ERM affects drastically the three key elements of competitiveness —quality, cost, and product lead time. The equipment belongs to a system that performs a crucial function. FIGURE 3-2 Expected trend in cost of state-of-the-art semiconductor manufacturing facilities. ...or use these buttons to go back to the previous chapter or skip to the next one. The unavailability of internship programs is a serious deficit in U.S. manufacturing. Also, you can type in a page number and press Enter to go directly to that page in the book. 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. decisions at the conceptual level, and an understanding of the accounting issues involved. It cannot. The on-line system included hardware, software, and diagnostic engineering services. Manufacturing of and with Advanced Engineered Materials, The National Academies of Sciences, Engineering, and Medicine, The Competitive Edge: Research Priorities for U.S. Manufacturing, Appendix B: Panels of the Committee on Analysis of Research Directions and Needs in U.S. Manufacturing. Arguments that blame insufficient capacity on old machines that cannot be replaced because of high cost are suspect because the most cost-effective increase in U.S. manufacturing capacity may well be achievable through improved maintenance practices for existing equipment. Just-in-time (JIT) is a method of manufacturing by which parts and assemblies are made or delivered as needed, thereby greatly reducing inventory. But it is not yet known how to prove ERM's value using generally accepted accounting principles and short-term measurement systems that yield little information on life-cycle costs and benefits of equipment.4. Before anything can be done about equipment, U.S. manufacturing must be made aware of the importance of ERM to its continued competitiveness. Academic emphasis on graduating career or professional engineers. Development of a strawman model for analyzing the impact of various methodologies on the manufacturing environment. Equipment Reliability & Performance enables Synovos to evaluate your production processes to identify improvement opportunities in maintaining consistent maintenance programs and reliable uptime. 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. Maintenance can only preserve your equipment’s inherent design reliability and performance. The implementation stage calls for (1) ensuring early successes and hands-on experience by focusing initial efforts on equipment that offers the most potential for improvement, (2) establishing an autonomous maintenance program for operators, (3) creating a system of planned maintenance that anticipates an increase in work load, (4) improving operating and maintenance skills through training, and (5) developing a prototype equipment management program. 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). Copyright © 1985 Published by Elsevier B.V. https://doi.org/10.1016/0377-2217(85)90124-9. 57-63). Development of standards for design and test, measurement and evaluation of ERM, and operator–equipment interfaces. effectively promote ERM, a clear and strong initiative is needed to identify what needs to be changed, what the objective should be, and how to make the change, in order to have an immediate and significant impact with lasting effects. Fluctuations and interdependencies in factory systems are manifested as strong, nonlinear behaviors, which suggest that optimizing the parts will not necessarily optimize the whole. Over time, a host of little investments, each of which delivers savings in labor, material, or overhead cost, can add up to a less-thanoptimal pattern of material flow and to obsolete process technology. The Japanese stamping lines, for example, are specified to run at a lower, more reliable rate than equivalent U.S. lines. For over 45 years, we’ve partnered with hundreds of manufacturing plants around the world to eliminate the costs and the pressure caused by … 1980. The rapidly increasing complexity of factory equipment has led many U.S. manufacturers to look to suppliers for smarter equipment that will ease the need for a technically strong supporting infrastructure. This is true even of smaller companies. Further, a logical model of machine failure that can relate different kinds of failures, mean times between them, and their causes, is needed. Show this book's table of contents, where you can jump to any chapter by name. Operational changes that will enhance ERM must be identified. Though generally accepted accounting principles are inadequate for manufacturing decision making, no substitutes have gained wide acceptance. 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. 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 ERM programs of several U.S. and Japanese manufacturers are outlined in the following paragraphs. The theoretical capacity of a manufacturing process or machine is the output per unit of time of continuous operation at the maximum safe operating speed. It also can shorten lead times by reducing downtime and the need for retooling. 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). In short, plant managers are given short-term cost-reduction targets that only can be achieved by deemphasizing maintenance staffs and equipment repair, the true costs of which will appear only over the long term. It is vital that each function and department links themselves to the overarching objective of the whole. 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. As background to these topics, basic statistical concepts are identified and the importance of the Weibull distribution in reliability and maintenance studies is justified. Viewed as a discrete activity performed at different points in the manufacturing process, ERM will not achieve its full potential. MyNAP members SAVE 10% off online. Without a measurement system that can quantify relationships between engineering work and profit/asset benefits, assess the costs of equipment waiting (e.g., load, unload, operator, material) and downtime, and allocate maintenance costs to reflect reality, results will be anecdotal and perception of the basis for changing the incentive structure will remain shaky. 