Manufacturing Of Spare Parts Research Articles

Analisis Performansi Nakayama Plant Menggunakan Metode Ramd di PT XYZ

PT XYZ is one of the manufacturing industries engaged in the manufacture of spare parts on a national scale. One of the products produced by PT XYZ is magnifold intake pipe which is made in nakayama plant. Based on data from nakayama plant obtained system breakdown structure of the system namely Sand Core, Furnace Gravity, Finishing, Machining, Leaktest. Of the five subsystems will be selected critical subsystems based on the results of RAMD analysis. The result of the data processing that has been done is known that the Reliability value of the system at the time of t = 8 hours is 63.92%. Availability markov process value is 98.546%. The average value of Maintainability at the time of t = 8 hours is 98.951%. The lowest Dependability and Dependability Ratio values are in the Gravity Furnace subsystem with values of 95.634% and 131.759. Therefore, it can be known that the critical subsystem in the system is gravity furnace so it needs to be maintained regularly and scheduled.

Reduce the Risk of Failure of The Automotive Part Manufacturing Process using PFMEA AIAG-VDA: Case Study of Automotive Motorcycle Supplier in Indonesia

Competition in the automotive industry, especially in Indonesia, is quite tight. Automotive OEMs require their suppliers, both Tier-1 and Tier-2, to supply quality products consistently. One of the indicators of supplier evaluation is the quality performance with abnormal product quality detection parameters from supplier to automotive OEM, and even to end-user if this happens on motorcycles. For this reason, this research aims to analyze and improve supplier performance level, mainly the manufacture of OEM motorcycle spare parts, by looking at the risk of production process failure. The method analyses for this research use AIAG-VDA PFMEA to analyze this starting from the closest case or the occurrence of abnormal violations on the assembly of OEMs and even end-users of motorcycles. The results showed that one of the suppliers processing with the lowest value, the Cap Camshaft product, in the casting process, there was a crack failure on the product. The cause of cracking by analyzing the casting process found that was due to bile on the casting and the instability of the bolting assembly area caused cracking on the camshaft cover. The repaired item standardizes the Nozzle Spray Die on Dies' lubrication direction and increases the level of abnormal detection, especially cracks with color detector inspection items. The Purpose of improvement proposals is to analyze the process with risk forecasting patterns and avoid process failures and even flow to customers.

PENJADWALAN MESIN DENGAN MENGGUNAKAN ALGORITMA JADWAL NON-DELAY DI PT. SNN SEKSI WORKSHOP

Production scheduling is the most important part in carrying out the production process that will be carried out on a production floor. Scheduling activities are carried out before the production process begins to ensure the smooth running of the production process. If the production scheduling is not done properly, there will be obstacles in the production process and will cause losses to the company. This study aims to determine the production machine scheduling in a company engaged in the manufacture of spare parts for automotive products. This company implements a job shop production process and uses the First In First Out method in completing its work. Due to the large number of products that have to be produced, there are often two or more products that must be worked on at the same time and machine. This condition causes some products to have to wait for the associated machine to finish operating and causes long product turnaround times. This problem is solved by making a production machine scheduling using the Non-Delay method. By applying this method, the makespan of completion time can be minimized.

Additive Manufacturing Under Lunar Gravity and Microgravity

Mankind is setting to colonize space, for which the manufacturing of habitats, tools, spare parts and other infrastructure is required. Commercial manufacturing processes are already well engineered under standard conditions on Earth, which means under Earth’s gravity and atmosphere. Based on the literature review, additive manufacturing under lunar and other space gravitational conditions have only been researched to a very limited extent. Especially, additive manufacturing offers many advantages, as it can produce complex structures while saving resources. The materials used do not have to be taken along on the mission, they can even be mined and processed on-site. The Einstein-Elevator offers a unique test environment for experiments under different gravitational conditions. Laser experiments on selectively melting regolith simulant are successfully conducted under lunar gravity and microgravity. The created samples are characterized in terms of their geometry, mass and porosity. These experiments are the first additive manufacturing tests under lunar gravity worldwide.

