scholarly journals Innovative Approach to Preventive Maintenance of Production Equipment Based on a Modified TPM Methodology for Industry 4.0

2021 ◽  
Vol 11 (15) ◽  
pp. 6953
Author(s):  
Filip Hardt ◽  
Martin Kotyrba ◽  
Eva Volna ◽  
Robert Jarusek
Keyword(s):  
Preventive Maintenance ◽  
Industry 4.0 ◽  
Production Equipment ◽  
Innovative Approach ◽  
Practical Implementation ◽  
Total Productive Maintenance ◽  
New Approach ◽  
Industrial Companies ◽  
Maintenance Process ◽  
Operational Data

Preventive maintenance (PM) in the production industry is one of the most essential measures to eliminate accidental machinery failures by replacing/repairing worn out machines or parts. The decision of when and where to perform preventive maintenance is non-trivial due to the complex and stochastic nature of the industry where PM is implemented. This article deals with the theoretical and practical implementation of preventive maintenance based on a unique modification of the total productive maintenance (TPM) methodology. The innovative approach of preventive maintenance management was implemented in the real production hall of ITT (Czech Republic) and has been verified. Within preventive maintenance, the new concept brings in an innovative method of managing the maintenance process as a whole, from abstract methodical conception to practical usage. The whole new approach has been verified and implemented on industrial equipment. A challenging task while implementing Industry 4.0 technologies is the issue of how to fully gather and analyse operational data from various items of equipment and users under various conditions, which would result in innovative services of equipment maintenance for clients. The solution to this problem is based on an innovative approach to preventive maintenance of complex equipment and could help many industrial companies to increase production and maintenance efficiency.

Optimizing preventive maintenance over a finite planning horizon in a semi-Markov framework

2020 ◽  
Author(s):  
Antonio Sánchez Herguedas ◽  
Adolfo Crespo Márquez ◽  
Francisco Rodrigo Muñoz
Keyword(s):  
Preventive Maintenance ◽  
Recurrence Relations ◽  
Direct Calculation ◽  
Planning Horizon ◽  
Practical Implementation ◽  
Practical Application ◽  
Mathematical Solution ◽  
Accumulated Reward ◽  
Finite Planning Horizon

Abstract This paper describes the optimization of preventive maintenance (PM) over a finite planning horizon in a semi-Markov framework. In this framework, the asset may be operating, and providing income for the asset owner, or not operating and undergoing PM, or not operating and undergoing corrective maintenance following failure. PM is triggered when the asset has been operating for τ time units. A number m of transitions specifies the finite horizon. This system is described with a set of recurrence relations, and their z-transform is used to determine the value of τ that maximizes the average accumulated reward over the horizon. We study under what conditions a solution can be found, and for those specific cases the solution τ* is calculated. Despite the complexity of the mathematical solution, the result obtained allows the analyst to provide a quick and easy-to-use tool for practical application in many real-world cases. To demonstrate this, the method has been implemented for a case study, and its accuracy and practical implementation were tested using Monte Carlo simulation and direct calculation.

scholarly journals Connectivity as a Design Feature for Industry 4.0 Production Equipment: Application for the Development of an In-Line Metrology System

2021 ◽  
Vol 11 (3) ◽  
pp. 1312
Author(s):  
Ana Pamela Castro-Martin ◽  
Horacio Ahuett-Garza ◽  
Darío Guamán-Lozada ◽  
Maria F. Márquez-Alderete ◽  
Pedro D. Urbina Coronado ◽  
...  
Keyword(s):  
Industry 4.0 ◽  
Design Feature ◽  
Production Equipment ◽  
Smart Manufacturing ◽  
Process Data ◽  
Industrial Sectors ◽  
Advanced Manufacturing Technologies ◽  
Manufacturing Technologies ◽  
Equipment Application ◽  
The Impact

Industry 4.0 (I4.0) is built upon the capabilities of Internet of Things technologies that facilitate the recollection and processing of data. Originally conceived to improve the performance of manufacturing facilities, the field of application for I4.0 has expanded to reach most industrial sectors. To make the best use of the capabilities of I4.0, machine architectures and design paradigms have had to evolve. This is particularly important as the development of certain advanced manufacturing technologies has been passed from large companies to their subsidiaries and suppliers from around the world. This work discusses how design methodologies, such as those based on functional analysis, can incorporate new functions to enhance the architecture of machines. In particular, the article discusses how connectivity facilitates the development of smart manufacturing capabilities through the incorporation of I4.0 principles and resources that in turn improve the computing capacity available to machine controls and edge devices. These concepts are applied to the development of an in-line metrology station for automotive components. The impact on the design of the machine, particularly on the conception of the control, is analyzed. The resulting machine architecture allows for measurement of critical features of all parts as they are processed at the manufacturing floor, a critical operation in smart factories. Finally, this article discusses how the I4.0 infrastructure can be used to collect and process data to obtain useful information about the process.

