Production Of Spare Parts Research Articles

Digital Twin-Based Prediction and Optimization for Dynamic Supply Chain Management

Manufacturing supply chains are becoming increasingly complex due to geopolitical issues, globalization, and market demand uncertainties. These challenges lead to logistics disruptions, inventory shortages, and interruptions in raw materials and spare parts production, resulting in delayed delivery, reduced market share, and lower customer satisfaction. Effective supply chain management is critical for improving operational efficiency and competitiveness. This paper proposes a supply chain digital twin methodology to enhance operational efficiency through real-time monitoring, analysis, and response to disruptions. This methodology defines a supply chain digital twin system architecture and outlines the operational process of digital twin applications. It introduces two key modules: a digital twin module for prediction and monitoring and an optimization module for determining the optimal movement of products. These modules are integrated to align digital simulations with real-world supply chain operations. The proposed approach is validated through a case study of an automobile body production company’s supply chain, demonstrating its effectiveness in reducing inventory and logistics costs while providing countermeasures for abnormal situations.

Optimizing Multi-Plant Supply Chains: A Case Study of Textile and Spare Parts Production in Qatar and Türkiye

Optimizing Multi-Plant Supply Chains: A Case Study of Textile and Spare Parts Production in Qatar and Türkiye

EXAMINATION OF MECHANICAL PROPERTIES OF FASTENERS PRODUCED WITH PET AND PLA MATERIALS IN EXTRUSION-BASED ADDITIVE MANUFACTURING METHOD

Additive manufacturing methods, with their potential to revolutionize many areas, especially spare parts production, enable the optimization of the supply chain in production processes with an on-site production approach. The increased number of users of additive manufacturing methods and easy access to material extrusion-based methods can potentially transform the manufacturing industry. In this study, to investigate the production performance of fasteners, which are indispensable components of the manufacturing industry, with additive manufacturing. This study focuses on the torque strengths, hardness, and microscope images of bolts and nuts produced by material extrusion-based additive manufacturing (MEX) using PLA (Polylactic Acid) and PET (Polyethylene Terephthalate) polymers with different production parameters. Unlike conventional manufacturing methods, M8x50 DIN (German institute for standardization) 933 bolts and M8 DIN 934 nuts were produced. The bolts produced were positioned on the MEX device in two different positions. The torque forces applied to the bolts were measured in mechanical tests. Hardness was measured, and bolt thread surfaces were examined using a stereo microscope. Data on the usage limits of polymeric bolts were determined with the data obtained.

Insourcing additive manufacturing for spare parts production: is it profitable? An extensive analysis and the proposal of a Decision Support System

Recently, Additive Manufacturing (AM) has gained significant interest as promising technology for spare parts production. Unlike Conventional Manufacturing (CM), insourcing AM machine(s) enables the production of spare parts on demand, which in turn reduces inventory levels. However, AM is characterised by high costs, primarily associated with the purchase of AM machines. Therefore, the question arises as to whether insourcing AM is profitable for spare parts production. Here, we elaborated a full factorial comparison of 2,187 instances. Following industrial applications, we considered on demand production for insourced AM, while for CM, a make-to-stock approach was used. We found that under unconstrained stock system, the insourcing of AM is not preferable due to the high costs of AM machines. Under constrained stock system, however, AM is profitable in 68.5% of the analysed instances, leading to an average saving of 46%. Furthermore, for each tested scenario, we determined the maximum order-up-to level that makes AM profitable. From this analysis, we derived a decision tree to identify under which spare parts characteristics (i.e. costs, lead time, and part reliability) and maximum order-up-to levels AM becoming profitable. This serves as a Decision Support System (DSS) to assist practitioners in selecting the best production technology.