PENERAPAN KAIZEN UNTUK MENGURANGI LOSS TIME DALAM PENINGKATAN PRODUKTIVITAS MESIN INFRARED WELDING (STUDI KASUS PT. MITSUBA INDONESIA)

PT Mitsuba Indonesia is a factory engaged in the manufacture of electrical automotive spare parts. The LED winker lamp is the newest product whose production demand is always increasing. The large demand for LED winker lamp products must of course be balanced with the readiness of production machines which are always in good condition. But in practice, the results of the production achievement are still low, this is due to the high machine loss time, especially in infrared welding machines. This study discusses the application of kaizen which aims to find the causes of loss time, make improvements in order to reduce loss time and determine loss time and productivity after repairs are made. The method used to analyze the causes of loss time is to calculate the value of six big losses and analysis of the cause and effect diagram. The analysis results showed that the idling minor factor and stoppages losses caused by part drop error and the set up and adjustment losses factor caused by a change in the type of production jig. Improvements made to the part drop error were adding 1 set of regulators. Meanwhile, the change in the production jig type is to modify the locking system on the lower and upper heater jig. Based on these improvements, it was able to reduce the loss time to 4.86% and productivity to increase 7.50% in July. Loss time fell 4.70% and productivity increased 7.90% in August.Keywords: LED winker lamp, infrared welding machine, loss time, six big losses, productivity.

Additive manufacturing in the process industry: A process-based cost model to study life cycle cost and the viability of additive manufacturing spare parts.

The potential applications of Additive Manufacturing technologies are capturing the interest of researchers and industries. Many researchers are now focusing on additive manufacturing and its potential to change the industrial paradigm in terms of economic, environmental, and social sustainability. One of the most promising areas for additive manufacturing adoption is maintenance, more specifically, manufacturing of spare parts. The customization potential, and excellent small series capabilities of AM can lead to reductions in size of central and local storages, eliminate the need to locate uncommon spare parts in the distribution network, shorten supply chains and diminish the duration and cost of logistics. The case for replacing conventional spare parts with additive manufactured equivalents has been the discussed in various studies focused of the aeronautic sector, however, its potential in other industries remains relatively unexplored. The continuous process industry is characterized by extremely high production volumes with costly machines and downtime. The combination of these characteristics with intermittent spare part demand patterns and the predominance of reactive maintenance, drives companies to keep large spare parts stock, which makes the case for introducing AM in process industry maintenance very appealing. This study focuses on how AM could change maintenance activities/supply chain in process industries and its economic impact using process based cost models. To further illustrate and study the problem, this paper contains a detailed evaluation of AM’s potential and impacts in a case study from the paper and pulp industry.

Remanufacturing System with Chatter Suppression for CNC Turning.

The paper presents the concept of a support system for the manufacture of machine spare parts. The operation of the system is based on a reverse engineering module enabling feature recognition based on a 3D parts scan. Then, a CAD geometrical model is generated, on the basis of which a machining strategy using the CAM system is developed. In parallel, based on the geometric model, a finite element model is built, which facilitates defining technological parameters, allowing one to minimize the risk of vibrations during machining. These parameters constitute input information to the CAM module. The operation of the described system is presented on the example of machining parts of the shaft class. The result is a replacement part, the accuracy of which was compared by means of the iterative closest point algorithm obtaining the RMSE at the level of scanner accuracy.

Optimum Laser Polishing Decision-Making for On-Demand Additive Manufacturing of Spare Parts: An Exploratory Study

Additive manufacturing is increasingly being used for satisfying spare parts needs of capital products using a nearby 3D printer. Such a technology allows inventory managers to start manufacturing after the demand realization which eliminates significant portion of spare parts inventory being held due to random nature of component breakdowns. Quality difference between printed and original parts, which is one of the biggest problems of using 3D printers, can be decreased by the use of laser polishing which alleviates surface roughness and increases reliability of parts in exchange of an additional cost term. Using different parameters, reliability of parts can be altered depending on needs of capital products and systems’ status. In this study, the problem where surface roughness and reliability of printed parts are jointly optimized with inventory levels of original spare parts is considered. In the problem setting, a machine part consisting of a constant number of identical products which are subject to random breakdowns over a finite planning horizon is considered. Using mathematical analysis and exhaustive numerical experiments, the relationship between optimum control policy and cost parameters was shown, which might be critical for cost-effective management of the system.

