Manufacturing Of Spare Parts Research Articles

Choosing between additive and conventional manufacturing of spare parts: On the impact of failure rate uncertainties and the tools to reduce them

Recently, there has been great interest in using additive manufacturing (AM) to produce spare parts: allowing to produce spare parts with short lead times and close to the point of use, AM reduces the need for large inventories otherwise required by conventional manufacturing (CM) techniques to deal with intermittent spare parts demand. However, using AM to produce spare parts is limited by two main drawbacks: high production costs and uncertain failure rates arising from AM still being a relatively new production technique. While the former can be counterbalanced by inventory cost reductions, it is unclear how the latter impacts the sourcing option decision (i.e. AM or CM). We aim to fill this gap by studying a periodic review model in which spare parts demands follow a Poisson process. To make our analysis accurate and reliable, we leverage a material science approach to obtain realistic values for the failure rate uncertainties. From the results, it emerges that AM is heavily penalized by failure rate uncertainties much higher than those of CM. Consequently, we then focus on some recent tools developed to reduce AM failure rate uncertainties: porosity assessment and in-situ monitoring. We find that the failure rate uncertainty should be reduced by five and six percentage points to make it worthwhile to invest in porosity assessment and in-situ monitoring, respectively. Finally, we determine under which circumstances each tool is preferred over the other and found that porosity assessment is typically the most competitive uncertainty reduction tool.

MODELING THE DACIA DUSTER 4x4 REAR AXLE

The success of the brand Dacia is explained by the fact that vehicles produced in Romania, from Mioveni, offer an unbeatable price-quality-benefit-reliability ratio. Over 93% of the vehicle production in Mioveni is exported in 34 countries on four continents. With a production capacity of 350,000 units per year, the Dacia Vehicle Plant ensures both the production range of vehicles made up of Logan sedan, Logan MCV, Logan Van, Dacia Sandero and Dacia Duster, one of the most popular car brands, and manufacture of spare parts. This paper aims to make the presentation of the steps to be followed in order to achieve the 3D model of a Dacia Duster's items of its rear axle and assembling the components using the software Autodesk Inventor 2015 in order to be able to do the calculations necessary to optimise the suspension.

An approach for reverse engineering and redesign of additive manufactured spare parts

AbstractThe spare parts play a vital role in sustaining the operation and longevity of products and systems, but their unavailability can lead to prolonged downtime or expensive replacements. The integration of 3D scanning and Additive Manufacturing (AM) presents a promising path for spare part production. However, to utilise the full potential of AM, sometimes, redesign of the original part is needed. This paper investigates and proposes a new approach that integrates reverse engineering and redesign of an original part based on functional analysis to support the manufacturing of AM spare parts.

POSSIBLE SOLUTIONS TO THE PROBLEM OF PROVIDING IMPORTED EQUIPMENT OF BREWERIES IN RUSSIA WITH SPARE PARTS AND COMPONENTS

In the context of Western sanctions pressure and current bans on the import of machinery and components in the Russian brewing industry, a problem arose with the supply of new production equipment, original spare parts and components, industrial service on imported equipment, which is largely equipped with large and medium-sized enterprises, due to the inability to find suppliers of the required original spare parts in Russia, components and materials. The article provides an express analysis of possible solutions to this problem in order to determine the strategy of survival or development of the enterprise. The methodological basis is the traditional methods of technical, economic and logical analysis, systematization and ranking. The advantages and disadvantages of three options are considered: import substitution of the brewery's fixed assets by gradually replacing imported units, semi-automatic and automatic lines with domestic analogues with financial support from regional governments; parallel import of spare parts and components, supported by the restoration of worn-out parts of technological equipment of breweries using the services of specialized reverse engineering firms; organization of a specialized company as part of the Rosspetsmash Association, carrying out reverse-engineering, manufacturing of spare parts and assemblies for imported equipment of all breweries in the industry and industrial service of imported equipment based on a specific repair specialization. Based on the express analysis, it was suggested that the choice of a survival or development strategy for a particular plant depends on the condition of the equipment, the availability of an enterprise development strategy, the availability of its own finances and the support of state authorities.