scholarly journals Digital Twins Collaboration for Automatic Erratic Operational Data Detection in Industry 4.0

2021 ◽  
Vol 11 (7) ◽  
pp. 3186
Author(s):  
Radhya Sahal ◽  
Saeed H. Alsamhi ◽  
John G. Breslin ◽  
Kenneth N. Brown ◽  
Muhammad Intizar Ali
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Systems ◽  
Interaction Mechanism ◽  
Semantic Knowledge ◽  
Smart Manufacturing ◽  
Data Detection ◽  
Workflow Model ◽  
Digital Twins ◽  
Potential Failure ◽  
Operational Data

Digital twin (DT) plays a pivotal role in the vision of Industry 4.0. The idea is that the real product and its virtual counterpart are twins that travel a parallel journey from design and development to production and service life. The intelligence that comes from DTs’ operational data supports the interactions between the DTs to pave the way for the cyber-physical integration of smart manufacturing. This paper presents a conceptual framework for digital twins collaboration to provide an auto-detection of erratic operational data by utilizing operational data intelligence in the manufacturing systems. The proposed framework provide an interaction mechanism to understand the DT status, interact with other DTs, learn from each other DTs, and share common semantic knowledge. In addition, it can detect the anomalies and understand the overall picture and conditions of the operational environments. Furthermore, the proposed framework is described in the workflow model, which breaks down into four phases: information extraction, change detection, synchronization, and notification. A use case of Energy 4.0 fault diagnosis for wind turbines is described to present the use of the proposed framework and DTs collaboration to identify and diagnose the potential failure, e.g., malfunctioning nodes within the energy industry.

scholarly journals The Role of Managerial Commitment and TPM Implementation Strategies in Productivity Benefits

2018 ◽  
Vol 8 (7) ◽  
pp. 1153 ◽  
Author(s):  
José Díaz-Reza ◽  
Jorge García-Alcaraz ◽  
Liliana Avelar-Sosa ◽  
José Mendoza-Fong ◽  
Juan Sáenz Diez-Muro ◽  
...  
Keyword(s):  
Least Squares ◽  
Structural Equation Model ◽  
Preventive Maintenance ◽  
Latent Variables ◽  
Structural Equation ◽  
Manufacturing Industry ◽  
Implementation Strategies ◽  
Equation Model ◽  
Total Productive Maintenance

The present research proposes a structural equation model to integrate four latent variables: managerial commitment, preventive maintenance, total productive maintenance, and productivity benefits. In addition, these variables are related through six research hypotheses that are validated using collected data from 368 surveys administered in the Mexican manufacturing industry. Consequently, the model is evaluated using partial least squares. The results show that managerial commitment is critical to achieve productivity benefits, while preventive maintenance is indispensable to total preventive maintenance. These results may encourage company managers to focus on managerial commitment and implement preventive maintenance programs to guarantee the success of total productive maintenance.

Crystallizing Metal Shrinkage: Automation of High-Pressure Crystallization Control

2022 ◽  
Vol 1049 ◽  
pp. 18-23
Author(s):  
Vladimir F. Korostelev ◽  
M.S. Denisov
Keyword(s):  
Transition Process ◽  
Production Equipment ◽  
Utilization Rate ◽  
Cast Aluminum ◽  
New Approach ◽  
Cast Aluminum Alloys ◽  
Metal Volume ◽  
Metal Products ◽  
Shrinkage Compensation ◽  
Pressure Crystallization

The properties of bulk metal products are formed when molten metal transforms from an unstructured liquid into a solid crystal state. We suggest a new approach to the automation of the control over crystallized metal shrinkage compensation based on controlling the law of change in pressure applied to crystallizing metal through a program taking into account the transition process in the hydraulic system of the production equipment. We observed the increase in rigidity, durability, and pliability of В95-alloy samples as compared to cast aluminum alloys. The metal utilization rate can be increased up to 0.90 of the liquid metal volume.