Facilitating the Production of 3D-Printed Spare Parts in the Design of Plastic Parts: A Design Requirement Review

Using additive manufacturing for spare part production can ensure that spare parts are available for a long time. However, spare parts are currently not designed for additive manufacturing. This study aimed to find how the production of 3D-printed spare parts can be facilitated in the design of plastic parts. We used a literature review and illustrative case to find how the design requirements for standard injection moulded plastic parts relate to the manufacturing capabilities of additive manufacturing for spare parts. The design requirements were defined by assigning corresponding structural and material properties. These requirements were then used to construct and evaluate the capabilities of additive manufacturing compared to injection moulding. It was found that additive manufacturing is especially suitable for requirements like Accuracy, Heat resistance, and Chemical resistance. However, to fully enable 3D-printed spare parts, certain design challenges still need to be tackled. Designers should pay careful attention to the synergies and trade-offs between design requirements and the challenges that might arise from the combination of certain requirements. Also, designers should ensure products are easily reparable before considering 3D-printed spare parts. If we target these challenges in the design phase, we can facilitate 3D-printed spare parts that enable product repairability.

Acoustic emission monitoring of a laser powder bed fusion process

Additive manufacturing (AM) metal parts offers opportunities for various industrial applications. From individual production of spare parts for unique mechanical components to prototyping of complex structures, the possibilities of production using the additive manufacturing process are manifold. One common AM technique is the Laser Powder Bed Fusion (PBF-LB/M) process, where a laser is used to selectively melt metal powder and create the parts layer wise as designed in a model. During manufacturing certain defects like pores, cracks and lack of fusion may be created in the built parts. As AM parts often have complex geometries, a postprocess non-destructive testing is difficult or even not possible. Thus, different optical monitoring techniques are applied to detect flaws during the build process with the aim to detect and repair defects right away during the manufacturing process. However, optical monitoring system require a clear view of the melt pool and quite expensive equipment. Acoustic monitoring by AE sensors attached to the built plate would be a cheaper alternative which also can be used without visual contact to the building chamber. This paper shows a first approach of an AE based process monitoring. The build plate of a PBF-LB/M machine therefore was adapted to hold four AE sensors that are then used to monitor the process. The build process itself creates AE signals caused by the melting and cooling and the mechanical application of powder. The formation of pores and cracks is expected to create additional acoustic emissions that will be distinct from the AE pattern from the printing process. This AE signals can be linked to the different layers of the printed part or in the long run to the laser position. Results from the first tests in a customized LPBF machine will be shown as well as the implementation of AE into the PBF-LB/M machine.

Repositioning of an Engineering Works Complex as an Industrial Hub for Spare Parts and Components Production

Ajaokuta Steel Company Limited (ASCL) comprises several units, including the Engineering Works Complex, which is one of the key auxiliary units of the steel plant. This complex is equipped with the necessary tools and machinery for producing fixtures and spare parts that meet a wide range of requirements. These machines are operated by welltrained engineers, skilled technicians, and artisans. The complex is designed to carry out repairs on equipment across the entire steel plant, as well as to manufacture spare parts for external agencies. Additionally, facilities are available for training technicians and artisans. The Engineering Works Complex consists of five major workshops: the Machine and Tools Shop, Forge and Fabrication Shops, Foundry and Pattern Making Shops, Power Equipment and Repair Shops, and the Rubberizing Shop. It is fully equipped to meet the industrial demand for spares and consumables, and it has the capacity to serve as a research institution where modern research can be conducted. This research aims to explore the potential of repositioning the Engineering Works Complex at Ajaokuta Steel Company as a leading industrial hub for the production of spare parts and components in Nigeria. The study will analyze the potential economic benefits of this repositioning, such as increased employment opportunities, higher productivity, and greater contributions to the national economy. By drawing on case studies from other countries that have successfully developed their engineering sectors, the research will provide insights and lessons that can be applied to the Nigerian context. The Engineering Works Complex is actively utilizing the government's local content policy to achieve these goals. With the necessary attention, including adequate funding for the various shops within the complex, it could generate significant revenue and create employment opportunities in downstream industries, ultimately contributing to the industrialization of local communities and the country at large.

