Mid-Life Refurbishment Maintenance Strategy to Sustain Performance and Reliability of Train System

2020 ◽  
Vol 899 ◽  
pp. 238-252
Author(s):  
Mohd Firdaus Mohamad Idris ◽  
Nor Hayati Saad
Keyword(s):  
Life Span ◽  
Automotive Industry ◽  
System Reliability ◽  
Current Practice ◽  
Evaluation Criteria ◽  
Rolling Stock ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Train System

Mid-Life Refurbishment (MLR) is a process conducted in many industries to improve or extend the life span of assets such as machines, infrastructures and systems. The objective of MLR works execution is to extend the life span, sustain the train performance and achieve system reliability. Typically, the refurbishment scope consists of overhaul, upgrading and rectification works. The biggest challenge is to determine) the scope of refurbishment works and to create equilibrium between the feasibility and viability of the project. Therefore, the main objective of this paper is to discuss the current practice of performing MLR maintenance through the utilization of Failure Mode and Effect Analysis (FMEA) and to transform the existing FMEA used by the automotive industry to fulfil the needs of Rolling Stock. The use of FMEA is critical in determining) the scope of train refurbishment work. It was carried out at the initial stages of the process in order to determine Risk Priority Number (RPN) to prioritize the type of refurbishment plans and scope. The design of the FMEA Worksheets, De-sign of FMEA severity Evaluation Criteria, Design of Occurrence Evaluation Criteria and Design of FMEA Prevention/Detection Criteria were adopted and adapted from the generic format so that it is coherent with Railway Industries. The results based on the transformation framework, the plan and scope of overhaul, upgrading and rectification were defined using the FMEA. Out of the 80 elements of MLR works that were analyzed using the FMEA approach, it was found that 46 elements needed overhaul, 23 elements needed upgrading and 11 elements needed rectification works. Finally, the application of the FMEA helped determine the MLR scope of work from 13 systems. The case study was taken from the Malaysia LRT Project, and currently the fleet has been in operation for more than 20 years (operated since year 1998).

scholarly journals Failure Mode and Effect Analysis in Automotive Industry: A Case Study

2019 ◽  
Vol 19 (2) ◽  
pp. 10-15
Author(s):  
L. Petrescu ◽  
E. Cazacu ◽  
Maria-Cătălina Petrescu
Keyword(s):  
Failure Mode ◽  
Automotive Industry ◽  
Failure Modes ◽  
Action Plan ◽  
Electronic Devices ◽  
Area Network ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Iso 26262

AbstractNowadays, Failure Mode and Effect Analysis (FMEA) is more present in any standard evaluation of a product or process. In automotive industry, the IEC 61508 Standard adapted the ISO 26262 restrictions for Electrical and Electronic Devices. Conducting an FMEA reduces the costs by focusing on preventing failures, improving safety and increasing customer satisfaction. This paper presents a case study of a FMEA on a CAN (Controller Area Network) Bus Harness considering the entire process from defining the scope and building the team, to the action plan that will reduce the Risk Priority Number below the acceptable risk value. Also, the brainstorming that identifies the possible failure modes is presented.

An Application of Failure Mode and Effect Analysis to Cylinder Head during Dismantle of Remanufacturing Process: A Case Study

2013 ◽  
Vol 845 ◽  
pp. 841-851 ◽  
Author(s):  
Mohd Yazid Abu ◽  
Khairur Rijal Jamaludin ◽  
Amiril Sahab Abdul Sani ◽  
Tajul Ariffin Abdullah ◽  
Dzuraidah Abdul Wahab
Keyword(s):  
Failure Mode ◽  
Automotive Industry ◽  
Real Life ◽  
Developed Countries ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Business Opportunity ◽  
Work Outcome ◽  
Industry Sectors

While the concept of remanufacturing is gaining in popularity, in practice the remanufacturing industry in Malaysia is still in its nascent stage, with approximately 32 fields in various industries claiming to be involved in the process. This is an indication for Malaysia to further develop the industry as competing developed countries already view remanufacturing as a huge business opportunity. The aim of this study is to identify and minimize the frequent failures occurring during the dismantling process. Ishikawa diagram is used to identify all possible causes of failures while the Failure Mode and Effect Analysis (FMEA) with two Risk Priority Number (RPNs), identifies the most significant failures. The case study is performed in an automotive industry as well as in a contract remanufacturing environment in Malaysia, specifically pertaining to the dismantling of cylinder heads. The work outcome of this project is expected to be the enhancement of the robustness of DfRem investigations among researchers in real life applications and to provide better solution to a wider variety of industry sectors in a developing country like Malaysia.