Unveiling the microstructure of LES manufactured parts for sustainable productive business

The Light Engineering Sector (LES) is regarded as the bloodline of Bangladesh’s economy for simultaneously creating jobs, poverty alleviation, and strengthening foreign currency reserves by reducing dependency on imported products for local industries. But this promising industry is now facing roadblocks mainly due to poor quality under service loading. Though many new and advanced manufacturing techniques are now available, conventional sand casting is the most widely used manufacturing technique utilized by the local spare parts manufacturer. It is well established that the mechanical properties (strength, toughness) of a material are determined by its microstructure. To date, the microstructure characterization of LES products has not been subject to much scrutiny. Therefore, in this work, an attempt has been made to systematically investigate the microstructure of an LES-manufactured marine propeller using an Optical microscope (OM) and Scanning Electron Microscope (SEM) equipped with Energy Dispersive Spectroscopy (EDS). A locally made marine propeller supplied by ACBD company was used for this study. It was found that the microstructure of both materials mainly consists of pores, needle-shaped particles, and Chinese script-like features embedded in the aluminum matrix. Based on EDS results it may be concluded that the needle-shaped particle is mainly composed of Si and Al. Moreover, the average pore size observed was about 5109.5 μm. Use of horse-and-buggy technology, and lack of knowledge of the casting process such as properties of molding sand, the composition of raw material, overall metallurgical control of the casting process, etc. might have resulted in these casting defects. As the conventional particle fracture mechanism for ductile fracture starts once the maximum load is applied, the presence of pores may exhibit premature growth soon after the beginning of plastic deformation. Therefore, the presence of large pores may exhibit premature growth immediately at the beginning of plastic deformation, thereby drastically reducing the mechanical properties under service loading. In summary, both the government and the private sector should involve themselves in strong and focused dissemination research activities with the support of universities so that suitable modifications and modernization can be adopted in the existing system.

PROMISING AREAS OF DIGITALIZATION IN THE TECHNICAL MAINTENANCE AND REPAIR OF AGRICULTURAL MACHINERY

In the agro-industrial complex, it is possible to reduce operating costs by improving the organization and technology of maintenance and repair of machines, including using digital solutions. (Research purpose) The research purpose is identifying the promising areas for the development of digital technologies and the possibilities of their application in the maintenance and repair of agricultural machinery. (Materials and methods) Used open information sources and Internet resources of specialized Russian scientific and educational organizations and industrial companies, as well as materials of various annual exhibitions, including international ones; electronic information resources in the form of databases that are created and maintained at Rosinformagrotech (Results and discussion) It was determined that such digital solutions as «smart spare parts warehouse», «smart oil storage» are used in repair and maintenance production. It was established that the promising areas of the use of digital technologies include digital enterprise management systems, intelligent systems for diagnosing machines, robotic systems. One of the most dynamically developing areas of «digital» production in the world is the use of additive technologies that can be used in the manufacture of spare parts and the restoration of parts, including for imported machinery. In recent years, the trend of digitalization development in various industries, including the agro-industrial complex, has been the use of «digital» doubles. (Conclusions) In the field of maintenance and repair, intelligent systems for diagnosing machines, «digital» doubles, 3D scanning and reverse engineering of parts, 3D printing of spare parts and additive technologies for repairing parts will be in demand.