Integrating Emerging Technologies in Military Maintenance and Repairs: An Overview of Current Status, Opportunities and Challenges

Maintenance and repair (M&R) of military equipment are crucial for operational readiness. The article highlights challenges faced by military forces, particularly in the US, with significant equipment non-operable due to inefficient M&R. It emphasizes modernizing M&R through Predictive Maintenance (PM) and 3D Printing (AM). PM employs AI and data analytics for real-time monitoring and foreseeing malfunctions, signifying a strategic shift in M&R. AM significantly curtails downtime by enabling on-demand spare parts production, presenting a solution to traditional military M&R challenges. The article also underscores the economic advantages and potential for operational efficiency improvements through these technologies. However, it points out hurdles in implementing PM and AM, including high initial costs, lack of trained personnel, and the threat of counterfeit production in AM.

OPTIMIZATION OF THE PROCESSES OF PRODUCTION OF SPARE PARTS FOR MOTOR VEHICLES

The purpose of the research is to develop a software simulation multi-product model designed for effective inventory management of spare parts. In the course of the work, a mathematical model was used to optimize the production and storage of spare parts for vehicles. At the same time, such significant factors as the total number of spare parts in stock, the frequency of failure of certain parts, operating conditions, the intensity of their use, as well as the influence of the human factor were taken into account. The results show that penalties for shipping and dynamic spare parts consumption significantly affect the cost function, while penalties for missing necessary parts significantly affect the minimum inventory level. The results can be applied to the management of spare parts stocks at authorized service centers. The study concludes that seasonal fluctuations in demand for spare parts can be eliminated by creating a scientifically sound spare parts inventory management system.

Spot Welding Error Analysis in Making Rear Brake Arm in Spot Welding Part at PT. XYZ

As a manufacturing company engaged in the manufacture of automotive parts, it produces components for motorized vehicles, especially for two wheels, with the production of spare parts in the form of arm rear brakes. In the manufacture of these spare parts, it is really necessary to pay attention to all the needs, such as materials which, in other words, really have an influence on the strength of the material. Included in the process that goes through spot welding, it needs to be considered in the stages of the process to be optimal because, if not, it will cause failure of a product so that defective products are obtained at this welding point. Improvement of the production process of this product can be done by identifying control factors and arrangements using the 5 why analysis, fishbone, and pareto methods until the production process is stable and the results obtained are good and according to the expected standards until the needs of all parties are met.

The Synergy Model of Quality Tools and Methods and Its Influence on Process Performance and Improvement

Implementing quality tools and methods creates a basic foundation for innovations, sustainability, optimization, and competitiveness in the era of Industry 4.0 and Quality 4.0. This paper aimed to investigate the use of quality tools and methods in the 24 divisions of a mother manufacturing company without the influence of external factors such as geographical location (America, Africa, Asia, and Europe). It was important for the mother manufacturing company to implement a uniform process standard for innovation and performance. Research methods focused on using the Kanban card, Ishikawa diagram, affinity diagram, Flowchart, 5S, OPL, layout, and Pareto analysis. It was determined in this research that the synergy (combination) of quality tools and methods in divisions improves the process performance. This hypothesis was confirmed by the results of implementing quality tools in processes within divisions. A top result was the new innovative model of synergy of the quality tools and methods for divisions of the parent company thus filling a gap in the scientific field. This model created the basis for the uniform process standard in all divisions. The results brought improvements in the processes such as material input inspection, spare parts production, production process, and product packaging. This model could be a proactive instrument for process innovation.

An integrative production-delivery system with mobile additive manufacturing and truck-drone delivery considering optimal printing sequence and preferred delivery time window

ABSTRACT Mobile additive manufacturing (MAM) involves deploying 3D printing in moving vehicles and has recently garnered significant attention from academia and industry. However, no prior work integrates MAM with truck-drone delivery systems to support daily operations, despite the benefits to supply chain management. This paper fills this gap by integrating these technologies, considering customer delivery time windows and optimal printing sequences. A mixed-integer linear programming model is proposed to establish this innovative mechanism. Both exact (CPLEX) and heuristic (Lagrangian relaxation algorithm) approaches are utilized and compared to solve the model. Computational studies validate the model and solution methods across various problem sizes (small, medium, and large), showing the superior performance of Lagrangian relaxation in optimality gap and CPU time. The model is then applied in a case study using the Lagrangian relaxation algorithm. Results indicate that drone flight range and printing job complexity significantly impact cost performance and on-time delivery. Beyond achieving timely and cost-effective customer satisfaction, this system offers insights into supply chain resilience, enabling companies to enhance service quality and reduce inventory dependence through on-demand spare part production via MAM technology.