New Business Models for Sustainable Spare Parts Logistics: A Case Study

Additive manufacturing of spare parts significantly impacts industrial, social, and environmental aspects. However, a literature review shows that: (i) academic papers on the adoption of additive manufacturing have focused mainly on large companies; (ii) the methods required by SMEs to adopt new technologies differ from those employed by large companies; and (iii) recent studies suggest that a suitable way to help small- and medium-sized enterprises (SMEs) to adopt new additive manufacturing technologies from the academic world is by presenting case studies in which SMEs are involved. Given the increasing number of global SMEs (i.e., SMEs that manufacture locally and sell globally), we claim that these companies need to be assisted in adopting spare-parts additive manufacturing for the sake of resource and environmental sustainability. To bridge this gap, the purpose of this article is to present a case study approach that shows how a digital supply chain for spare parts has the potential to bring about changes in business models with significant benefits for both global SMEs (more effective logistic management), customers (response time), and the environment (reduced energy, emissions, raw materials, and waste).

A methodology for the decentralised design and production of additive manufactured spare parts

ABSTRACT The production of spare parts using Additive Manufacturing (AM) is an emerging area that impacts the supply chain management. To give designers a way to proceed at the moment of redesign and produce a spare part using AM, this contribution presents a methodology for the design and manufacturing of digital spare parts using AM in decentralized facilities. The re-design of the spare parts is tackled by giving design considerations based on agile hardware development practices to improve the quality of the spare parts and reduce the lead time. Since this methodology is derived from different case studies of the military over two years, the approach is suited for the defence industry but can be adapted to other industries that operate reduced facilities abroad. Additionally, three different use cases following the methodology are presented. The weaknesses of the processes are highlighted and some recommendations for production engineers and designers are given.

KINERJA MESIN BUBUT GEMINIS DITINJAU DARI KEBULATAN BENDA KERJA

Mesin perkakas dibidang manufaktur yang menghasilkan benda kerja dengan ketelitian yang tinggi sangat diperlukan untuk dunia Industri Manufaktur. Mesin perkakas yang menghasilkan benda kerja (penyimpangan kebulatan yang rendah ) dengan kualitas baik akan menghasilkan harga sebanding dengan yang ditawarkan. Sehingga menuntut perawatan dan pemeliharaan mesin yang lebih optimum. Laboratorium Mekanik Politeknik Manufaktur Negeri Bangka Belitung mempunyai beberapa mesin bubut untuk menghasilkan benda kerja berupa produk latihan mahasiswa, suku cadang mesin dan kegiatan produksi dengan ukuran yang presisi, mesin bubut ini sudah digunakan selama kurang lebih 20 tahun, pemakaian yang terbilang sudah lama dapat mengakibatkan terjadinya perubahan penyimpangan geometri mesin. Penyimpangan yang terjadi akan mempengaruhi kualitas produk yang dihasilkan. Di antara mesin bubut ada mesin bubut Geminis berjumlah 3 unit. Untuk mengetahui penyimpangan kebulatan yang terjadi setelah digunakan pada proses belajar mengajar dan pembuatan suku cadang selama 20 tahun serta untuk mengetahui kelayakan mesin bubut jika digunakan untuk memproses benda kerja dengan toleransi ukuran tertentu, maka perlu dilakukan pengujian. Pengujian yang di lakukan adalah pengujian geometrik mesin pada kebulatan benda kerja.. Hasil proses pemotongan benda uji akan di ukur kebulatannya dianalisis dengan cara lingkaran daerah minimum. Ketiga mesin bubut geminis mempunyai rata-rata penyimpangan sebesar 45,33 μm dan penyimpangan terkecil rata rata 20 μm dapat memproduksi benda kerja dengan toleransi diatas 41 μm.

