In a highly competitive world market, a manufacturer that needs two machines to produce what another manufacturer, by assuring the reliability of its equipment, can produce with one, will not be cost competitive. SUBSTANTIAL CAPITAL investments, in the form of facilities and equipment, are required for manufacturing almost all goods of economic significance. The U.S. facilities of Japanese automakers, using U.S. workers to operate three to five presses, often achieve at least twice the productivity of comparable U.S. facilities on a per-line or perpress basis. Eliminating the nominal stress from the failure theory inequality results in a final equation in which the nominal yield stress is a common factor permitting the factor of safety “n” to be determined as 1.4. In one instance, the expert system embedded in the diagnostic system recommended that a generator in which it had detected a fault be kept in service until the scheduled outage. If few numbers of machines are to be manufactured then expensive materials and high production costs can be considered, but for the mass production economy of the machine should be top priority. Reliability is a measure of the probability that an item will perform its intended function for a specified interval under stated conditions. To search the entire text of this book, type in your search term here and press Enter. They will not begin to address these issues, however, unless they are convinced of the importance of ERM for competitiveness. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. 1 Reliability factor from ISO 281 - K R Reliability factor from AGMA 2001 - The Art of Designing a Gearbox When challenged with the job of designing a new gearbox, the engineer has several suitable calculation methods available for the sizing of the components. This testing helps discover many problems in the software design and functionality. Cost: Cost has always been the major factor of consideration while designing the machine elements or machine and in this age of competition it has become more important. Problems have been diagnosed in time for corrective action, greatly minimizing damage to turbines. Attainment of set performance levels by equipment is celebrated with the sipping of sake. Japanese efforts in this area have dramatically improved quality, lowered cost, and reduced plant breakdowns from 10 percent to as little as 1 percent of previous levels within three years. 3. Reliability Leads to Profitability:This highlights that consistent reliability exhibited by product or system leads to increase in … A more enlightened approach to reducing equipment life-cycle costs would be to increase capital investment at the concept and design stages in order to improve equipment reliability, maintainability, and predictability and thereby reduce operations and support costs that inflate factory overhead (Figure 3-6). beam machine at a number of increasing loads. Across each industry is a reli-. 2. Software and sensors have the potential to enhance ERM and so mitigate the added complexity associated with these technologies (see Figure 3-1). Number of machines to be built: Designing of the machine will depend a lot on the number of machines to be manufactured. Ease and simplicity of servicing and control: The machine and its element should be simple enough so that very little maintenance and servicing is required. Indirect benefits often outweigh direct savings. A strawman model that would support analysis of the impacts of various methodologies on the manufacturing environment would be useful. Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. Source: Intel Corporation, 1989. able body of knowledge, much like that available for engines in the aircraft industry today. Obtain the load factor for the case of bending. But without substantive supporting uptime data, it is difficult to convince manufacturing management to operate otherwise. Existing systems offer few incentives for manufacturing managers to ask appropriate questions. Not a MyNAP member yet? Utilizing hydraulic energy from the flow of a river or stream, the Noria utilized buckets to transfer water to troughs, viaducts and other distribution devices to irrigate fi… 57-63). In fact, to the extent that they lead management to treat maintenance as an indirect cost that increases factory overhead, these systems may be putting the U.S. asset base at risk. Light weight and minimum dimensions: The machine elements and machine should be strong, rigid and wear resistant with minimum weight and least dimensions. These bridges outside the engineering school will help recast the industrial engineer of yesterday as the systems engineer of today. 2. Partnerships with key equipment suppliers were critical to the success of both parts of the program. Advanced engineered materials that offer the prospect of better life-cycle performance and other gains. The U.S. view is that “the equipment is now performing at its best and over time performance will degrade.” The Japanese view is that “the equipment is now performing at its worst and work needs to be done to improve its performance dramatically.”, Emphasis on short-term profitability at the expense of preventive maintenance programs, personnel, and spare parts actually decreases long-term profitability by increasing the frequency of catastrophic events (i.e., breakdowns that demand emergency repair). 1980. FIGURE 3-1 Improvements in equipment reliability with increasing computerization. 3. Initial emphasis was on detecting problems before they became serious enough to force outages. 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. In any real manufacturing environment, some output inevitably is lost because of factors like shift changes, materials defects, maintenance, product changeovers, and operational inefficiencies. Other failure modes might come from extreme operating environments leading to corrosion. Factors to be considered during Machine Design: Part-1, Factors to be considered during Machine Design: Part-2, Skills a Good Machine Designer should possess, Commercial Energy Usage: Learn about Emission Levels of Commercial Buildings, Time to Upgrade Your HVAC? For this the machine should be designed for least maintenance requirements and long-life. Development of guidelines and practices for designing the human– machine interface to enhance ERM. MyNAP members SAVE 10% off online. Intelligent manufacturing control for improved reliability and greater precision. Some days than on others systematic servicing of equipment should improve through use needed to delineate guidelines... 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