FMEA Analysis Research Articles

PERENCANAAN PEMELIHARAAN MESIN PRODUKSI DENGAN MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) (Studi Kasus: PT. S)

PT. S is a company that produces steel pipe. As a manufacturing company, the company relies heavily on its production machines, one of the main engines in this company is mill 303. However, the high frequency of failure and downtime caused the production decreased. This research use reliability centered maintenance (RCM) method. This method is used to determine the machine maintenance schedule as well and the interval optimal time. The stages of this research begin with determining the critical machine then make the system description followed by FMEA analysis, ABC analysis to determine critical component, FTA analysis, analysis of time distribution up to interval optimum maintenance. The result of this research is known 11 critical component with highest RPN value. 11 components that have been identified then analyzed the distribution of the time to failure and distribution of the time to repair and get the value of MTTR and MTTF. Bearing drive roll is the component with the highest RPN value of 512, the MTTR value of 3.56259, the MTTF value of 730,537 and the optimal maintenance interval of 504.64 hours.

4. Application of the FMECA analysis in breast radiotherapy with active breath hold

Purpose The Deep Inspiration Breath Hold (DIBH) technique was introduced in order to freeze the breathing motion in a mid-inhale position with a computer controlled valve, with the purpose of lowering heart dose in left breast radiotherapy. A training project with FMECA analysis was started, aiming to write and implement a protocol, improved by proactive clinical risk analysis and feedback from the operators (radiotherapists, radiographers and medical physicists). Methods and materials At first, few operators were involved to take knowledge and dexterity with the system. They became the tutors and the core of the improvement group for the subsequent training project. The project was comprised of four stages: (1) implementation of the technique (tutors); (2) field training (tutors and operators); (3) training course on FMEA/FMECA analysis (all operators and clinical governance department); (4) implementation of the FMECA analysis in left breast radiotherapy DIBH treatments (tutors and FMEA-workgroup; the FMEA workgroup consisted of these professional roles: radiotherapists, radiographers, medical physicists and clinical governance area’s physicians). Results The outputs for each stage were: (1) redact the protocol and the training checklist; (2) training of all operators and application of the self-evaluation checklist; (3) understanding the clinical risk principles; (4) application of the FMEA analysis, data processing and final report. The self-evaluation checklist was comprised of 37 targets, with achieved/partially-achieved/not-achieved check boxes. The FMEA table was comprised of 48 activities, subdivided in 5 phases (DIBH-suitable-patients detection, treatment simulation, planning, radiotherapy treatment delivery, quality control), with pertinent Risk Probability Numbers associated. Points 1–3 were completed, while completion of point 4 is expected for the first half of 2018. Conclusion The application of the FMEA/FMECA method allowed us to introduce proactive methods to analyze and manage the clinical risk related to the introduction of the new DIBH technique. The FMEA/FMECA method was included in a training project which allowed to obtain feedback from all the involved operators, improving the understanding of the work process, the skill and safety in the practical use and the redaction of a multidisciplinary protocol.

Application of FMEA method for an analysis of selected production process

Purpose: The article presents an application of FMEA method in a process of chimney system production. The analysis allowed to decrease a potential defects and their effects in the analysed process. Design/methodology/approach: The technical analysis of the process of chimney system production indicated many defects in the product. Based on the FMEA results (value of RPN – Risk Priority Number) corrective and preventive actions were proposed. These actions decrease RPN level by half. Findings: In this paper characteristics of the chimney system and technical analysis of its production process were presented. Failure mode and effects analysis for selected operations of the production process was performed. Practical implications: In the analysed process are possible the nonconformities above the appointed RPN level, because they are dependent on applied technology and machinery. Increase of a quantity of control points and training employees caused a reduction of manufacturing costs, improvement of the product quality and creation of the possibility of effective quality control. Originality/value: FMEA analysis is an effective tool for identification, determination of a risk level, planning and implementation of corrective and preventive actions to decrease a quantity of defects in the final product. Periodic application of this method enables the continuous improvement of the processes and products in enterprises.