ELASTOMERIC POLYMER COMPOUNDS FOR PRODUCTION OF SPARE PARTS FOR ROBOTIC MILKING SYSTEM

Currently, the import of spare parts of systems, in particular, nipple rubber and elastomeric parts of the milk pump of the milking unit, has been discontinued. In this regard, the problem of developing technologies for manufacturing elastomeric spare parts for milking machines becomes urgent. One of the possible ways of cost-effective production of spare parts in conditions of small-scale production is free casting or low-pressure casting. To implement such technologies, materials with low viscosity (less than 50 pascals per second) are needed, which include polymer compounds. (Research purpose) The research purpose is determining the brands of elastomeric polymer compounds suitable for the manufacture of spare parts for milking machines. (Materials and methods) Used scientific and technical literature as materials for studying, including articles of indexed periodicals and open sources of information containing information about elastomeric polymer compounds. Research methods are the collection, study and comparative analysis of information. (Results and discussion) It was found that among all polymer compounds, epoxy, polyester, polyurethane and silicone compounds were the most widespread in mechanical engineering and the food industry. It was determined that compounds based on polyurethane or silicone are the most suitable for the manufacture of spare parts for milking machines. These materials provide sufficient mechanical characteristics and high elasticity of the manufactured part. It was noted that silicone-based compounds are used for food purposes, which ensures the chemical and biological inertia of the part. (Conclusions) The most suitable brands of elastomeric silicone compounds are Elastolux Platinum 40 and Silagerm 8040. These materials are manufactured in Russia, have low shrinkage, provide high strength and elasticity of the final parts.

Additive Manufacturing of Slow-Moving Automotive Spare Parts: A Supply Chain Cost Assessment

This study develops a cost model for the additive manufacturing (AM)-produced spare parts supply chain in the automotive industry. Moreover, we evaluate the economic feasibility of AM for slow-moving automotive spare parts by comparing the costs of the traditional manufacturing (TM) spare parts supply chain (SPSC) with centralized, outsourced AM SPSC. Data from a multiple case study of an OEM in the automotive industry regarding SPSC is utilized. The supply chain costs of 14 individual spare parts were analyzed, and the total SPSC cost for the AM and TM, were compared. Three of the fourteen parts showed potential for cost-savings, if they were produced with AM instead of TM. In this context, AM polymer parts showed greater potential than metal to replace TM as the more economical option of manufacturing from a total supply chain cost perspective. This study shows that the AM competitiveness to TM, from a financial perspective, increases for spare parts with low demand, high minimum order quantity, and high TM production price. The SPSC cost model included: cost of production, transport, warehousing, and service costs. This study contributes to the emerging field of part identification for AM and the existing literature regarding cost modeling in SPSCs.

PRODUCTION OF BIMETALLIC SLIDING BEARINGS FOR DRILLING PUMPS IN CONDITIONS VENTURE FIRM POISK LLP

The equipment of the oil and gas industry has very high requirements for the quality and reliability of products, because the products in most cases work in extremely difficult conditions, which leads to wear of parts and requires both current and major repairs of pumps. In both cases, it is necessary to have spare parts. Due to its ease of operation and maintenance, reliability and operability, the НБ-125 drilling piston pump has found wide application in the oil and gas industry of Kazakhstan, Russia and other CIS countries. Currently, VF Poisk LLP is engaged in the manufacture of spare parts for this equipment and the main aspect is the development and development of the production of bimetallic sliding bearings, which will prolong the successful operation of pumps of this type. The development of the manufacturing process, the selection of equipment, the design of devices for processing and pouring the sliding bearing has become a priority task in the conditions of its own production of VF Poisk LLP.

Managing Manufacturing innovation Strategically through Design Thinking

This article is a case study on a company in the manufacturing sector, named Cosmos Automotive Engineering Pvt Ltd, involved in the manufacturing of automotive spare parts on a large scale. The study will enable one to understand deeply the concept behind design thinking and how its implementation can ensure economic revival. The different stages involved in design thinking are explained and pragmatically applied in real time giving a quantum leap in revival of Cosmos as a company.