ISO 9001: a vaccine for time of crisis

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ronny Alexander Zayas-Mateo ◽  
Ángel Rafael Martínez-Lorente
Keyword(s):  
Economic Crisis ◽  
Design Methodology ◽  
Iso 9001 ◽  
New Approach ◽  
Content Type ◽  
Operating Income ◽  
Industrial Companies ◽  
The World

Purpose ISO 9001 is applied by hundreds of thousands of companies throughout the world. For this reason, its effect on company results has been extensively studied. However, the results of those studies are inconclusive and sometimes contradictory. More in-depth research, with a new approach, is therefore necessary. The purpose of this paper is to analyse whether ISO 9001-certified companies suffered the effects of the financial and economic crisis of 2007–2008 to a lesser degree than non-certified ones. Design/methodology/approach A set of 179 companies certified by ISO 9001:2008 and 154 non-certified ones were analysed, as well as the accounting figures for net sales and operating income (EBIT: earnings before interest and taxes) from 2004 to 2012. Findings Companies from the industry and services sectors showed different results. Certified industrial companies achieved better outcomes than their non-certified counterparts. However, the deviations in outcomes were not significant for services companies. Research limitations/implications One limitation of this study is that companies’ official results are not always their true results. Another limitation is that having to do with the criteria followed to suppress extreme cases, which is always subjective. Furthermore, the implications of the results could be of use for those managers who are responsible for implementing ISO 9001 and for deciding whether obtaining the ISO 9001 certification would be beneficial to their companies. Originality/value This study constitutes a new approach for the assessment of the benefits of the ISO 9001 certification.

scholarly journals Computer aided design of sequencing problem – the concept of Paint Shop 4.0

Mechanik ◽  
2018 ◽  
Vol 91 (7) ◽  
pp. 529-531
Author(s):  
Jolanta Krystek ◽  
Sara Alszer ◽  
Szymon Bysko
Keyword(s):  
Automotive Industry ◽  
Computer Aided Design ◽  
Industry 4.0 ◽  
Paint Shop ◽  
Actual Structure ◽  
New Approach ◽  
Digital Factory ◽  
Sequencing Problem ◽  
Car Body ◽  
Aided Design

Presented is the concept of paint shop operation for the automotive industry – Paint Shop 4.0, based on the ideas of Industry 4.0 and Digital Factory. A new approach to the issue of car body sequencing, taking into account the actual structure of the paint shop department with buffers, has been presented. In the created application, proprietary car body sequencing algorithms were implemented.

scholarly journals Repair procedure of belt wagon BRs 1200 crawler unit

2020 ◽  
Vol 26 (2) ◽  
pp. 29-34
Author(s):  
Vladimir Jakovljević ◽  
Eleonora Desnica ◽  
Slavica Prvulović
Keyword(s):  
Preventive Maintenance ◽  
Complex Interventions ◽  
High Quality ◽  
Repair Procedure ◽  
Maintenance Process

The paper presents and describes in detail the specific procedures that are carried out during the repair of the crawler unit on the belt wagon BRs 1200.29/32, whose performance is the basis for high quality and efficient maintenance of these machines on site, as well as in repair shops. These procedures are complex interventions performed as part of the preventive maintenance process. The success of the maintenance process is presented as a workflow with as few failures and downtime as possible, also as a process without accidents, and in case of their occurrence, the possibility of the fastest elimination, all of which result in the satisfaction of both users and maintainers.

scholarly journals Putting resilient sustainability into strategy decisions – case studies

2018 ◽  
Vol 56 (7) ◽  
pp. 1598-1612 ◽  
Author(s):  
Julie Winnard ◽  
Jacquetta Lee ◽  
David Skipp
Keyword(s):  
Case Studies ◽  
Real World ◽  
Design Methodology ◽  
Strategic Decision ◽  
New Approach ◽  
Content Type ◽  
Industrial Companies ◽  
Different Types ◽  
Strategic Decision Support ◽  
Practical Implications

Purpose The purpose of this paper is to report the results of testing a new approach to strategic sustainability and resilience – Sustainable Resilient Strategic Decision-Support (SuReSDS™). Design/methodology/approach The approach was developed and tested using action-research case studies at industrial companies. It successfully allowed the participants to capture different types of value affected by their choices, optimise each strategy’s resilience against different future scenarios and compare the results to find a “best” option. Findings SuReSDS™ enabled a novel integration of environmental and social sustainability into strategy by considering significant risks or opportunities for an enhanced group of stakeholders. It assisted users to identify and manage risks from different kinds of sustainability-related uncertainty by applying resilience techniques. Users incorporated insights into real-world strategies. Research limitations/implications Since the case studies and test organisations are limited in number, generalisation from the results is difficult and requires further research. Practical implications The approach enables companies to utilise in-house and external experts more effectively to develop sustainable and resilient strategies. Originality/value The research described develops theories linking sustainability and resilience for organisations, particularly for strategy, to provide a new consistent, rigorous and flexible approach for applying these theories. The approach has been tested successfully and benefited real-world strategy decisions.

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