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A computer-based total productive maintenance model for electric motors
Abstract
The paper describes the development of a computer-based total productive maintenance (TPM) model to improve electrical motors readiness and uptime while reducing capital overhead. The TPM model includes the consideration of reactive, periodic, and predictive practices. The input data is processed and the generated report details a set of periodic recommendations providing guidelines on recommended actions and their frequency. The details about test results indicating the current condition of the motor as well estimated reactive, periodic, and predictive maintenance cost details are presented. Based on the historic data stored in its database, the model can predict potential problems prior to failure as well as prescribe periodic maintenance actions to maximise motor life. The TPM model will be a useful tool to predict the degradation in motor life due to deterioration in insulation, bearing, rotor bar and stator windings of the motor.
يهدف البحث الى بيان مدى إمكانية تحسين أداء إدارة الصيانة الإنتاجية الشاملة عن طريق تطبيق التكامل بين تقنية بطاقة العلامات المتوازنة وتقنية إعادة هندسة العمليات الخضراء، وكذلك إبراز الجوانب المعرفية لأحد التقنيات المعاصرة لتحسين الأداء الاستراتيجي المتمثل في بتقنية (إعادة هندسة العمليات الخضراء)، مع إظهار إلى أي مدى يمكن تحسين أداء إدارة (الصيانة الإنتاجية الشاملة) من خلال تطبيق التكامل بين تقنية (بطاقة العلامات المتوازنة) وتقنية (إعادة هندسة العمليات الخضراء)، ولتحقيق أهداف البحث فقد تم الاعتماد على البيانات والمعلومات المالية لمصنع حامض الكبريتيك في محافظة بابل وتم الحصول عليها من خلال الزيارات الميدانية والمقابلات الشخصية للعاملين في المصنع، لغرض تطبيق خطوات تقنيتي (بطاقة العلامات المتوازنة) وتقنية (إعادة هندسة العمليات الخضراء) بشكل تكاملي، وتم استخدم تقنيات البحث المطلوبة ومنها اتباع خطوات تطبيق تقنية (بطاقة العلامات المتوازنة) وخطوات تطبيق تقنية (إعادة هندسة العمليات الخضراء) بصورة متتابعة لإظهار التكامل بصورة تطبيقية بينهما، وتوصل الباحث إلى جملة من الاستنتاجات أهمها: أن تنفيذ وتطبيق خطوات تقنية (إعادة هندسة العمليات الخضراء) يسهم في تقليص مراحل المسار التكنلوجي للعمليات الحالية في المصنع وزيادة سرعة الإنتاج والتجهيز وكذلك تخفيض فترات التوقفات للصيانة، وتقليل مسببات التلوث البيئية، وإن التكامل بين تقنية (بطاقة العلامات المتوازنة) وتقنية (إعادة هندسة العمليات الخضراء) يسهم في تحسين الأداء الاستراتيجي للوحدات الاقتصادية، وبالتالي تحسين أداء إدارة (الصيانة الإنتاجية الشاملة) وبالشكل الذي يؤدي إلى زيادة كفاءة وفاعلية العمليات الإنتاجية.
The main purpose of this paper is to determine suitable maintenance strategy with the aid of analytic network process (ANP) by which, the inner and mutual dependencies between criteria and strategies can be considered. For this purpose, maintenance strategies are assumed as alternatives and reliability, availability, maintainability and cost as criteria. The proposed approach has been examined in a group of equipments of Chadormalu Mining-Industrial Company. Findings imply that the priorities of maintenance strategies include TPM, CBM, TBM, DOM and EM, and the priorities of criteria include availability, maintainability, reliability and cost, respectively.
Total productive maintenance (TPM) is one of the maintenance strategies that aim to increase availability and reliability of production machines/equipment. The key to TPM success is the development of autonomous maintenance (AM) practice. The AM refers to human capital development among operators supported by technicians and engineers to perform easy daily maintenance activities aside from planned maintenance. This paper presents the implementation process of AM in a semiconductor company in Malaysia. An AM implementation framework is developed based on four systematic stages: AM initial preparation, AM training and motivation, AM five-step execution and AM audit. The framework is implemented in one of the production lines identified as the most critical area in the company chosen as the case study. The findings based on the developed AM framework are reported in this paper.
Purpose
The purpose of this paper is to review the literature on Total Productive Maintenance (TPM) and to present an overview of TPM implementation practices adopted by the manufacturing organizations. It also seeks to highlight appropriate enablers and success factors for eliminating barriers in successful TPM implementation.
