria to determine if the objectives and goals are being met. Based on these criteria, evidence and performance information is collected. Following, performance is graded based on the researcher’s predetermined criteria and finally a merit-based judgment is made on the performance. Practical implications The results contribute to enrich decision making of political authorities and public officials from San Martin subnational governments. They provide information, according to Peruvian national requirements, on the perceptions needed to rethink and improve provided government services, especially in rainforest area productive activities. This adds up to improvement or creation of new extension services to increase the quality of Chazuta’s cocoa and chocolate products, and to facilitate their entry into more demanding and profitable markets. Social implications The situation of San Martín region and Chazuta district is contextualized and emphasis is given to socioeconomic conditions and the value of cocoa as an alternative crop to coca. From 1980 to early 2000, Peru lived a period of generalized violence due to narcoterrorism, which had large-scale outreach in southern highland and rainforest areas. To deal with this situation, subnational governments in collaboration with international cooperation decided to consolidate agro-industrial value chains in order to generate legal income for rural populations. For this purpose, alternative crop policies were implemented and San Martin region achieved the best results. Originality/value This fieldwork was carried out as part of the undergraduate thesis but after fieldwork, with the use of online software tool WebQDA, codes were created to systematize and quantify the collected information in the content manager. The codes were created taking into account assessment and evaluation variables. Each value represented a code referred to a performance level as perceived by Chazuta cocoa and chocolate value chains stakeholders.

Good problem solvers? Leveraging knowledge sharing mechanisms and management support

2019 ◽  
Vol 23 (6) ◽  
pp. 1017-1038 ◽  
Author(s):  
Ambra Galeazzo ◽  
Andrea Furlan
Keyword(s):  
Transformational Leadership ◽  
Problem Solving ◽  
Knowledge Sharing ◽  
Hierarchical Linear Modeling ◽  
Shop Floor ◽  
Management Support ◽  
Linear Modeling ◽  
Content Type ◽  
Problem Solvers ◽  
Good Problem

Purpose Organizational learning relies on problem-solving as a way to generate new knowledge. Good problem solvers should adopt a problem-solving orientation (PSO) that analyzes the causes of problems to arrive at an effective solution. The purpose of this paper is to investigate this relevant, though underexplored, topic by examining two important antecedents of PSO: knowledge sharing mechanisms and transformational leaders’ support. Design/methodology/approach Hierarchical linear modeling analyses were performed on a sample of 131 workers in 12 plants. A questionnaire was designed to collect data from shop-floor employees. Knowledge sharing was measured using the mechanisms of participative practices and standardized practices. Management support was assessed based on the extent to which supervisors engaged in transformational leadership. Findings Knowledge sharing mechanisms are an antecedent of PSO behavior, but management support measured in terms of transformational leadership is not. However, transformational leadership affects the use of knowledge sharing mechanisms that, in turn, is positively related to PSO behavior. Practical implications The research provides practical guidance for practitioners to understand how to manage knowledge in the workplace to promote employees’ PSO behaviors. Originality/value Though problem-solving activities are intrinsic in any working context, PSO is still very much underrepresented and scarcely understood in knowledge management studies. This study fills this gap by investigating the antecedents of PSO behavior.

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