Strategy development for supplier selection process with smart and sustainable criteria in fuzzy environment

Supply chain management has been mutated to adapt to the developments over the last couple of decades. Smart paradigms, one of today's most significant paradigm shifts, occur in almost every moment of our daily lives. On the other hand, the importance of sustainability has increased more and more, reducing available resources of our world and increasing the effect of climate change and environmental degradation. In this context, this study it is aimed to develop a strategy for the supplier selection process by investigating the impacts of using different fuzzy environments and different decision-making methods on smart and sustainable supplier selection. The applicability of the proposed approaches has been demonstrated by a supplier selection case study of Company V, an automobile spare parts manufacturer. With the comparative analyzes made, it has been observed that although different fuzzy environments or varying decision-making methods in supplier selection create minor differences in criterion weights, it does not make any difference in supplier evaluations. For this reason, it has been concluded that it does not affect supplier selection. In addition, it was investigated how different supplier distributions in the strategies developed with the scenario analyzes affected each purpose of Company V, and an increase was observed in purchasing costs, carbon emission rates, quality rates, and on-time delivery rates when their importance levels increased from sustainable to smart criteria. To the authors' best knowledge, strategy development for the smart and sustainable criteria-based supplier selection process is a pioneering work in this field as it has never been studied before in the literature.

Rancang Bangun Alat Pembaca Uji Kompresi Beton Dan Mortar Otomatis Berbasis Arduino

In the construction process, the calculation of the strength of concrete and mortar is very important to avoid realko from accidents in buildings that fail. Concrete and mortar structures with good quality are still being tested for strength so that they are sexual with predetermined national standards. Concrete and mortar are elements in construction which are simple structures formed by a mixture of cement, water, fine aggregate, coarse aggregate consisting of crushed stone or gravel, and other mixed materials. Concrete is usually applied to foundations, columns, slab beams, culverts, weirs and dams. The creation of a concrete compressive strength test tool with an automation system based on a microcontroller, the design of an effective and simple concrete compressive strength machine control device, can test the hardness level of a concrete test object. both in accordance with applicable SNI in civil engineering. For Testing the Compressive Strength of concrete is the maximum force per unit area acting on concrete specimens. Concrete compressive strength testing is carried out based on SNI 03-6882. The Arduino Uno microcontroller-based concrete compressive strength test tool is specifically designed for concrete and mortar testing. not too complicated and the operation does not require special skills and components can be easily found in the market so that the manufacture and replacement of spare parts can be done easily.

Development of Spare-Parts Process Chain in Oil & Gas Industry Using Industry 4.0 Concepts

Through the expansion of Industry 4.0, the Oil & Gas industry in the world is undergoing a major transformation, so that the formalization of a process chain for the manufacture of spare-parts becomes increasingly necessary. This work aims to create work patterns using the concepts of industry 4.0 applied to the Oil & Gas industry, through the study of several work- pieces of this area. All spare-parts were used to create a chain of manufacturing processes. From there, they were recreated through different digital or hybrid manufacturing techniques. Several points such as geometry, type of acquisition of geometry, types of raw materials, types of manufacturing technology and machinery were addressed. Mechanical tests were carried out at different stages of the process. The results obtained formed a basis for strategies aiming solving problems of the studied spare-parts, using hybrid and additive manufacturing techniques, combined with the concepts of Industry 4.0. The created protocol was a descriptive and detailed standardization of the production chain process. The evaluation of the processes, justifications and solutions was applicable for each demand, generating a virtual catalog of spare-parts and that fed a cyclical model of experiences that continually update the database itself.

Additive Manufacturing Technology for Spare Parts Application: A Systematic Review on Supply Chain Management

Additive manufacturing (AM) is gaining interest among researchers and practitioners in the field of manufacturing. One major potential area of AM application is the manufacturing of spare parts, which affects the availability of the operation and supply chain. The data show that the application and adoption of AM has contributed to a reduction in lead times and inventory, which also contributes to a reduction in holding costs. This paper provides a review of recent work on the application of AM technology specifically for spare parts. The review shows that there are supply chain opportunities and challenges to the adoption of AM in spare parts within various application sectors. Our research reviews both the quantitative and qualitative models used for analysis to meet the emerging needs of the industry. The review also shows that the development of technology and its application is still emerging; therefore, there will be further opportunities to develop better spare parts supply chains to support AM applications. This paper concludes with future research directions.