scholarly journals Risk analysis of production process for food SMEs using FMEA method: a case study

2021 ◽  
Vol 331 ◽  
pp. 02010
Author(s):  
Prima Fithri ◽  
Muhammad Rafi ◽  
Pawenary ◽  
A. S. Prabuwono
Keyword(s):  
Human Resources ◽  
Production Process ◽  
Critical Value ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Increase Productivity ◽  
Fmea Method ◽  
Bread Production ◽  
A Company

The increasing development of the industry makes every industry have to compete with other competitors to gain an edge. The advantages of competition are influenced by several factors, one of which is good human resource management. Where if a company has good human resources, it will increase profits indirectly and can increase productivity. This research discusses case studies about the potential dangers of IKM Heppy Bakery’s potential dangers that can harm workers in bread production. The method used is Failure Mode And Effect Analysis (FMEA). Later, the data will be filled and given a rating distinguished into three parts: severity, occurrence, and detection. The data were obtained through questionnaires given to 3 workers at IKM Heppy Bakery and filled in rating values based on the provisions that have been given to the questionnaire. This Value helps determine the Risk Priority Number (RPN) obtained from multiplication between severity, occurrence, and detection. After processing the RPN multiplication data, the highest RPN value was obtained by 193 with the danger factor of the operator overheating and dehydrating due to high temperatures. Furthermore, the calculation of critical Value was obtained by 109. Based on the critical Value obtained seven hazard factors above the critical value, these seven hazard factors need to be improved so that workers do not avoid accidents when conducting the production process.

scholarly journals Implementation of Failure Mode and Effect Analysis and Fault Tree Analysis in Paper Mill: A Case Study

2020 ◽  
Vol 9 (3) ◽  
pp. 171-176
Author(s):  
Nurul Retno Nurwulan ◽  
Wilcha Anatasya Veronica
Keyword(s):  
Quality Control ◽  
Failure Mode ◽  
Fault Tree Analysis ◽  
Paper Mill ◽  
Control Methods ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Increase Productivity ◽  
Prevention Methods

A good quality control system is important to be implemented to increase productivity and minimize defects in products. One of the quality control methods is failure mode and effect analysis (FMEA). This study uses the FMEA to identify the causes of the defects and recommend the prevention methods to overcome the causes of the defects in an Indonesian paper mill. The risk priority number (RPN) is calculated by multiplying the severity, occurrence, and detection of the failures that have been determined. Unsymmetrical and tainted products are the most dominant defects in the paper mill. An inappropriate machine setting is the cause of unsymmetrical products with the highest RPN of 343. The second highest RPN is problems with bleaching machines that caused tainted products with an RPN value of 216. This study offers suggestions to Indonesian paper mill to prevent and minimize defective products. 

scholarly journals Analysis and Defect Improvement Using FTA, FMEA, and MLR Through DMAIC Phase: Case Study in Mixing Process Tire Manufacturing Industry

2021 ◽  
Vol 54 (5) ◽  
pp. 721-731
Author(s):  
Tubagus Hendri Febriana ◽  
Hasbullah Hasbullah
Keyword(s):  
Manufacturing Industry ◽  
Fault Tree Analysis ◽  
Added Value ◽  
Mixing Process ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Tree Analysis ◽  
Industry Competition ◽  
Dmaic Method

In line with the increasingly fierce industry competition, all companies strive to make continuous improvements to increase added value and reduce waste which will impact the company's ability to maintain its existence in the future. One of the problems found in the tire manufacturing industry is the quality problem of the occurrence of defects in the mixing process which is dominated by the viscosity out standard on the compound steel breaker. In this study, analysis and improvement of the defect problem were carried out using Fault Tree Analysis (FTA), Failure Mode and Effect Analysis (FMEA), and Multiple Linear Regression (MLR) to test the correlation between the root causes found to the main problem. Based on the results of the analysis found thirteen root causes where the factor of variation in material viscosity and the suitability of determining the design process has the largest Risk Priority Number (RPN) value and has a strong correlation to defects that occur based on hypothesis testing. Furthermore, improvements are made using the DMAIC method on all factors that affect the occurrence of defects. As the result, the improvement can be effective in reducing the defect to 34.5% and achieve the expected target.