Modelling and optimization for integrated scheduling problem considering spare parts production, batch transportation and equipment operation

Modelling and optimization for integrated scheduling problem considering spare parts production, batch transportation and equipment operation

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.

Peran Purchasing Departemen Dalam Pengadaan Barang Pada PT. Jawa Metalindo Prima Industri

PT. Jawa Metalindo Prima Industri was founded in 1985 by Mr. Suryanto Wibowo. Initially, the company focused on the production of small metal components and spare parts for the automotive industry. With strong determination and a vision to become a major player in the industry, PT. Jawa Metalindo Prima Industri started its journey with limited but quality production facilities. In the first few years, the company experienced steady growth. With increasing demand for metal products, PT. Jawa Metalindo Prima Industri is developing production capacity and improving the quality of its products. This is supported by investment in technology and modern production machines which enable the company to meet higher quality standards and increase production efficiency. In 1995, PT. Jawa Metalindo Prima Industri is diversifying its business by expanding its product range. The company began producing metal components for the electronics and household appliance industries. This step helps the company to diversify sources of income and reduce dependence on one particular market segment. At the beginning of the 21st century, PT. Jawa Metalindo Prima Industri is carrying out significant expansion. The company acquires several small companies in the same industry to expand its market share and gain competitive advantage. Apart from that, PT. Jawa Metalindo Prima Industri has also invested in improving production facilities, research and product development, as well as developing a qualified workforce. In recent years, PT. Jawa Metalindo Prima Industri continues to show positive growth. The company has succeeded in expanding its distribution network to export markets, so that its products can be sold to various countries throughout the world

3D-Printed Polymer Spare Parts for Various Applications

3D-printed polymer component parts and spare parts are now being widely used in various applications. In this paper, the 3D printing technologies and materials for spare part production in several applications are presented. Some opportunities and challenges faced when using 3d-printed spare parts are also discussed. The acrylonitrile butadiene styrene (ABS) has mostly been used. And it was found out that the durability of the spare parts could vary depending on the application.

Peramalan Jumlah Persediaan Sparepart Carburetor Assy dengan Metode Exponential smoothing Brown dengan Genetic Algorithm (order cross over dan one point mutation) di PT Hitachi Astemo Bekasi Powertrain System

Abstrac: One of the business people in the automotive sector who continues to move as a manufacturing company in the production of vehicle spare parts is PT ABC which is the largest manufacturer of spare parts for several vehicle companies such as Astra Honda Motor (AHM), Yamaha and so on. One type of production from PT ABC is the carburator assy which functions to mix fuel and air to produce propulsion for vehicles. Seeing its very important function, PT ABC places the carburator assy as a type of spare part that must be produced every month In research, a method is needed to solve the problems that occur. Research methods are scientific ways to obtain data / information as it is and not as it should be, with certain purposes and uses. This research is based on descriptive research. This study used the double exponential smoothing Brown method for forecasting carburator assy 052A with Alpha assessment using Genetic Algorithm order Cross over PT ABC.Calculations carried out for forecasting the Double exponential smoothing Brown method using Alpha values of 0.36 and 0.32 obtained randomly resulted in RMSE values that were greater than Alpha values obtained using Genetic Algorithms, namely 103.7234 for Alpha values of 0.36 and 117.6129 for Alpha values of 0.32. Therefore, it can be interpreted that determining the Alpha value using the Genetic Algorithm method can be a solution to reduce the RMSE error value in Double exponential smoothing Brown forecasting. In research conducted at PT ABC by analyzing the influence of Genetic Algorithms in determining α values, several conclusions can be obtained, namely as follows: Determination of α value for the calculation of Double exponential smoothing Brown using the Genetic Algorithm obtained an Alpha value of 0.43 with the smallest error result of 95.29633. Calculations MADe on Genetic Algorithms can determine α value that can minimize errors in forecasting compared to α values without Genetic Algorithms.

