In addition to a broader professional Master of Science degree, greater emphasis is needed on the production of master technicians. Still, the system has served the utility well. Click here to buy this book in print or download it as a free PDF, if available. %PDF-1.6 %���� Software maintenance and lack of skills have emerged as major contributors to the perception that mechatronic equipment is less reliable than electromechanical equipment. Finance-driven managers who do not understand manufactur-. These figures are often given on a yield basis (e.g., output per unit of time or material input). Intel and several of its key equipment suppliers have begun to turn the domestic situation around. This would be helped greatly by a competitiveness assessment that reflects ERM differentials. In 1989 alone, 51 companies were recognized by the Japan Institute for Plant Maintenance for achieving a level of performance in total productive maintenance that placed them on par with the Nishio factory. To analyze the factors which affect the reliability based on scores, let us see the factors which can affect the scores of test papers. 1980. The entire manufacturing organization, including executive management, recognizes the value of high equipment availability and the role of ERM in achieving it. Initial emphasis was on detecting problems before they became serious enough to force outages. Equipment reliability assures that subsystems and components function as intended without failure for desired periods during their design life. Benefits of Intel's ERM program have included reduced cost per unit at each process step, as factory operations and support costs associated with downtime or slower area throughput time have been reduced. One utility moved from manual plotting of stator performance data to a computer-based, continuous monitoring system on its 10-year-old turbines that were installed in the mid-1980s. Development of standards for design and test, measurement and evaluation of ERM, and operator–equipment interfaces. Procurement specifications have been upgraded to require that all key process equipment suppliers have a basic level of ERM expertise. ITG SUBJECT: RELIABILITY OF MANUFACTURED PRODUCTS. Managers and engineers should be aware of the benefits of using simulation methodology during process design. Needed are more career or professional engineers from interdisciplinary programs that cut across engineering disciplines to also embrace elements of business, psychology, and sociology. Not a MyNAP member yet? SUBSTANTIAL CAPITAL investments, in the form of facilities and equipment, are required for manufacturing almost all goods of economic significance. The potential. Equipment reliability and maintenance practices for better returns on capital investment. The theoretical capacity of a manufacturing process or machine is the output per unit of time of continuous operation at the maximum safe operating speed. While total abandonment of tradition, or complete cultural change, is neither possible nor desirable, U.S. manufacturers may need to import, adapt, and fine-tune techniques from other countries such as Japan. Unplanned downtime results into undesirable indirect cost of maintenance due to losses in production and the idleness of other machines in the production system. Japanese suppliers, in contrast, benefit from close customer technology exchange programs with leading Japanese semiconductor manufacturers. This trend is producing a generation of catalog engineers who are adept at ordering equipment from a catalog but who lack the knowledge to evaluate equipment designs. Preventive maintenance, therefore, loses its urgency and breakdown maintenance becomes the order of the day. This approach should delineate basic principles that are demonstrably effective and universally applicable. Small investments (under $100,000, say) may need only the approval of the plant manager; expenditures in excess of several million dollars may require the board of directors' approval. National Advisory Committee on Semiconductors. A few basic definitions are used in this chapter. 4) The after sales services provided are not monitored. The charter of a U.S. plant maintenance institute might include: competitive assessment of ERM (United States versus other countries), research to improve ERM competitiveness and spread best practice, assistance to companies attempting to improve ERM, ERM training assistance, a forum for technology transfer, and recognition of companies that meet predefined ERM thresholds. The panel has ranked research needs in ERM within two broad categories. To search the entire text of this book, type in your search term here and press Enter. Schools have followed business's lead in the past; when business deemphasized manufacturing in the 1960s, schools closed their manufacturing laboratories. I feel the factors which affect reliability are: 1) Aim to build vehicles at cheapest cost to cater to the masses in an effort to capture market. The panel considers ERM to be a significant factor in the competitiveness of manufacturing firms, an assessment supported by the case studies in the section on present practice (pp. Act on the recommendations and opportunities identified. The replacement and displacement of conventional electro-mechanical factory equipment by mechatronic equipment have given rise to a very different set of reliability and maintenance requirements. This is due to accelerated wear mechanisms by environmental factors or the end of the useful life by normal wear and tear. RAO: INFLUENCE OF ENVIRONMENTAL FACTORS ON COMPONENT/EQUIPMENT RELIABILITY 123 occur. The rapidly increasing complexity of factory equipment has led many U.S. manufacturers to look to suppliers for smarter equipment that will ease the need for a technically strong supporting infrastructure. Simultaneous design, or concurrent engineering, i.e., designing the production line or process at the same time as the product it is to produce, is the watchword. endstream endobj startxref Critical specifications must be defined and formulated to ensure reliability and identify pitfalls, stumbling blocks, and best practice. Workshops sponsored by the National Research Council could serve to acquaint manufacturing executives with present practice in the United States and Japan. With an aging complement of steam turbine generators and few new plants in the planning cycle, the U.S utilities industry is responding