Application of the risk management tool to reduce the failures of spare parts in manufacturing systems

Abstract

Higher productivity and cost economy in manufacturing are achieved by operating the production machines efficiently with the least downtime. Failure of machine parts is a critical reason for machine downtime and restoration requires spare parts and consumables. Costs of spare parts and downtime reduce the profit margin of the organisation and hence, require management's attention. A case study on the failures of a cutting blade in a tube drawing machine, a special purpose machine intended to draw solder-coated brass coils into radiator tubes, is examined. A Reactive Failure Reduction Model (RFRM) is developed in which one of the Risk Management Techniques (RMTs) is used to analyse the causes of machine parts failure. Based on the analysis, suitable corrective measures are taken to reduce the blade failures. In this research paper, an analysis of the blade failure, the development of the failure reduction model and the results of implementation of the model are presented.