Numerical Analysis of A Spare Parts Supply Chain With Additive Manufacturing

Numerical Analysis of A Spare Parts Supply Chain With Additive Manufacturing

Framework for Adoption of Metal Additive Manufacturing in the Oil and Gas Industry in Africa

The oil and gas industry in Africa is under mounting pressure to elevate operational efficiency and curb costs, even as supply chain challenges stemming from the pandemic persist. Additive manufacturing (AM) emerges as a unique solution with the potential to free segments of the industry from conventional supply chains. This study introduces a framework tailored to the distinctive challenges and opportunities of the African oil and gas sector, aiming to facilitate the effective adoption of metal AM. Considering constraints such as supply chain limitations, unstable electricity supply, remote locations, and limited manufacturing facilities, this framework intends to guide stakeholders in leveraging the transformative potential of AM technology while overcoming potential barriers. Leveraging a literature review, expert insights, and real-world scenarios, the study assesses the current state of metal AM in the oil and gas sector. The framework's applicability is demonstrated through a case study of the Nigerian National Petroleum Company (NNPC) Limited, while acknowledging the specific African context. It uncovers the existing state of metal AM in Africa and identifies various facilities along with their constraints. Encompassing domains such as prototyping, customized tooling, complex component fabrication, and spare part production, the framework addresses challenges like cultural shifts, quality control, and facility sustainability. It offers key stages encompassing technology assessment, workforce training, and strategic planning to drive the transition toward additive manufacturing. The adoption of metal AM in Africa's oil and gas sector holds the potential to significantly enhance operational efficiency and competitiveness, yet it necessitates overcoming multifaceted challenges. The proposed framework presents a strategic roadmap for harnessing this technology's transformative potential. By embracing innovation and surmounting region-specific obstacles, Africa's oil and gas industry can attain enhanced efficiency, cost-effectiveness, and adaptability

Finite Element Analysis of SMC Core Magnetic Gear for Vehicle Powertrain Systems

The utilization of gears as intermediary components for power transmission in electric drive systems addresses the insufficiency of electric machines in handling torque loads effectively. Gears, commonly employed in the industry, can be either mechanical or magnetic, allowing for the balanced transfer of torque and speed at specified ratios. The mechanical and electrical actuation of in-vehicle accessories persists both in traditional and next-generation vehicles. Particularly concerning safety and the sustainability of spare part production and supply, various electrical accessories continue to operate at the 12 V level in modern vehicles. In this context, the use of the Lundell alternator (claw pole) also continues in next-generation vehicles. While the mechanical accessories are driven by a belt-pulley system connected to an internal combustion engine in conventional vehicles, in next-generation vehicles, both belt-pulley systems and x-drive by wire are present. The low efficiency and operational costs of belt-pulley power transmission systems necessitate the adoption of more efficient transmission systems. This study focuses on the development of a soft magnetic composite (SMC) core magnetic gear power transmission system that can serve as an alternative to belt-pulley systems in both traditional and next-generation vehicles. In the proposed system, mechanical power transfer to the Lundell alternator is realized through the intended magnetic gear. The gear ratio is determined to ensure a speed of 1800 rpm at the input of the Lundell alternator while the drive system operates at 6000 rpm. To achieve low volume and high efficiency for the proposed magnetic gear, the SMC material is considered, and a comprehensive analysis using the Ansys Maxwell finite element software is conducted. As a result of the analyses, in the magnetic gear designed with a transmission ratio of 3:1, when a torque of 11.7547 Nm is applied to the input shaft, a torque transmission of 35.9806 Nm has been achieved with an efficiency of 84.73% through the output shaft.