One utility moved from manual plotting of stator performance data to a computer-based, continuous monitoring system on its 10-year-old turbines that were installed in the mid-1980s. There are two commonly used measures of reliability: * Mean Time Between Failure (MTBF), which is defined as: total time in service / number of failures Lacking standard measures of ERM and using reward systems that typically do not encourage operators or supervisors to record or try to maximize equipment performance, industry can give suppliers very little information about its equipment beyond installation. promoting productive maintenance through motivation management and autonomous, small group activity. 2. The cost of a typical state-of-the-art manufacturing facility for semiconductor memory chips has risen eightfold since 1980, from $25 million to $200 million. Finally, a way must be found to address, as a nation, the underlying problem of a deteriorating level of basic talent. The panel considers ERM to be a significant factor in the competitiveness of manufacturing firms, an assessment supported by the case studies in the section on present practice (pp. MyNAP members SAVE 10% off online. No available method of measuring system reliability (e.g., equipment effectiveness = availability × speed ratio × yield) has yet been widely accepted by U.S. manufacturers, and manually collected production downtime data are questionable, inasmuch as waiting time for repairs is seldom reported. Economy of repairs and maintenance: While designing the machine elements and machine the designing should be such that least amount of repairs and maintenance will be required for the machine. A conservative specification of rated capacity, however, can yield misleading data for equipment performance. The Japanese have done it by adhering to the basic principles of motivation, commitment and understanding, and training and discipline. Very slight changes to the design of a component can cause profound changes in reliability, which is why it is important to specify product reliability and maintainability targets before any design work is undertaken. U.S. manufacturing also needs an equivalent to the Japan Institute of Plant Maintenance—an active group unencumbered by antitrust legislation and supportive of joint R&D, production ventures and standard-setting efforts—to spearhead advances in ERM practice. Results in trial fabrication plants for both wafer etch and implanter equipment show a substantial increase in average monthly uptime and increased predictability by reducing the range of monthly. Rapid product realization techniques to speed delivery to the marketplace. Software problems during system installation and checkout and numerous false diagnoses attending a later upgrade incurred extensive debugging that involved both vendor and user. make all of the foregoing accepted practice from the shop floor to the executive suite. Washington, D.C. November 1989. In 1989 alone, 51 companies were recognized by the Japan Institute for Plant Maintenance for achieving a level of performance in total productive maintenance that placed them on par with the Nishio factory. Industrywide collections of such information will facilitate sharing of technical data—both ERM statistics and qualitative information about the relative effectiveness of different techniques—and help pinpoint areas where improvement is essential to global competitiveness. In 1980, U.S. industry's utilization of capital and value-added time was low (Table 3-1 and Table 3-2), its average machine utilization was less than 50 percent, and the country ranked lowest among the major industrialized nations in percentage of machines less than 10 years old (Table 3-3). The ideal manufacturing environment of the future has no maintenance organization and every piece of equipment is expected to be available 100 percent of the time. The number of reversed load cycles to failure is recorded as a function of the applied load, i.e. Five critical areas receive in-depth analysis of present practices, needed improvement, and research priorities: This sound and accessible analysis will be useful to manufacturing engineers and researchers, business executives, and economic and policy analysts. Management leadership is essential to solving manufacturing 's problems because only management is positioned to have the overview essential for effective decision making and leading. When a project is in development, the individual or organization commissioning it will provide some specifications on what kind of stresses the system needs to endure. manufacturing control. 6–17 assumption. Important characteristics of reliability are as follows: 1. Though the uncertainties involved make exact predictions impossible, designers can solve many problems based on past experience, trial and error, tests, and the like. Academic emphasis on graduating career or professional engineers. The replacement and displacement of conventional electro-mechanical factory equipment by mechatronic equipment have given rise to a very different set of reliability and maintenance requirements. Click here to buy this book in print or download it as a free PDF, if available. A few basic definitions are used in this chapter. The cumulative effect of these practices is reflected in the product—mass-produced automobile body parts that are. Designers have access to comprehensive data from the equipment itself, as well as a wealth of information about the needs and performance of the installed base of industrial users. This awareness must be pervasive; it must run all the way from the executive suite to the shop floor. Do you want to take a quick tour of the OpenBook's features? The goal of the strategy is to eliminate the six main downtime losses: losses from setup time associated with periodic changes and adjustments of tools and dies; losses that result from idling, minor stoppages induced by sensors, and blockages of work in chutes; losses attributable to differences between actual and design speeds of equipment; process-related losses associated with defects and reworking; and. Here some basic concepts of machine design or mechanical design have been covered. Reliability is extremely design-sensitive. Equipment reliability and maintenance practices for better returns on capital investment. The uptime of a facility, infrastructure component, machine, device, service, product, function, system, business capability or process. The Noria, for instance, is an ancient pump thought to be the world’s first sophisticated machine. This situation is reflected in the radically different perceptions of the performance of newly installed equipment in the United States and Japan. This is true even of smaller companies. While total abandonment of tradition, or complete cultural change, is neither possible nor desirable, U.S. manufacturers may need to import, adapt, and fine-tune techniques from other countries such as Japan. Too often, engineers work hard to improve one element of a system, only to discover that in doing so they have degraded the total system. Development of guidelines and practices for designing the human– machine interface to enhance ERM. Do you enjoy reading reports from the Academies online for free? Manufacturing management has labored against prevailing views of manufacturing as an appendage to business, a necessary evil, bureaucratic and hence slow to respond, driven by internal pressures and short-term thinking, and not part of the strategic business plan. To this end, the training of finance and accounting people to guide and support the concurrent engineering process is critical. Japanese suppliers, in contrast, benefit from close customer technology exchange programs with leading Japanese semiconductor manufacturers. Mean time between failures for a wide variety of assembly equipment has increased in the range of 200 to 2300 percent, resulting in equipment uptime averages in excess of 90 percent of available hours (in a 168-hour week). Over the next several product generations, the cost of such facilities is expected to reach between $500 million and $750 million (Figure 3-2 ). Durability: The longer the life of the machine more it develops the reputation of being the dependable machine and more will be its sale. Here's What You Need to Know, 4 Most Common HVAC Issues & How to Fix Them, Commercial Applications & Electrical Projects, Fluid Mechanics & How it Relates to Mechanical Engineering, Hobbyist & DIY Electronic Devices & Circuits, Naval Architecture & Ship Design for Marine Engineers. Aircraft engine manufacturers, for example, the capital approval process specifies different levels of authorization depending the! Practice elaborate on it failure, and repairs are completed to original specifications before problems become.. Leading Japanese semiconductor manufacturers complexity associated with these technologies ( see chapter 6, manufacturing skills improvement for more this... 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