Quality management system for improvement of quality and efficiency of food production: case of dairy products enterprise

On the basis of the conducted researches the strategic directions of development of the enterprise are scientifically based. The conceptual principles of creation and functioning of processes at Company JSC are formulated and the structural model of network of processes is created. The functional model and the mechanism of creation of process including its identification, formation, management and improvement are developed. The possibility of use of scientific methodology of FMEA analysis in technology of preparation of production Kefir from Fudmaster is shown. On the basis of the offered scientific and methodical approach the process of the production of fermented milk product Kefir from Fudmaster is structured. The standard of the organization for formation of processes of dairy production is developed and evidence-based.

Risk analysis for clean and sustainable production in a urea fertilizer industry

PurposeThe purpose of this paper is to develop a fuzzy methodology approaches based framework for carrying the risk analysis of a real industrial system of a urea fertilizer industry located in northern part of India.Design/methodology/approachPetri Net approach was applied for representing the series-parallel arrangement of the considered system. Various failure causes related to different subsystems or equipment of the considered system were listed under FMEA approach and their Risk Priority Number was tabulated. Further, to overcome the drawbacks of traditional FMEA approach in risk ranking fuzzy FMEA and grey relation analysis (GRA) approaches were applied within traditional FMEA approach and the ranking results were compared for better and effective decision making of risky components.FindingsThe proposed framework has overcome the drawbacks of tradition FMEA approach in an effective and efficient manner. Causes AC7, CL3, ST2, DR3 and NR3 of centrifugal compressor, hot heat exchanger, ammonia convertor reactor, cold condenser and ammonia separator have been identified as the most critical failure causes of the considered system.Originality/valueThe proposed framework has been tested with its application on an ammonia synthesis system of the considered process industry. The risk ranking results would be highly useful in developing a planned maintenance policy for the considered system which further results in improving the system availability.

Application of lean six sigma in energy saving lamp assembly process

Lean Six Sigma is an improvement strategy. Stimulated by global high-profile enterprises including CE, Motorola, Pfizer and Boeing, increasingly number of enterprises select it and promote its implementation. It can be observed, as an important measure, to study Lean Six Sigma and how to effectively apply the management approache of it gives preference to further the development of enterprises. Attributing to the high demand in energy-saving lamp, herein energy-saving lamps manufacturing industry is selected. Taking its one-off assembly yield as an instance, we integrate the data pre-treatment into the Lean Six Sigma Management Process, employ specific DMAIC implementation pattern and apply measuring system analysis, SIPOC analysis, fishbone diagram, FMEA analysis etc. For analysis to reduce in-process defectives, improve first time success ro, thereby to have the operation cost lowered, company quality level lifted and company competitiveness enhanced.

Internal transport in sugar-producing company

Paper characterizes the internal transport occurring in a sugar-producing company. The production process of sugar is presented with special regard to internal transport equipment. The data from this enterprise were obtained using the methods of observation and examination of documents and using the collected literature. In addition, an FMEA analysis of internal transport was carried out.

DISEÑO DE UN CENTRO DE MANDO Y CONTROL TERRESTRE PARA UAVS UTILIZANDO TÉCNICAS AMFE

Summary: We present the design proposal for a center of remote control for UAVs, based on the improvement of different types of ground stations by analysis of mode effect and mode of failure, FMEA and Ishikawa diagrams. So, that has been a center of command and control robust and reliable analysis FMEA analysis of the basic functions of control center. This Control Center, allows to remotely control UAVs in NLOS (Non Line Of Sight) mode as well as the transmission and the reception of data and video from a local earth station that controls the UAV in the LOS (Line Of Sight) mode. Key words: FMEA, diagrams of Ishikawa, ground stations, command and control center, UAV, UAS

Risk management in automotive manufacturing process based on FMEA and grey relational analysis: A case study

Risk management in automotive manufacturing process based on FMEA and grey relational analysis: A case study

The application of the FMEA method in the selected production process of a company

Abstract The aim of this article is to show the use of the analysis of the failure causes and effects as a prevention tool in controlling the quality of a given production process in the company. The scope of the work covers an analysis of a selected process, definition of inconsistencies present in this process, and then the FMEA analysis. In the production company one should implement thinking and actions based on the so-called ‘quality loop’ – it is an interdependence model of the undertaken actions which affect the quality shaping. It is carried out from the possibility for identifying a customer’s requirements through a project, production process, up to the assessment of effective capability for meeting the defined requirements. The application of such an approach enables to take the actions improving the operation of quality management in a systemic way.