to increasing demand for electricity by adopting new practices for maintaining and improving the availability of existing equipment. The contrary connection between equipment risk and reliability is not obvious, but it reveals itself to us when the risk equation is divided into its fundamental elements. Source: VLSI Research Inc. Key elements of the design/development phase include training and development to enable suppliers to perform highly specialized equipment analyses, such as failure modes and effects criticality analysis (FMECA), fault tree analysis, design for testability, design for fault tolerance/isolation/tracking, and design for remote diagnosis. Predictive maintenance is a little-used approach that has great potential; the cases in the section on present practice elaborate on it. As a result, it is difficult to make comparisons, share results and good practices among cooperating operations, and measure ERM performance trends in any one factory in a universally credible way. Since 1987, Intel Corporation has used ERM techniques to increase uptime and speed throughput for both the currently installed and the next generation of equipment. The strategy was implemented in four stages. Not only are they unhappy, but they take Breakdown maintenance and repair is the after-the-fact restoration of failed equipment. Assemble a multidisciplinary team to participate in the equipment reliability process. To this end, research in the area of ERM should be directed at finding ways to: inculcate the attitude that equipment should improve through use;use; identify and analyze operational changes that might enhance ERM and inform equipment suppliers of these changes; communicate ERM requirements in clear, operational terms; support industrywide collection and analysis of standardized ERM data; foster an understanding of enterprise optimization; and. Operational changes that will enhance ERM must be identified. ERM practices contribute significantly to this achievement. performance), project complexity, clear scope definition, accuracy and reliability of cost information, site. This volume presents a concise and well-organized analysis of new research directions to achieve these goals. Making a case for increased spending on ERM to a management that perceives itself to be at a strong competitive disadvantage relies on demonstrating a benefit-to-cost relationship. More importantly, the important maintenance issues do not surface. FIGURE 3-2 Expected trend in cost of state-of-the-art semiconductor manufacturing facilities. Making them optimal is the key to human reliability. Software and sensors have the potential to enhance ERM and so mitigate the added complexity associated with these technologies (see Figure 3-1). A clear link must be established between equipment requirements and reliability. Science 245 (August 25): 819-823. MTTR and MTBF are the independent variables in the availability function, A: You can also derive some other functions from this one, including the probability of failure F, which is 1-A; and reliability (R) which is 1/F, or 1/ (1-A). In addition to understanding the human error types it is necessary … Rather, it is the result of a strategy for achieving zero defects and zero breakdowns through common-sense engineering, attention to basics, and hard work and team effort guided by a top-management vision. The factory is becoming a web of interdependent subsystems, interconnected by computer controllers that communicate horizontally across peer processes. effectively promote ERM, a clear and strong initiative is needed to identify what needs to be changed, what the objective should be, and how to make the change, in order to have an immediate and significant impact with lasting effects. Just-in-time (JIT) is a method of manufacturing by which parts and assemblies are made or delivered as needed, thereby greatly reducing inventory. endstream endobj 24 0 obj <. 2) No suitable R&D setup 3) Sourcing spares from vendors who are not quality certified. A Strategic Industry at Risk. Moreover, Japanese plants are characterized by a highly disciplined approach to basic housekeeping—floors and manufacturing equipment are kept spotlessly clean. General attention to the inadequacy of the basic level of talent. 4. 2. The cumulative effect of these practices is reflected in the product—mass-produced automobile body parts that are. Preventive maintenance practices in this industry evolved by trial and error. h�bbd``b`�$���=��$X� �O ��u�� ���f�XSA,7��Zb ���L��A�10�K�g�� � _+ : Well-maintained machines hold tolerances better, help to reduce scrap and rework, and raise part consistency and quality. Die change time, which necessarily represents scheduled machine downtime, is a critical element of overall operating performance, and rapid, efficient die changing is a key basis of competition in stamping operations. Source: Intel Corporation, 1989. Concurrent engineering warrants study as a means of building ERM considerations into equipment from the beginning. FIGURES 3-3 and 3-4 Results in trial fabrication plants for both implanter equipment (1987-8) and wafer etch equipment (1988), with and without service contract, show a substantial increase in average monthly uptime and increased predictability by reducing the range of monthly uptime. Between 1979 and 1982, the Japanese Nishio pump factory of Aishin Seiki reduced equipment breakdowns from 700 per month to effectively zero, while achieving an extraordinary level of quality— 11 defects per 1 million pumps produced. Many of the other topics on this website (such as fatigue, workload, competence, supervision) are actually Performance Influencing Factors. Learn the terms, explanations and formulas needed to help you design reliable products. ning, the cost of generator outages, prevention of in-service failure, and the increasing percentage of older units in service. Identification of operational changes to enhance ERM. The reliability of the measures are affected by the length of the scale, definition of the items, homogeneity of the groups, duration of the scale, objectivity in scoring, the conditions of measuring, the explanation of the scale, the characteristics of the items in scale, difficulty of scale, and reliability estimation method. U.S. industry is not without examples of emphasis on ERM. %%EOF The company developed a two-part strategy that focused on reducing the operations and support costs of installed equipment