Improving Daily Total Complete Shipment by Using System Dynamics Simulation in an Indonesian Car Spare Parts Manufacturer

PT. Nusahadi Citraharmonis is a leading manufacturing company in Indonesia that produces spare parts for various automotive industries. The company is an active supplier for several well-known car manufacturer in Indonesia, which are: NTC, HMMI, TMMIN, and ASKA. However, the company is currently having difficulty in fulfilling all customer demand on time. Thus, creating backlogged order in the system and decreasing the daily total complete shipment. The objective of this research is to redesign new inventory level to increase the daily total complete shipment. To solve the problem, Define-Measure-Analyze-Improve-Control (DMAIC) is used as the procedure, cause effect analysis is used as a tool to identify the key factors affecting daily total complete shipment, and system dynamics simulation is used as a tool to redesign inventory level. From the result of system dynamics simulation, the newly redesigned inventory level is able to decrease the backlogged order in the system and increase the daily total complete shipment. Besides the system dynamics simulation, standard operating procedure for operating the system is also made and given to the company for future use.

Wear Analysis of Additively Manufactured Slipper-Retainer in the Axial Piston Pump

Additive manufacturing (AM) of spare parts is going to become more and more common. In the case of hydraulic solutions, there are also some applications of AM technology related to topological optimization, anti-cavitation improvements, etc. An examination of all available research results shows that authors are using specialized tools and machines to properly prepare AM spare parts. The main aim of this paper is to analyze the influence of quick repair of the damaged slipper-retainer from an axial piston pump by using an AM spare part. Hence, it was prepared with a 100-h test campaign of the AM spare part, which covers the time between damage and supply of the new pump. The material of the slipper-retainer has been identified and replaced by another material—available as a powder for AM, with similar properties as the original. The obtained spare part had been subjected to sandblasting only to simulate extremely rough conditions, directly after the AM process and an analysis of the influence of the high surface roughness of AM part on wear measurements. The whole test campaign has been divided into nine stages. After each stage, microscopic measurements of the pump parts’ surface roughness were made. To determine roughness with proper measurements, a microscopical investigation was conducted. The final results revealed that it is possible to replace parts in hydraulic pumps with the use of AM. The whole test campaign caused a significant increase in the surface roughness of the pump’s original parts, which was worked with the AM spare slipper-retainer: (1) from Ra = 0.54 µm to Ra = 3.84 µm in the case of two tested pistons; (2) from Ra = 0.33 µm to Ra = 1.98 µm in the case of the slipper-retainer. Despite significant increases in the surface roughness of the pump’s parts, the whole test campaign has been successfully finished without any damages to the other important parts of the whole hydraulic test rig.

Identifikasi Penyebab Terjadinya Kecacatan pada Produk Induktor Toroidal dengan Menggunakan Metode Fault Tree Analysis (FTA) di CV. Cipta Karya Mandiri

Abstract. CV. Cipta Karya Mandiri is a company engaged in the manufacture of electronic device spare parts in the form of toroidal inductors. Based on the results of the study, in 2020 the company experienced a significant increase in demand compared to 2019. However, it turns out that there is a problem at the company, namely an increase in the percentage of toroidal inductor defects. This shows that the company's efforts to reduce product defects are still not optimal. So that the company needs to know the cause of disability as effort to reduce and eliminate defects that occur. The purpose of this study is to identify the causes of defective toroidal inductor products. The method used to reduce or even eliminate toroidal inductor product defects is by using the Fault Tree Analysis (FTA) method. The process of identifying the causes of failure is carried out on five types of defects which are included in 80% of the cumulative defects on the Pareto diagram. As for what is included in the 80% cumulative Pareto diagram defects consist of loose winding defects, bad windings, bonding overs, red pins, and wound wires. The results of the identification of the causes of defects from the five types of defects using fault tree analysis (FTA), namely the factors that cause defects to consist of human or worker factors, machine factors, and tools used during the production process.
 Abstrak.CV. Cipta Karya Mandiri is a company engaged in the manufacture of electronic device spare parts in the form of toroidal inductors. Based on the results of the study, in 2020 the company experienced a significant increase in demand compared to 2019. However, it turns out that there is a problem at the company, namely an increase in the percentage of toroidal inductor defects. This shows that the company's efforts to reduce product defects are still not optimal. So that the company needs to know the cause of disability as effort to reduce and eliminate defects that occur. The purpose of this study is to identify the causes of defective toroidal inductor products. The method used to reduce or even eliminate toroidal inductor product defects is by using the Fault Tree Analysis (FTA) method. The process of identifying the causes of failure is carried out on five types of defects which are included in 80% of the cumulative defects on the Pareto diagram. As for what is included in the 80% cumulative Pareto diagram defects consist of loose winding defects, bad windings, bonding overs, red pins, and wound wires. The results of the identification of the causes of defects from the five types of defects using fault tree analysis (FTA), namely the factors that cause defects to consist of human or worker factors, machine factors, and tools used during the production process.

