Reliability Analysis for Parallel-Serial Robots in Automotive Assembly Plant: A Case Study

2015 ◽  
Vol 799-800 ◽  
pp. 1035-1039
Author(s):  
Ahmad Fauzi Fudzin ◽  
Mohd Amin Abd Majid
Keyword(s):  
Reliability Analysis ◽  
Preventive Maintenance ◽  
Production Line ◽  
Block Diagram ◽  
Assembly Plant ◽  
Serial Robots ◽  
Automotive Assembly ◽  
In Series ◽  
Series Configuration

Robot arrangement in the automotive assembly plant in manufacturing environment consists of series and parallel configurations. Robot subsystems at painting lines were configured in series configuration while overall system was configured in parallel. Interruption of operations due to breakdown at both subsystems during operation would affect the production throughput. The robots’ breakdown data for each subsystem were acquired for reliability analysis of parallel-serial configuration of robots. This study is to analyze the serial subsystems robot reliability compared to reliability of robots in overall system in parallel-serial configuration. The seven years actual breakdown data were acquired from the automotive painting plant. By using the reliability block diagram (RBD) method, at the 5000 operating hours, the two subsystems at the painting lines were evaluated. Reliability of the two subsystems are 0.029 and 0.119 respectively. While the overall parallel-serial system has the reliability of 0.145. It is proven that the parallel-serial reliability of the system is better compared to series configuration of the subsystems. With parallel-serial system, the production line would not be interrupted during the corrective or preventive maintenance worked.

Case Study on Reliability of Automotive Painting Shop Robots

2015 ◽  
Vol 1125 ◽  
pp. 516-520
Author(s):  
Mohd Amin Abd Majid ◽  
Ahmad Fauzi Fudzin
Keyword(s):  
Reliability Analysis ◽  
High Reliability ◽  
Mean Time Between Failures ◽  
Assembly Plant ◽  
Failure Data ◽  
Time Between Failures ◽  
Plant Maintenance ◽  
Automotive Assembly ◽  
Mean Time

Robots in automotive assembly plant are crucial for automation of the plant. As the robots are expensive, they are the main contributor to plant investment. Thus, it is important for the robots to have high reliability. This paper presents the reliability analysis of robots at an automotive assembly plant. The analysis was based on operating hours and frequency of the failures of the robots. The data were acquired from plant maintenance data. Using seven years of failure data, the robots’ mean time between failures (MTBF) and reliability were evaluated. Constant failure rate was assumed in the analysis. From the analysis it is noted that the reliability of the robots at the plant varies from 15% to 62% and 2% to 39% for 10,000 hours and 20,000 hours respectively. These findings could assist the maintenance manager to schedule the maintenance and replacement of the robot at the plant.

STANDARDIZED WORK IN TPS PRODUCTION LINE

2015 ◽  
Vol 76 (6) ◽  
Author(s):  
Nurul Hayati Abdul Halim ◽  
Ahmed Jaffar ◽  
Noriah Yusof ◽  
Roseelena Jaafar ◽  
Ahmad Naufal Adnan ◽  
...  
Keyword(s):  
Continuous Improvement ◽  
Production System ◽  
Manufacturing Process ◽  
Production Line ◽  
Assembly Line ◽  
Process Stability ◽  
Automotive Assembly ◽  
Study Implementation

This paper presents a case study implementation of one of the Toyota Production System (TPS) tools, known as Standardized Work (SW), in an automotive assembly line in Malaysia. The main functions of SW are to design, develop, document and visualize a set of a manufacturing process with detail and proper study of it. SW is conducted to raise production consistency and quality of a produced product and the job performed. With the proper SW implementation, good results have been obtained from the increase in efficiency, productivity, quality and process stability of the operator’s performance. Thus, the findings are consistent with TPS philosophies which are waste elimination and continuous improvement in any manufacturing area.

scholarly journals Reliability-based Optimization of Maintenance Scheduling of Mechanical Components with the Method of Accelerated Tests