Design/methodology/approach
The paper systematically categorizes the published literature and then analyzes and reviews it methodically.
Findings
The paper reveals the important issues in Total Productive Maintenance ranging from maintenance techniques, framework of TPM, overall equipment effectiveness (OEE), TPM implementation practices, barriers and success factors in TPM implementation, etc. The contributions of strategic TPM programmes towards improving manufacturing competencies of the organizations have also been highlighted here.
Practical implications
The literature on classification of Total Productive Maintenance has so far been very limited. The paper reviews a large number of papers in this field and presents the overview of various TPM implementation practices demonstrated by manufacturing organizations globally. It also highlights the approaches suggested by various researchers and practitioners and critically evaluates the reasons behind failure of TPM programmes in the organizations. Further, the enablers and success factors for TPM implementation have also been highlighted for ensuring smooth and effective TPM implementation in the organizations.
Originality/value
The paper contains a comprehensive listing of publications on the field in question and their classification according to various attributes. It will be useful to researchers, maintenance professionals and others concerned with maintenance to understand the significance of TPM.
maintenance management has found new vigor and purpose to increase equipment capacity and capability due to increasing focus on lean manufacturing (lean) in today's competitive environment. Tremendous efforts have been made to develop different types of maintenance strategies for enhancing the performance of equipment but nothing has been done to actually streamline Breakdown Maintenance Activities (BMA). This refers to systematically evaluating the Non-Value Added (NVA) activities within BM. The primary lean tool that provides insights on identifying and analyzing NVA activities is Value Stream mapping (VSM). However, traditional VSM cannot be utilized 'as is' because the BMA do not completely correspond with VSM terminology. Therefore, this paper develops a VSM to evaluate BM operations.
This article addresses the question of why total quality management
(TQM) and total productive maintenance (TPM) are valuable strategies for
American businesses today. While each process is beneficial on its own,
the synergy created by simultaneously doing both is incredibly powerful.
In the era of global competition, almost all the power, processing and manufacturing sectors are required to reduce their overall cost while maintaining the value and reliability of their assets. The electric power utilities are also active in looking for effective ways to improve the economic efficiency. One area, in particular, the equipment maintenance, is being scrutinised for reducing costs while keeping the overall reliable system. The use of reliability centred maintenance (RCM) can help these utilities to develop a systematic maintenance programme to meet these requirements in a cost-effective manner. This paper presents an extensive review of different applications of RCM and is intended as a guide in exploring the feasible areas of successful implementation of RCM to a thermal plant. A case study of the outage review data of a thermal power plant in Punjab has been done to single out vital few reasons of forced outages and feasibility of implementation of RCM has also been discussed.
In the past few decades, various maintenance policies with different operation principles, such as preventive or predictive maintenance were developed due to importance of maintenance in current industries. However, the implementation of a maintenance policy must suit the specific conditions and constraints of a specific company. Thus it is important to identify and then select the optimal maintenance policy for a system in order to gain maximum effectiveness. This paper reviews current research on selecting the optimal maintenance policy in various industries and recommendations for future research regarding new methods of selecting an optimal maintenance.
In today's dynamic environment, a reliable production system has been envisioned as a critical factor for competitiveness, thus maintenance has become a strategic issue for the manufacturers. The recent competitive trends have been pushing manufacturing managers to reconsider the significance of increasing equipment availability and utilisation, increasing maintenance productivity, resource utilisation, and increasing quality and responsiveness of maintenance services in achieving world-class status to meet global competition. In the highly dynamic and challenging environment, the quest for reliable production equipment has necessitated manufacturing organisations to accept equipment maintenance as an indispensable function for ensuring sustained profitability of enterprises. The implications of total productive maintenance (TPM) implementation initiatives in the Indian manufacturing enterprise have been highlighted in this study. This study demonstrates the strong potential of TPM implementation initiatives in affecting significant organisational performance improvements.
Research on quality had always been the key problem in study on enterprise management. As the product quality always depends upon the organisation's infrastructural adequacies and abilities of the organisation and how well they manage their equipment and facilities. The quality requirements all over the world had forced industries to use tools such as total quality management (TQM) and total productive maintenance (TPM), effectively to get higher achievements in business performance. This empirical research evaluates the combined TQM-TPM strategic factors to determine the critical success factors in environmental uncertainty using analytical hierarchy process. The study decision criteria include TQM, TPM and transfusion of TQM-TPM, whereas the competitive advantages taken are strategic business performance, quality, production, cost, employee safety and morale. The research findings are applicable to manufacturing organisations, suggesting them the adoption of flexibility of TQM-TPM as a major competitive advantage with a higher uncertainty and delivery with a lower uncertainty.