On the suitability of insourced Additive Manufacturing for spare parts management

Additive Manufacturing (AM) has recently emerged as a promising technique in spare parts manufacturing. Unlike conventional manufacturing (CM) techniques, AM can lead to a reduction in inventory levels, particularly when insourced, through manufacturing spare parts on demand. However, due to the high production costs, the economic benefits of manufacturing spare parts through AM are unclear to managers and practitioners. Recent studies aimed at assisting in this decision have two main limitations: (i) they assume that AM spare parts typically have higher failure rates than CM parts: and (ii) they do not consider the AM machinery investment costs and parts are assumed to be externally supplied. We have developed a model that overcomes these limitations, first by assessing the failure rates of AM spare parts through an interdisciplinary approach rather than making arbitrary assumptions, which enables a comparison with the failure rates through CM reported in the literature. Second, we considered that the manufacturing of AM spare parts can be insourced and thus the investment costs for AM printers are also included, while the manufacturing of CM spare parts is considered to be outsourced. The model was tested with unconstrained and constrained stock systems, and clearly demonstrates the advantages of an insourced 3D printer for on-demand printing under constrained stock systems. Neither is AM preferable under an unconstrained system, due to the high costs of purchasing the printer and of production.

A framework to assess the sustainability of additive manufacturing for spare parts

Additive manufacturing (AM) is a promising technology for the optimization of the spare parts supply chain. A complete evaluation of whether it is advantageous to switch to this technology for spare parts management should include a comprehensive assessment of its sustainability in addition to its techno-economic viability. General analyses of the economic, environmental, and social impacts of AM have been conducted, but assessments of the sustainability effects of AM in the spare parts field is limited to specific industries. Thus, based on the literature, we designed a framework that can support a life cycle evaluation of the emerging application of AM technology. It represents a methodological approach that covers all the stages of the spare parts life cycle and the three dimensions of sustainability. It has been designed to support both researchers and practitioners who are considering AM for the manufacturing of spare parts.

Decentralized Spare Parts Production for the Aftermarket using Additive Manufacturing - A Literature Review

Additive manufacturing of spare parts to supply the aftermarket of long-life primary products beyond the End of Production has gained attention, because economic production of small batch sizes and a decentralized production close to the place of demand has become possible. This not only changes production processes but also affects the design of supply networks. In this paper, a literature review is conducted to identify and evaluate approaches in the scientific literature to determine the effects of using additive manufacturing processes in spare parts production for the aftermarket, considering the spatial and temporal configuration of a supply chain. The procedure of the literature review consists of three phases: plan, conduct and report and is broken down into six steps: research question and objective, scope, search, analysis, synthesis, and discussion. Out of more than 650 identified publications, 31 articles relevant to the research question were extracted using formal and content-related criteria. The PRISMA flow diagram is used to present the selection process. The results are objectively described using descriptive statistics and a keyword analysis. The publications are subsequently compared based on predefined evaluation criteria. On this basis, research gaps and future research needs are identified.