The Use of Linguistic Variables and the FMEA Analysis in Risk Assessment in Inland Navigation

The Use of Linguistic Variables and the FMEA Analysis in Risk Assessment in Inland Navigation

Failure Mode and Effect Analysis of Air Cargo Freight Services Provider

In the theoretical part, this article presents the basic conditions for the organization of air transport cargo divided into different types of cargo shipments. Then an analysis of the Polish market of air cargo shipments is presented, taking into account the type of companies, airlines and airports that support them. In the research part, an FMEA analysis of an entity providing air cargo transport organization services was made, presenting several disadvantages and possible remedial actions that contribute to the improvement of the quality of services.

Application of failure mode and effects analysis in ecology in Russia

The article presents a comprehensive review of the FMEA analysis (the failure modes and effects analysis) in the construction industry in the Russian Federation and suggests the same analysis, which can be applied to ecological issues. The paper analyzes the existing legislative and normative acts in this area, modern approaches to the introduction and regulation of the definition of defects in production and construction. Particular attention is paid to the consideration of Failure Mode and Effects Analysis - this is a formalized procedure for analyzing and finalizing the projected technical facility, the manufacturing process, the operation and storage rules, the maintenance and repair systems of technical facilities, based on the identification of possible (observed) defects with their consequences and cause-effect relationships in their occurrence, and an assessment of the criticality of these defects.

The idea of fuzzy logic usage in a sheet-based FMEA analysis of mechanical systems

The main purpose of the work which was carried out and is presented in this paper was to examine the possibility of using fuzzy logic inference for conducting a risk analysis with the help of a sheet-based Failure Mode and Effects Analysis method (FMEA). At the beginning, the main features of the analysed method were presented, with particular emphasis put on the Risk, Priority and Number parameters. Then, a proposal has been made which suggests using Matlab Fuzzy Logic Toolbox package in order to convert the factors into the form of fuzzy sets and to define rules for fuzzy inference process has been made. Finally, the created fuzzy logic model was used to present an example analysis of a turbocharger failure in the fuzzified form.

Enhancing the management of the noise level using six sigma method: a case study on the machining industry

The hearing disorder is caused by noises in the workplace, it has been a concern for numerous researchers. This study aims to improve the performance of the management of the noise level by applying the six sigma method. Data collection is done directly by using a sound level meter. In addition, several key informants also used in order to gather information related to the problem. The results showed the values of Cp and Cpk on the entire department are still below the recommended value. Moreover, the results also showed the potential failure (DPMO) approximately 115,260.6 and equivalent to the Sigma value is approximately 2.70. Furthermore, the highest value of the RPN in FMEA analysis is the workers not wear factor of earplug which is about 56. Thus, it is necessary to make enhancements to the process of managing the noise level in the framework of continuous improvement.

Identification and FMEA analysis of working fluid properties for OTEC plants

In OTEC low vaporization temperature organic fluid used as the working fluid. So to obtain an efficacious output, the selection of working fluid must be accurate. It’s entirely depends upon the properties of the fluid. So there should be a focus on the fluid property and probability of failure should also take into account while selecting a fluid. In this study, the required properties of the OTEC working fluid are discussed and analysis of failure mode also performed by the application of FMEA method. FMEA method gives a prioritize list of working fluid properties for failure study and this prioritize list consist of the failure mode and their associated measured quality characteristics or key output variables. Then a prioritize list is also developed for the criteria, Thermal efficiency, exergy effciency and cost. By the pairwise comparison, a mapping of the individual property is created with respect to each criterion.

Analisis Pemeliharaan Mesin Blowmould Dengan Metode RCM Di PT. CCAI

PT. Coca-Cola Amatil Indonesia is a company that produces carbonated beverages. Most of the production activity uses automatic machines. The problem faced is the damage that often occurs suddenly on the blowmould machine so that corrective maintenance must be done. The purpose of this research is to know the cause of the damage and to propose the action plan to minimize downtime. The method used is Reliability Centered Maintenance to determine the selection of action and time interval of replacement for critical components on the blowmould machine. From the FMEA analysis, it is known that the critical components of each blowmould machine subsystem are bearing roller feed, mandrel, seal gasket, and fitting. The results of LTA analysis are the category of failure (outage problem and economic problem) and the selection of action for the critical component (time directed). From the calculation of Total Minimum Downtime, known that the replacement schedule for critical component are 23 days for bearing roller feed, 9 days for mandrel, 8 days for seal gasket, and 8 days for fitting, that is resulting in decreased downtime of 1.56% with a value of 99.63% availability.