In the recent past, researchers and practitioners have been attempting failure prevention as one of the major enablers of attaining continuous quality improvement. For this, failure mode and effect analysis (FMEA) technique is adopted to reduce the probability of system failure and achieve good product quality. However, there has been no significant effort made by the researchers to overcome the pitfalls of FMEA. This practical gap is overcome by applying a technique called total failure mode and effect analysis (TFMEA). This research gap has been indicated and explored further by conducting literature review to draw synergy out of TFMEA along with the unconquered areas of the TFMEA, where TFMEA can be applied. A roadmap for implementing TFMEA has also been contributed in this paper.
The manufacturing and service industries in developing countries have grown rapidly in the last few years. Most of the industries are equipped with large number of machines and equipments for which preventive maintenance (PM) is essential. To perform the maintenance activities, the facility manager, subordinates and customers need to track the status of the maintenance work on their assets and the associated costs of that work. This study proposes a model for PM management systems and develops the corresponding application database software supporting the proposed model. A case study is conducted in different industries to track the present status of the maintenance management and to select the features of the database software. The outcome of this research will benefit first and foremost the maintenance manager to manage the planning, day-to-day operations and maintenance activities.
TQM is a set of management practices throughout the organisation, geared to ensure the organisation consistently meets or exceeds customer requirements. This research tries to investigate the most important barriers to successful TQM implementation in Iranian manufacturing organisations. The authors have studied samples of manufacturing organisations, comprising those that have invested on TQM after the end of March 2009 and were located in Iran. This descriptive and cross‐sectional research is carried out via two questionnaires – general questionnaire for success of TQM principles and specific questionnaire for barriers to successful TQM implementation. The statistical population of this research consists of all managers of manufacturing organisations who implemented TQM in their organisations. Results showed that the main root causes of unsuccessful implementation of TQM were the lack of management commitment, resource problem and failure to use the right framework for TQM. In addition, there is a significant coincidence between the results of two questionnaires. Finally, regarding the findings of this research, we offer a relation between TQM principles and barriers to successful TQM implementation. Therefore, in order to reduce the barriers to successful TQM implementation, some suggestions were proposed.
This contribution establishes a new approach to evaluating the sensitivity of a preventive maintenance scheduling model that is based on an integrated operations-maintenance activity schedule in a resource constrained environment. In particular, this paper deals with sensitivity analysis of Total Preventive Maintenance (TPM) scheduling cost using optimal Gantt Charting principles as the framework. The approach has been tested in a shipping company. The work is motivated by the need to improve on the quality of maintenance scheduling models through the development and application of robust models in practice. From the results obtained, it was shown that some shipping maintenance scheduling parameters are sensitive and could therefore be manipulated for the best performance of maintenance scheduling models. The framework seems promising for other applications, and opens up a new gate of investigations that may keep researchers busy for some decades to come.
An enhanced approach for implementing total productive maintenance (TPM) in the manufacturing environment is discussed. The failure mode, effects, and critical analysis (FMECA) is an excellent tool that can be used in identifying system failures, failure modes and frequencies. The reliability centered maintenance (RCM) which is based primarily on the FMECA, can be used in developing a life-cycle oriented preventive maintenance programme. Finally, managers, engineers and technicians must be familiar with what is available and must utilize these tools.
Purpose
The purpose of this paper is to ascertain overall system health and maintenance needs with degree of certainty using condition‐monitoring data with hierarchical fuzzy inference system.
Design/methodology/approach
In process plants, equipment condition is ascertained using condition‐monitoring data for each condition indicator. For large systems with multiple condition indicators, estimating the overall system health becomes cumbersome. The decision of selecting the equipment for an overhaul is mostly determined by generic guidelines, and seldom backed up by condition‐monitoring data. The proposed approach uses a hierarchical system health assessment using fuzzy inference on condition‐monitoring data collected over a period. Each subsystem health is ascertained with degree of certainty using degree of match operation performed on fuzzy sets of condition‐monitoring data and expert opinion. Fuzzy sets and approximate reasoning are used to handle the uncertainty/imprecision in data and subjectivity/vagueness of expert domain knowledge.
