What was the diferent genreaions of maintenace work ?
- First generation:
- If it aint broke, dont fix it
- Second generation
- The birth if preventive maintenance. Measurs was done: MTBF, MTTR
- Total productiv maintenance:
- Maintenence prevention
- Preventative maintenance
- Autonomous maintenance
- Thrird generation
- Smart machines, birth of indutrial digital age
- After
- Industry 4.0- Digitalized manufacturing
What are the four parts of maintenance ?
- actions
- strategies
- concepts
- management
What is included in the actions of maintenance ?
- Reactive: Repair, run to failure
- Preventive: Time- based, ex. lubrication
What are the stregies in maintenance?
- Preventive
- Condition-based
- Autonomous
What are the concepts of maintenance ?
- Preventive
- Mainability
- Reliability
- TPM
- CMMS
Wht is included in the mangement of maintenance ?
- KPI:s,
- equipment performance
- Cost performance
- Process performance
- Planning and scheduling
- PSS for maintenance
- Tools
- What if
- Root cause analysis
- Faut tree anaylisis
- Safety analysis
- Simulation
Why is maintentance important ?
- In the last 10 years (1990 study) maintenance cost has increased 300%
- Next to enery, cost maintenance is the seccond largest part of industries operational budget
- 15% tp 70% of totalt production cost goes to maintenance activities
- Unplanned downtome cost 250 000 per hours
–>> Cost of poor maintentance is the cost that ni industry can ever manage
- Production inefficiency
- Equipment failures can cause blockage and idle time
- It can often safety critical
- Consumes more energy to repait than produce
- 30% of energy consumed is wasted on system losses
–>> Poor maintenance can cause social, economical, and ecological sustainability losses.
What are the eleven steps of development?
- product design
- Process planning
- Time measurment
- cost calculations
- Layout planning
- Ergonomics
- Robot / off- line
- NC simulation quality assurances
- Factory flow simulation
- Production system design
- production management
What is important to think about in step one product design in development?
- The product features, how is the product going look like. What is the components?
- Go in and do a CAD simulation
- Break done to a BoM Bill of materials, break done to first the components, and then break done to what the components is build up from…
- Then also do EBoM- Engineering bill of material, its what happens in the steps from example a raw material to a part, e.g. remove material from some places. Or connect to material with each other
What is important to think about in the seccond step process planning for development?
EboM to MboM(manufacturing bill of material) gives even more information. How can we do the operation, e.g. what do we need to remove material?
- Machines (types, capabilities, auxiliary equipment)
- Equipment (tooling, fixture)
- Workers ( involvement, competence)
To do this we need Technology acquisition
- Industrially available (on the market)
- Standard
- Faster because already on the market
- Cost effective, nothing extra
- Examples:robots(think about: weight, payload, repeatability, TCP Velocity, reach/ workspace) machinery,Can be CNC machines for milling etc. (think about: product requirements, process speed, work envelope, set- up time, flexibility) Modular fixtures( for Colum’s, grid plates etc.)
- Custom order
- Outsourced
- Customized
- Mostly occurs for fixtures
- Examples dedicated fixtures(custom made)
Instead of acquisition you can do in-house design
- Requires competence
- Gives freedom
- Costly
To think about during this process:
Production engineering perspective:
- Automation design
- Robot & CNC –
- preferred to have industrially available machines
- for only very specific cases, they are customized
- Robot & CNC –
- Majority of the customization is in the end of the process
- Fixtures are more subject to design/ development
- Dedicated,
- Modular
- Reconfigurable
What is important to think about in the time measurment and cost calcualtions step 3 & 4 in development?
Design- Equipment designer´s perspective
- Can provide more details analysis tools on production equipment
- THis perspective is used in early design phases
- These perspectives are often grouped as
- Technical capabilities
- Design process
- Running performance
The technical capabilities is what you need to fulfil the design process and the running performance is the measurement of how well the design process is doing.
E.g.
Design process: Mass production
- Characteristics (1.): Standardization, time and quality effectiveness
- Metric (3.): cost, quality, time
Flexible manufacturing system
- Characteristics (1.): flexibility
- Metric: cost, quality (3.) time, flexibility
Is this what you want or is it something else EVALUATE !!!!
What is important to think about in step 5 layout planning in development?
Process- cell design
- Individual cells are created in this phase
- The relationship between machines are evaluated
- Spatial, easy to overlook the hole space
- Operational, how the machines/functions are connected
- Simulation tools:
- CAD /CAM
Process simulation
- Identifying the operations
- Creating order for operations
- Determining cycle times
- Calculating cost
- Balancing load among multiple machines (if any) ’
Production system design
Layout planning:
- Map the relationships
- Determine the functional requirements
- Sketch the function of the cells
- Draw alternative master plans
- Evaluate the alternate master plans
- Final layout
What is important to think about in step 6-9 in the development process ?
Have a broader perspective
- Discrete event simulation
- Maintenance and system roughness
- FMEA (Failure mode and effects analysis
- What is the risks? How often can they happen? Rank the effects off it. Then you get a ranking order on which risk is important to work on.
- FTA- Fault tree analysis
- FMEA (Failure mode and effects analysis
- Ergonomics evaluation
- Key indicator method (KIM)
- Pulling & pushing
- Lifting, holding & carrying
- Key indicator method (KIM)
- Ecological analysis
- LCA