ANALISIS RISIKO USAHATANI BUNGA KRISAN POTONG (Chrysanthenum indicum L) (Studi kasus di PT Alam Indah Bunga Nusantara)

Horticulture is one of the sub-sectors in agriculture that have the potential to be developed asit has a high economic value. One of the featured plants that have good prospects for development in Indonesia is the chrysanthemum. In the process of cultivation of chrysanthemums, required skills and intensive treatment of the chrysanthemum. therefore at high risk of cultivation process. PT Alam Indah Bunga Nusantara is one of the companies engaged in the agribusiness plants located in West Java. The purpose of this research was to determine factors that will influence the risk in chrysanthemum cut flower farm, to determine the extent of risk management which conducted in PT Alam Indah Bunga Nusantara, and know the strategies to improve risk conducted in PT Alam Indah Bunga Nusantara. The study design used was a qualitative design using FMEA analysis (Failure Mode and Effect Analysis). Engineering research is tostudy the case. The result was the risks faced in PT Alam Indah Bunga Nusantara is the weather and the climate change problem that occurs is uncertain. In addition, pests and diseases is also a risk that must be covered by the company. This can lead to a lot of things that could detrimental to the company in the business of chrysanthemums. In addition to natural factors, uncertainty in consumer tastes is a cause of risk faced by PT Alam Indah Bunga Nusantara. The new effort conducted by PT Alam Indah Bunga Nusantara in improving the quality of human resources in the company is to conduct junior secondary education program. The strategy must do for PT Alam Indah Bunga Nusantara for improve the risk is repair the greenhouse to be more optimized than previous, adding a thermostat in the greenhouse.

Enhanced GO methodology to support failure mode, effects and criticality analysis

Failure mode, effects and criticality analysis (FMECA) is a prerequisite and significant task for reliability analysis of a safety critical complex system; meanwhile, it is complicated, error-prone and time-consuming due to the gap between a dedicated process for system functional design and fault propagation analysis. Moreover, traditional empiricism analysis usually omits potential fault propagations, and the Risk Priority Number cannot display the risk of failure modes that attribute to the entire system effectively and precisely. In this article, GO methodology, a wide-spread intuitive reliability and safety model technique in practical engineering systems, is enhanced to support FMECA in a qualitative and quantitative way. Function operators in the GO model are extended to support the function hierarchy, failure modes definition, parameters, failure computation and the connectivity with other components. Based on the information above, the failure propagation algorithm is presented, utilizing the relationship signified by signal flows in the GO model. Next, depending on the extended GO model and automatic FMEA synthesis algorithm, all of the existent and potential failure effects are obtained automatically without artificial experience. With Bayesian Network, the reliability of the system and the risk assessment of each failure mode are obtained simultaneously. Finally, a case study of a mobile platform of robot is introduced to verify and validates the applicability of the proposed method in reliability analysis domains. The proposed method is compared with conventional FMECA approach. It is shown that the proposed method has a better performance in qualitative FMEA analysis and quantitative analysis in risk assessment and sensitivity analysis.

Application of Reliability-centered Maintenance Method in Maintenance and Control Optimization in NPPs

The safety is a prerequisite for the nuclear power plants’ operation. Various measures have been considered at the design stage to ensure the reliability of the NPPs. During the nuclear power plants’ operation, equipment reliability management is one of the primary means to ensure NPPs operate safety. RCM, Reliability-centered Maintenance, an important method for the equipment reliability management in NPPs, can be used to complete FMEA analysis for the systems and components, and develop or optimize maintenance strategies to ensure the effectiveness of preventive maintenance strategy according to RCM decision logic. At the same time, it can be used to find the insufficient of the design, improve the control logic and layout. This article describes the RCM analysis process, illustrates the application and effectiveness of the RCM analysis in maintenance and control optimization combined with the practice of nuclear power plants.