Findings
The proposed approach has been applied to a large electric motor (> 500kW), which is treated as four subsystems i.e. power transmission system, electromagnetic system, ventilation system and support system. Fuzzy set of condition‐monitoring data of each condition indicator on each subsystem is used to ascertain the degree of match with the expert opinion fuzzy set, thus inferring the need for periodical overhaul. Subjective expert opinion and quantitative condition‐monitoring data have been evaluated using hierarchical fuzzy inference system with a rule base. It is found that the certainty of each subsystem's health is not the same at the end of 600 days of monitoring and can be classified as “very good”, “good”, “marginal” and “sick”. Degree of certainty has helped in taking a managerial decision to avoid “over‐maintenance” and to ensure reliability. Large volumes of condition‐monitoring data not only helped in assessing motor overhaul health, but also guide the maintenance engineer to suitably review maintenance/monitoring strategy on similar systems to achieve desired reliability goals.
Practical implications
Condition‐monitoring data collected for long periods can be utilized to understand the degree of certainty of degradation pattern in the longer time frame with reference to domain knowledge to improve effectiveness of predictive maintenance towards reliability.
Originality/value
The paper gives an opportunity to evaluate quantitative condition‐monitoring data and subjective/qualitative domain expertise using fuzzy sets. The predictive maintenance cycle “Monitor‐analyse‐plan‐repair‐restore‐operate” is scientifically regulated with a degree of certainty. Approach is generic and can be applied to a variety of process equipment to ensure reliability through effective predictive maintenance.
Focuses on total productive maintenance (TPM) practices in Italy. Surveys a set of companies in manufacturing industry and where programme kick-off only has been performed. Employs the most important findings of the survey to design and implement a new taxonomy, by means of which TPM programmes can be classified along seven dimensions that refer to the most relevant characteristics and properties of each TPM programme. Finally, suggests a more general conceptual model capable of outlining the distinctive features of each TPM approach when facing a specific industrial environment.
During the recent years, a few competitive strategies such as lean manufacturing and Six Sigma are integrated by the researchers and practitioners to reap the synergy. In this direction of progress, one conspicuous absence is an integrated model of total productive maintenance (TPM) and ISO 9001 certification. In this context, this paper reports a literature review which was carried out to establish the relationship between these two strategies. To explore the feasibility of this integration, this paper reports a literature review. During this literature review, the origin, tools, characteristics and benefits of TPM and ISO 9001 certification were studied. At the end of this review, the connectivity between these two competitive strategies is explained. After describing this literature review, this paper prescribes a roadmap for integrating TPM with ISO 9001:2008 standard.
In this paper we present the diagnostic approach and the
techniques developed by KEMA for condition based maintenance of
transformers, switchgear, generators and cables. The diagnostics include
UHF and VHF PD-detection techniques, dynamic measurements on moving
parts including the electric drives used (switchgear, tap changers) and
loss measurements. The condition-assessment techniques involve pattern
recognition, fingerprint techniques and the application of performance
indicators and knowledge rules obtained from field experience. As an
example our approach will be illustrated with two techniques employed to
assess the dielectric condition and the remaining life of transformers
Management of electric motor repair is a process that begins prior to failure of the equipment itself. The major components of this process are: identifying total motor repair cost; developing repair specifications; identifying quality repair vendors; establishing a motor management program; and upgrades to premium efficiencies on failure. All of these are necessay components for the management of electric motor repair. Identifying motor repair cost provides the information to document program savings. Developing repair specifications will control the cost and quality of repair. Motor repair vendors best suited for the requirements need to be identified. Establishing repair-replace guidelines will assure the most cost-effective decisions are made when equipment fails. In addition, establishing a motor management program will control storage, repair, operation, and maintenance.
The squirrel-cage induction motor remains the workhorse of the
petrochemical industry because of its versatility and ruggedness.
However, it has its limitations, which, if exceeded, will cause
premature failure of the stator, rotor, bearings or shaft. This paper is
the final abridgement and update of six previous papers for the
Petroleum and Chemical Industry Committee of the IEEE Industry
Applications Society presented over the last 24 years and includes the
final piece dealing with shaft failures A methodology is provided that
will lead operations personnel to the most likely root causes of
failure. Check-off sheets are provided to assist in the orderly
collection of data to assist in the analysis. As the petrochemical
industry evolves from reactive to time based, to preventive, to
trending, to diagnostics, and to a predictive maintenance attitude, more
and more attention to root cause analysis will be required. This paper
will help provide a platform for the establishment of such an evolution.
The product scope includes low- and medium-voltage squirrel-cage
induction motors in the 1-3000 hp range with anti friction bearings.
However, much of this material is applicable to other types and sizes