Abstract: Additive Manufacturing processes are becoming increasingly established in the industry for the economic production of complex prototypes and functional components. Laser beam melting (LBM), the most frequently used Additive Manufacturing technology for metal parts, has been gaining in industrial importance for several years. The LBM process chain – from material storage to machine set-up and component post-processing – requires many manual operations. These steps often depend on the manufactured component and are therefore not standardized. These operations are often not performed in a standardized manner, but depend on the experience of the machine operator, e.g., levelling of the build plate and adjusting the first powder layer in the LBM machine. This lack of standardization limits the reproducibility of the component quality. When processing metal powders with inhalable and alveolar particle fractions, the machine operator is at high risk due to the high reactivity and the toxic (e.g., carcinogenic) effect of the various metal powders. Faulty execution of the operation or unintentional omission of safety-relevant steps can impair the health of the machine operator. In this paper, all the steps of the LBM process chain are first analysed in terms of their influence on the two aforementioned challenges: reproducibility and work safety. Standardization to avoid errors increases the reproducibility of component quality as well as the adherence to and correct execution of safety-relevant operations. The corresponding lean method 5S will therefore be applied, in order to develop approaches in the form of recommended actions that standardize the work processes. These approaches will then be evaluated in terms of ease of implementation and their potential for improving reproducibility and work safety. The analysis and evaluation showed that sorting tools and spare parts as well as standardizing the workflow are likely to increase reproducibility. Organizing the operational steps and production environment decreases the hazards of material handling and consequently improves work safety.
Abstract: A need exists to identify the sources of risks associated with the process automation systems within petrochemical companies or similar energy related industries. These companies use many different process automation technologies in its value chain. A crucial part of the process automation system is the information technology component featuring in the supervisory control layer. The ever-changing technology within the process automation layers and the rate at which it advances pose a risk to safe and predictable automation system performance. The age of the automation equipment also provides challenges to the operations and maintenance managers of the plant due to obsolescence and unavailability of spare parts. The main objective of this research was to determine the risk sources associated with the equipment that is part of the process automation systems. A secondary objective was to establish whether technology managers and technicians were aware of the risks and share the same viewpoint on the importance of the risks associated with automation systems. A conceptual model for risk sources of automation systems was formulated from models and frameworks in literature. This model comprised six categories of risk which forms the basis for identifying specific risks. This model was used to develop a questionnaire that was sent to 172 instrument technicians and technology managers in the company to obtain primary data. 75 completed and useful responses were received. These responses were analyzed statistically to determine the highest risk sources and to determine whether there was difference in opinion between technology managers and technicians. The most important risks that were revealed in this study are: 1) the lack of skilled technicians, 2) integration capability of third-party system software, 3) reliability of the process automation hardware, 4) excessive costs pertaining to performing maintenance and migrations on process automation systems, and 5) requirements of having third-party communication interfacing compatibility as well as real-time communication networks.
Abstract: Vehicle is one of the most influential and complex
product worldwide, which affects people’s life, state of the
environment and condition of the economy (all aspects of sustainable
development concept) during each stage of lifecycle. With the
increase of vehicles’ number, there is growing potential for
management of End of Life Vehicle (ELV), which is hazardous
waste. From one point of view, the ELV should be managed to ensure
risk elimination, but from another point, it should be treated as a
source of valuable materials and spare parts. In order to obtain
materials and spare parts, there are established recycling networks,
which are an example of sustainable policy realization at the national
level. The basic object in the polish recycling network is dismantling
facility. The output material streams in dismantling stations include
waste, which very often generate costs and spare parts, that have the
biggest potential for revenues creation. Both outputs are stored into
warehouses, according to the law. In accordance to the revenue
creation and sustainability potential, it has been placed a strong
emphasis on storage process. We present the concept of storage
method, which takes into account the specific of the dismantling
facility in order to support decision-making process with regard to the
principles of sustainable development. The method was developed on
the basis of case study of one of the greatest dismantling facility in
Poland.
Abstract: A repairable mechanical system (as agricultural
tractor) is subject to deterioration or repeated failure and needs a
repair shops and also operator’s capability for the repair and
maintenance operations. Data are based on field visits and interviews
with 48MF 285 tractor operators from 14 villages collected in north
of Khouzestan province. The results showed that most operators were
lack the technical skill to service and repair tractors due to
insufficient training, specific education and work experience.