The integrated PFMEA approach with interval type-2 fuzzy sets and FBWM: A case study in the automotive industry

2021 ◽  
pp. 095440702110347
Author(s):  
Nikola Komatina ◽  
Danijela Tadić ◽  
Aleksandar Aleksić ◽  
Nikola Banduka
Keyword(s):  
Risk Factors ◽  
Risk Factor ◽  
Automotive Industry ◽  
Real Life ◽  
Relative Importance ◽  
Effect Analysis ◽  
Stable Conditions ◽  
Interval Type

The change of market’s demand could be predictable to a certain degree at stable conditions but it may vary due to disruptive events. This research contributes by establishing the improvement of PFMEA (Process Failure Mode and Effect Analysis) analysis in the domain of assessment and determining severity risk factor, as well as identifying of failure priority. According to the researchers’ and practitioners’ suggestions, severity needs to be considered from the multiple aspects. The risk factor severity is considered from the aspects of product importance, quality, and cost. These aspects have different relative importance, which is determined in an exact way. The relative importance of the aspects, as well as the values of the risk factors, was described by linguistic expressions that are modeled by using the Interval type-2 trapezoidal fuzzy numbers (IT2TrFNs). IT2FBWM was used to determine weight vectors of risk factors. The priority of failures is determined according to the Action priority model which proposed by AIAG & VDA (Automotive Industry Action Group and German Association of the Automotive Industry). The proposed methodology is tested in a Case study where the real-life data originated from a company from the Republic of Serbia that operates as a part of an automotive supply chain.

scholarly journals Failure Mode and Effect Analysis (FMEA) for confectionery manufacturing in developing countries: Turkish delight production as a case study

2012 ◽  
Vol 32 (3) ◽  
pp. 505-514 ◽  
Author(s):  
Sibel Ozilgen
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Chemical Contamination ◽  
Risk Priority Number ◽  
Analysis Model ◽  
Production Potential ◽  
Effect Analysis ◽  
Potential Failure

The Failure Mode and Effect Analysis (FMEA) was applied for risk assessment of confectionary manufacturing, in whichthe traditional methods and equipment were intensively used in the production. Potential failure modes and effects as well as their possible causes were identified in the process flow. Processing stages that involve intensive handling of food by workers had the highest risk priority numbers (RPN = 216 and 189), followed by chemical contamination risks in different stages of the process. The application of corrective actions substantially reduced the RPN (risk priority number) values. Therefore, the implementation of FMEA (The Failure Mode and Effect Analysis) model in confectionary manufacturing improved the safety and quality of the final products.

Current Situation in Cleaning Process of Remanufacturing in Malaysia: A Case Study

2013 ◽  
Vol 845 ◽  
pp. 904-914
Author(s):  
Mohd Yazid Abu ◽  
Khairur Rijal Jamaludin ◽  
Amiril Sahab Abdul Sani ◽  
Tajul Ariffin Abdullah ◽  
Dzuraidah Abdul Wahab
Keyword(s):  
Developed Countries ◽  
Current Situation ◽  
Cleaning Process ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Business Opportunity ◽  
Work Outcome ◽  
Green Ideas ◽  
Real World Situation

Remanufacturing process among industries is relatively new in Malaysia. In USA, Europe, Japan, China and India, remanufacturing is already viewed as a huge business opportunity that significantly stimulates growth in Gross Domestic Product (GDP) and employment. The aim of this paper is to expose all possible causes of failures using the Ishikawa diagram and identify the most significant failures using Failure Mode and Effect Analysis (FMEA) with two Risk Priority Number (RPNs). The cleaning process is both time-consuming as well as the most costly of the entire remanufacturing processes. The case study is performed in an automotive contract remanufacturing environment in Malaysia, specifically the remanufacturing of cylinder heads. This work outcome explores the current situation pertaining to the cleaning process in a real world situation, and attempts to promote among researchers green ideas that will bring Malaysias remanufacturing on par with that of other developed countries.

scholarly journals A Case Study on Recall of used Scopes in the Endoscopy Department by using a Failure Mode & Effect Analysis (FMEA) Proactive Risk Management

2020 ◽  
pp. 13-24
Author(s):  
Zuber Mujeeb Shaikh
Keyword(s):  
Risk Management ◽  
Failure Mode ◽  
Failure Modes ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Mode Effect ◽  
Potential Failure ◽  
Failure Mode Effect Analysis

Failure Mode and Effects Analysis (FMEA) is the process of reviewing as many components, assemblies, and subsystems as possible to identify potential failure modes in a system and their causes and effects. The study revealed that the Risk Priority Number (RPN) was initially 450 and it has decreased to 90 after implementing all the actions in FMEA.

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