2020 ◽  
Vol 14 ◽  
Keyword(s):  
Reliability Analysis ◽  
System Reliability ◽  
Block Diagram ◽  
Practical Method ◽  
Accelerated Tests ◽  
Planning And Control ◽  
System Reliability Analysis ◽  
Short Period ◽  
In Series ◽  
Reliability Based Optimization

To have effective production planning and control, it is necessary to calculate the reliability and maintenance of a production system as a whole. Therefore, with today’s highly reliable components, we are often unable to obtain a reasonable amount of test data under normal use condition. For this reason, accelerated tests method is the reasonable procedure to be applied. It is used to determine the reliability of a product in a short period of time by accelerating the use environment. Application of the method of accelerated tests can save cost that we used to pay for overcoming the dilemma of not being able to estimate failure rates by testing directly at use conditions. In this paper, we propose a practical method for system reliability analysis. Among the existing methods for system reliability analysis, reliability graph theory is particularly attractive due to its intuitiveness, which is an extension of the conventional reliability graph. A function library was developed and designed to calculate the reliability-maintainability and availability of parallel series complex systems, whose functional description is translated into a block diagram that combines in series and parallel components studied. An Extensive analytical modeling study has been performed also to verify the effectiveness of the proposed technique.

scholarly journals Effect of Preventive Maintenance on the Production Line Machines and Systems Reliability: Case Study

2020 ◽  
pp. 58-65
Author(s):  
A. M. Badiea ◽  
A. A. Adel ◽  
H. A. Aamer
Keyword(s):  
Preventive Maintenance ◽  
Production Line ◽  
Production Lines ◽  
Mean Time Between Failure ◽  
One Year ◽  
Mean Time

The aims of this study are to introduce the appropriate preventive maintenance to the production line machines at the company to increase their reliability and reduction the shutdown, and to obtain more safety. Mean time between failure, mean down time and availability are investigated as the best indicators to generally evaluate all type of maintenance. Pareto diagram and Effect-Cause techniques both have been used for identifying where and what are the problems in the production lines. The big and serious way that the company staff was using was maintenance of run to failure. Many solutions in this paper are introduced to the company to follow the proper preventive maintenance. After one year monitoring to those production lines, their productivity increases by 15.47% and the reliability becomes high.

Temperature and Humidity Dependent Reliability Analysis of RGB LED Chips

2006 ◽  
Author(s):  
Jun-Xian Fu ◽  
Shukri Souri ◽  
James S. Harris
Keyword(s):  
Reliability Analysis ◽  
Printed Circuit Board ◽  
Light Emitting Diode ◽  
Circuit Board ◽  
Light Emitting ◽  
Printed Circuit ◽  
Root Cause ◽  
Micro Cracks ◽  
Temperature And Humidity

Abstract Temperature and humidity dependent reliability analysis was performed based on a case study involving an indicator printed-circuit board with surface-mounted multiple-die red, green and blue light-emitting diode chips. Reported intermittent failures were investigated and the root cause was attributed to a non-optimized reflow process that resulted in micro-cracks and delaminations within the molding resin of the chips.

The Implementation of Biological Phosphorus and Nitrogen Removal with the Bio-Denipho Process on a 265,000 PE Treatment Plant

1992 ◽  
Vol 25 (4-5) ◽  
pp. 161-168 ◽  
Author(s):  
J. Einfeldt
Keyword(s):  
Nitrogen Removal ◽  
Treatment Plant ◽  
First Year ◽  
In Series ◽  
Design Loads ◽  
Last Stage ◽  
Two Stages ◽  
The City ◽  
Biological Phosphorus

A process, called Bio-Denipho, for combined biological phosphorus and nitrogen removal in a combination of an anaerobic tank and two oxidation ditches is described. In this process the anaerobic tank consisting of three sections working in series is followed by two oxidation ditches. These too are working in series, but with both inlet to and outlet from the tanks changing in a cycle. The Bio-Denipho process is described specifically for the process itself and as a case study for the implementation of the process on a 265,000 pe wastewater treatment plant for the city of Aalborg in Denmark. The plant was designed and erected in two stages and the last stage was inaugurated October 31,1989. Lay-out and functions for the plant is described and design loads, plan lay-out and tank volumes are given in this paper together with performance data for the first year in operation.

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