Redistributed manufacturing of spare parts: an agent-based modelling approach

Maintenance and repair activities from the perspective of OEMs are both considerable sources of revenue and expenses, particularly when part of a Product Service System (PSS). It is therefore necessary for an OEM that provides services bundled with products to ensure timely response without significant impact on cost. This paper proposes a make-to-order spare parts supply chain strategy through the adoption of Redistributed Manufacturing (RdM) where the supply chain is shortened and total cost is decreased. An agent-based model that portrays an OEM’s response to repair a failed equipment is developed to exhibit the potential time and cost savings gained by OEMs.

Sustainable supplier selection: A multi-criteria intuitionistic fuzzy TOPSIS method

The concept of sustainability is becoming an essential philosophy for numerous industrial sectors because of the increase in environmental protection and social obligations awareness. A sustainable supplier selection is the first step towards this trend. It is also a challenging problem since multi-criteria group decision-making is engaged with numerous conflicting requirements in which decision makers’ knowledge is commonly imprecise and vague. This research presents an intuitionistic fuzzy TOPSIS method to select the right sustainable supplier that concerns nine criteria and thirty sub-criteria for an automotive spare parts manufacturer. The proposed approach provides an accurate sustainable ranking of suppliers and a reliable solution for sustainable sourcing decisions that is validated through a real-world case study. This paper ends with research and theoretical findings, managerial insights and directions for future research.

Multi-objective open shop scheduling by considering human error and preventive maintenance

This study presents an open shop scheduling model by considering human error and preventive maintenance. The proposed mathematical model takes into account conflicting objective functions including makespan, human error and machine availability. In order to find the optimum scheduling, human error, maintenance and production factors are considered, simultaneously. Human error is measured by Human Error Assessment and Reduction Technique (HEART). Three metaheuristic methods including non-dominated sorting genetic algorithm-II (NSGA-II), multi-objective particle swarm optimization (MOPSO) and strength Pareto evolutionary algorithm II (SPEA-II) are developed to find near-optimal solution. The Taguchi method is applied by adjusting parameters of metaheuristic algorithms. Several illustrative examples and a real case study (auto spare parts manufacturer) are applied to show the applicability of the multi-objective mixed integer nonlinear programming model. The proposed approach of this study may be used for similar open shop problems with minor modifications.

Evaluating the Readiness Level of Additively Manufactured Digital Spare Parts: An Industrial Perspective

Additive manufacturing of digital spare parts offers promising new possibilities for companies to drastically shorten lead times and to omit storage costs. However, the concept of digital spare parts has not yet gained much footing in the manufacturing industry. This study aims to identify grounds for its selective rejection. Conducted from a corporate perspective, outlining a holistic supply chain network structure to visualize different digital spare part distribution scenarios, this survey study evaluates technical and economic additive manufacturing capabilities. Results are analyzed and discussed further by applying the Mann-Whitney test to examine the influence of the company size and the presence of 3D-printed end-use components within supply networks on gathered data. Machines’ limited build chamber volumes and the necessity of post-processing are considered as the main technical challenges of current additive manufacturing processes. Furthermore, it can be concluded that company sizes have a significant effect on perceived technological limitations. Overall, the results lead to the conclusion that the readiness level of the digital spare parts concept demands for further development.