while simultaneously influencing the design of a new generation of equipment using life cycle cost data from the factory floor. Technology of MachineTools, Machine Tool Systems Management and Utilization. One relates to people, the other to equipment (Table 3-4). Suppliers are reluctant to project ERM performance, claiming lack of control over user application, adherence to recommended preventive maintenance schedules, and adequacy of repair. All rights reserved. For example, a maintenance professional intentionally using a tool on a piece of equipment to damage it. The errors made by the psychologist proving a test are another type of environmental factor that can affect reliability. Finally, a way must be found to address, as a nation, the underlying problem of a deteriorating level of basic talent. Fundamentals: Understanding reliability terminology and factors that affect power supply reliability. Emphasis on sensor technologies and self-diagnosis. Program complexity. The use of first-class equipment, operating at full capacity, is vital to competitiveness in the world market, a fact U.S. manufacturing managers must be made to believe and given the tools to act upon. 54 0 obj <>stream Preventive maintenance is the systematic servicing of equipment to reduce the possibility of failure. McCabe’s V(G), Halstead’s E and program size are well-known complexity measures. Development of a standard methodology for measuring ERM. Historically, the evolution of ERM can be traced from breakdown maintenance and repair to preventive maintenance to predictive maintenance. tomer demands or regulatory influences, are forced overseas in their search for suppliers who are willing to quantify machine reliability and to work to meet ERM goals. Quantifiable reasons must be found for employing technologists in the manufacturing sector of an enterprise. 23 0 obj <> endobj The term artificial intelligence is appearing in sales literature that increasingly is offering catalog solutions as alternatives to technical proficiency. In circumstances where others will be procuring, if options between equipment choices will still be made, it is important to rank two to five of the highest evaluated equipment, with short comments why. Sign up for email notifications and we'll let you know about new publications in your areas of interest when they're released. The ideal manufacturing environment of the future has no maintenance organization and every piece of equipment is expected to be available 100 percent of the time. uptime (Figure 3-3 and Figure 3-4). Some factors that will affect its performance include their power source as well as the reliability. The Japanese stamping lines, for example, are specified to run at a lower, more reliable rate than equivalent U.S. lines. There exists a significant relationship between each of these measures. (See Chapter 6, Manufacturing Skills Improvement for more on this topic.). Perhaps the greatest is a general lack of awareness in the manufacturing organization, especially at the top, of the nature of ERM and its capacity for improving quality and productivity. A new attitude that equipment should improve through use. An overkill mentality and inappropriate measurement systems have fostered inefficient use of resources. A complementary focus is needed on using technology. A more enlightened approach to reducing equipment life-cycle costs would be to increase capital investment at the concept and design stages in order to improve equipment reliability, maintainability, and predictability and thereby reduce operations and support costs that inflate factory overhead (Figure 3-6). A better job of debugging these systems via simulation, analysis, and rapid development needs to be done. Making progress with people-related issues will be much harder than solving technological problems. ��c�+�&Ҟ�p2�M���q�xo�idp"�YƤmya�C�D�+mq�x���[�!K�%Ȍ�T3F����N�����|9A��?ݻ5:�� �i�#��2bJ�W̼�q��x�+�sw�9&� In fact, to the extent that they lead management to treat maintenance as an indirect cost that increases factory overhead, these systems may be putting the U.S. asset base at risk. Culture refers to an organization’s values, beliefs and behaviors. 1989. Well-understood methods of directing the work of these technologists are needed, as are mechanisms for implementing the results they achieve. Rather, research should follow the model that takes the long-term view while working hard on short-term activities. Share a link to this book page on your preferred social network or via email. Inquiries into ERM in the next generation of equipment should be based on practical investigations into improving it in the present generation. Events that slow or interrupt the manufacturing process or degrade the product impair the competitiveness of a manufacturing enterprise. What makes a good test? SOURCE: Lawrence Livermore Laboratory. Standards are published for maintenance and operation and for comparing performance of aircraft engines. Though generally accepted accounting principles are inadequate for manufacturing decision making, no substitutes have gained wide acceptance. MyNAP members SAVE 10% off online. A standard methodology for measuring the performance of ERM is needed, as is a way to quantify the benefits of ERM for top management. Needed in equipment design is a design-for-reliability approach that takes into account all life-cycle costs (acquisition, installation, operation, maintenance, repair, and salvage). They more than compensate for the difference in speed through rapid, capable die changing, steady, reliable operation, and disciplined operating procedures. Factors that affect the performance of networks. It cannot. Institutionalize a program that engages operators with equipment reliability focus goals. Mean time between failures for a wide variety of assembly equipment has increased in the range of 200 to 2300 percent, resulting in equipment uptime averages in excess of 90 percent of available hours (in a 168-hour week). Develop a maintenance strategy based on equipment criticality- RCM, PMO or RTF. Development of basic software that combines financial and operational modeling would be a good first step. To evaluate the cost of machine downtime, one must first know a machine 's value per unit of time, which can be obtained through a variety of methods related to capacity utilization (see definition of theoretical capacity on p. 55).
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