Inadequate repair and maintenance facilities, such as workshops,
mechanics and spare parts depots cause delays in repair work in the
survey areas. Farmers do not keep accurate service records and most
of them disregard proper maintenance and service of their tractors,
such as changing engine oil without following the manufacturer’s
recommendations. Since, Repair and maintenance facilities should be
established in village areas to guarantee timely repair in case of
breakdowns and to make spare parts available at low price. The
operators should keep service records accurately and adhere to
maintenance and service schedules according to the manufacturer’s
instructions. They should also be encouraged to do the service and
maintain their tractors properly.
Abstract: Optimization of business processes in trading companies is reviewed in the report. There is the presentation of the “Wholesale Customer Order Handling Process” business process model applicable for small and medium businesses. It is proposed to apply the algorithm for automation of the customer order processing which will significantly reduce labor costs and time expenditures and increase the profitability of companies. An optimized business process is an element of the information system of accounting of spare parts trading network activity. The considered algorithm may find application in the trading industry as well.
Abstract: Accurate demand forecasting is one of the most key
issues in inventory management of spare parts. The problem of
modeling future consumption becomes especially difficult for lumpy
patterns, which characterized by intervals in which there is no
demand and, periods with actual demand occurrences with large
variation in demand levels. However, many of the forecasting
methods may perform poorly when demand for an item is lumpy.
In this study based on the characteristic of lumpy demand patterns
of spare parts a hybrid forecasting approach has been developed,
which use a multi-layered perceptron neural network and a
traditional recursive method for forecasting future demands. In the
described approach the multi-layered perceptron are adapted to
forecast occurrences of non-zero demands, and then a conventional
recursive method is used to estimate the quantity of non-zero
demands. In order to evaluate the performance of the proposed
approach, their forecasts were compared to those obtained by using
Syntetos & Boylan approximation, recently employed multi-layered
perceptron neural network, generalized regression neural network
and elman recurrent neural network in this area. The models were
applied to forecast future demand of spare parts of Arak
Petrochemical Company in Iran, using 30 types of real data sets. The
results indicate that the forecasts obtained by using our proposed
mode are superior to those obtained by using other methods.
Abstract: Avoidable unscheduled maintenance events and unnecessary
spare parts deliveries are mostly caused by an incorrect choice
of the underlying maintenance strategy. For a faster and more efficient
supply of spare parts for aircrafts of an airline we examine options for
improving the underlying logistics network integrated in an existing
aviation industry network. This paper presents a dynamic prediction
model as decision support for maintenance method selection considering
requirements of an entire flight network. The objective is
to guarantee a high supply of spare parts by an optimal interaction
of various network levels and thus to reduce unscheduled maintenance
events and minimize total costs. By using a prognostics-based
preventive maintenance strategy unscheduled component failures are
avoided for an increase in availability and reliability of the entire
system. The model is intended for use in an aviation company that
utilizes a structured planning process based on collected failures data
of components.
Abstract: Spare parts inventory management is one of the major
areas of inventory research. Analysis of recent literature showed that
an approach integrating spare parts classification, demand
forecasting, and stock control policies is essential; however, adapting
this integrated approach is limited. This work presents an integrated
framework for spare part inventory management and an Excel based
application developed for the implementation of the proposed
framework. A multi-criteria analysis has been used for spare
classification. Forecasting of spare parts- intermittent demand has
been incorporated into the application using three different
forecasting models; namely, normal distribution, exponential
smoothing, and Croston method. The application is also capable of
running with different inventory control policies. To illustrate the
performance of the proposed framework and the developed
application; the framework is applied to different items at a service
organization. The results achieved are presented and possible areas
for future work are highlighted.
Abstract: This paper considers the problem of scheduling maintenance actions for identical aircraft gas turbine engines. Each one of the turbines consists of parts which frequently require replacement. A finite inventory of spare parts is available and all parts are ready for replacement at any time. The inventory consists of both new and refurbished parts. Hence, these parts have different field lives. The goal is to find a replacement part sequencing that maximizes the time that the aircraft will keep functioning before the inventory is replenished. The problem is formulated as an identical parallel machine scheduling problem where the minimum completion time has to be maximized. Two models have been developed. The first one is an optimization model which is based on a 0-1 linear programming formulation, while the second one is an approximate procedure which consists in decomposing the problem into several two-machine subproblems. Each subproblem is optimally solved using the first model. Both models have been implemented using Lingo and have been tested on two sets of randomly generated data with up to 150 parts and 10 turbines. Experimental results show that the optimization model is able to solve only instances with no more than 4 turbines, while the decomposition procedure often provides near-optimal solutions within a maximum CPU time of 3 seconds.