ГЕОПОЛИТИЧЕСКИЕ ВЫЗОВЫ И МОДЕРНИЗАЦИОННЫЕ ОТВЕТЫ: ЖЕЛЕЗНОДОРОЖНЫЙ ТРАНСПОРТ ВОСТОКА РОССИИ В УСЛОВИЯХ ГРАЖДАНСКОЙ ВОЙНЫ

The article deals with the peculiarities of railway management in the Asian part of Russia in the days of anti-Bolshevist governments. The material is presented within the broad context of railroad construction history. The main railway lines constructed by the state before the revolution of 1917 in the Asian part of Russia led to the territory development. Private funds were invested in the warrantable projects. The Civil War mostly went along the railroads situated in the East of Russia. It is not unexpected that railway economy incurred substantial costs and, at the same time, railroads became a guide to the source of almost all the goods for the army and citizens. The state of the railway transport in the East of Russia was researched fragmentarily or formally and on the basis of fragmentary data. The author introduces documents of the Railway Department of the Ministry of Finance of the Russian Government and materials of periodical press into scientific use. The author considers it necessary to point out that laying train tracks in the Asian part of Russia was enhanced by private companies before the revolution. At the same time, the state recognized the importance of creation of a single plan of train tracks development, prioritizing and investments in laying train tracks. But the Civil War temporarily disorganized the unity of administration, and transfer of the railroads to railway committees made them unprofitable. Since the autumn of 1918, the Ministry of Railways of the Provisional Siberian Government and All-Russian Government managed to reconstruct the unity of administration and financing of all the state-owned and private railroads of the Urals, Siberia, the Steppe and the Far East. As shown in some sources researched by the author the Ministry used the sources of rail materials effectively, organized manufacturing of new carriages and spare parts in the Urals, which helped restore the damaged communications and build about 505 miles of new railway lines. The Ministry had to abandon the ambitious prerevolutionary plans of railway lines construction in the taiga zone of Siberia, but it continued construction of short railway lines that connected Siberian extractive industries with the Trans-Siberian Railway and the lines that delivered grain from Siberia. Construction of new railway lines and exploitation costs of private railway companies were paid from the funds of the Provisional Siberian and All-Russian Governments. The companies applied for a loan upon the security of the enterprises to the State bank, and it resulted in the transfer of private railroads of the eastern regions of Russia to the state. New railway construction continued within the frame of prerevolutionary directions and priorities. But the authorities had to put an end to the projects of the taiga and subarctic territories.

Design Control Systems of Human Machine Interface in the NTVS-2894 Seat Grinder Machine to Increase the Productivity

In the Manufacturing of automotive spare parts, increased sales of vehicles is resulted in increased demand for production of engine valve of the customer. To meet customer demand, we carry out improvement and overhaul of the NTVS-2894 seat grinder machine on a machining line. NTVS-2894 seat grinder machine has been decreased machine productivity, the amount of trouble, and the amount of downtime. To overcome these problems on overhaul the NTVS-2984 seat grinder machine include mechanical and programs, is to do the design and manufacture of HMI (Human Machine Interface) GP-4501T program. Because of the time prior to the overhaul, NTVS-2894 seat grinder machine does not have a backup HMI (Human Machine Interface) program. The goal of the design and manufacture in this program is to improve the achievement of production, and allows an operator to operate beside it easier to troubleshoot the NTVS-2894 seat grinder machine thereby reducing downtime on the NTVS-2894 seat grinder machine. The results after the design are HMI program successfully made it back, machine productivity increased by 34.8%, the amount of trouble, and downtime decreased 40% decrease from 3,160 minutes to 1,700 minutes. The implication of our design, it could facilitate the operator in operating machine and the technician easer to maintain and do the troubleshooting the machine problems.

Redesigning layout in the palm oil tank plant to enhance the utility

Material transfer is one of the most important activities in the production process activities and has a close relationship with the design of the layout of production facilities. A manufacturing company engaged in the manufacture and assembly of machine spare parts at the oil palm plant constraints in terms of material handling so that the decline in utility of the production floor layout and the increasing cost of moving raw materials. To improve the utility on the production floor using group technology method that is Rank Order Clustering (ROC) and Similarity Coefficient (SC). From the result of matrix rank calculation in pairs or between machines then SC method is the best layout design with decreasing material displacement moment by 56,86%. And to improve the layout of facilities on the production floor using BLOCPLAN algorithm that is the value of the degree of Adjency Score of 0.5317. This proposed layout provides a smaller displacement moment so as to shorten the processing time of all parts by 338 minutes and increase utility on the production floor.

Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study

Reverse engineering represents a method to retrieve information from an existing product, information which are then used for designing a new product or to reproduce it in order to make spare parts. In this paper is presented a case study on making a spare part of complex shape from a worn part. There are presented the stages of acquisition of data by scanning, the use of reverse engineering for the realization of the 3D model, the virtual manufacturing and then the machining of the workpiece CNC machine tools.

Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study

Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study