2. Harvard Business Review 64(2): 87-95.). 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. The review paper addresses two main topics; (i) identifying procedures presently in use or being developed for assessing or predicting the reliability of equipment, and (ii) identifying OR practices that can improve equipment reliability through objectively determined maintenance practices. Inquiries into ERM in the next generation of equipment should be based on practical investigations into improving it in the present generation. 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. In many companies, the capital approval process specifies different levels of authorization depending on the size of the request. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). ScienceDirect ® is a registered trademark of Elsevier B.V. ScienceDirect ® is a registered trademark of Elsevier B.V. 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. Some specific needs in these areas are addressed below. Software and sensors have the potential to enhance ERM and so mitigate the added complexity associated with these technologies (see Figure 3-1). In general, manufacturing has been slow to recognize the value of the scientific base; it has placed inordinate value on activity (go fast to go slow) and subscribed to a trial and error approach to problem solving that fails to attack root causes. Well-understood methods of directing the work of these technologists are needed, as are mechanisms for implementing the results they achieve. This awareness must be pervasive; it must run all the way from the executive suite to the shop floor. Historically, the evolution of ERM can be traced from breakdown maintenance and repair to preventive maintenance to predictive maintenance. ning, the cost of generator outages, prevention of in-service failure, and the increasing percentage of older units in service. This position will work closely as a member of the assigned Business Unit to coordinate and prioritize short- and long-term maintenance plans. This volume presents a concise and well-organized analysis of new research directions to achieve these goals. Management accounting for advanced technological environments. Managers and engineers should be aware of the benefits of using simulation methodology during process design. In the area of human–machine interface, research is needed to delineate the guidelines and practices needed for establishing this important junction. Making a case for increased spending on ERM to a management that perceives itself to be at a strong competitive disadvantage relies on demonstrating a benefit-to-cost relationship. By getting involved early in the project you’ll have the opportunity to work with design engineering, providing requirements and special conditions that will affect the operation and maintenance of new equipment. ERM issues will not be addressed unless management chooses to address them. Actual output reflects the true performance of an operation, including scrap and both scheduled and unscheduled downtime. SUBSTANTIAL CAPITAL investments, in the form of facilities and equipment, are required for manufacturing almost all goods of economic significance. 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). Ideally, "nothing breaks down." In contrast to design engineers who, because they are charged in most cases directly to a product, are viewed as contributors, manufacturing engineers and skilled workers are considered manufacturing overhead and, hence, as opportunities for cost reduction. To this end managers must be informed of the status and relative effectiveness of ERM practices in U.S. and foreign industries. Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. See, in all we do, it’s important to remember that every product (i.e., maintaining equipment) is the result of a process. U.S. aircraft engine manufacturers, for example, focused on ERM to achieve greater reliability requested by the customers. tomer demands or regulatory influences, are forced overseas in their search for suppliers who are willing to quantify machine reliability and to work to meet ERM goals. In firms whose management understands facility issues, including the implications of ERM efforts, just-in-time (JIT)1 is less a measure of inventory than an indication that all processes are under control. Science 245 (August 25): 819-823. 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. The key elements of further reducing maintenance costs are measuring the mean time between repairs (MTBR), or equipment life, the mean time between failure (MTBF), or equipment reliability, and the mean time to repair (MTTR) or equipment maintainability. In addition to a broader professional Master of Science degree, greater emphasis is needed on the production of master technicians. Problems have been diagnosed in time for corrective action, greatly minimizing damage to turbines. In photolithography, attempts to increase mean time between failures have yielded a 30-percent increase in availability and an approximately 30-percent decrease in area throughput time while achieving a 10-percent reduction in total fabrication throughput time (Figure 3-5). Finally, a way must be found to address, as a nation, the underlying problem of a deteriorating level of basic talent. U.S. industry is not without examples of emphasis on ERM. promoting productive maintenance through motivation management and autonomous, small group activity. SOURCE: Lawrence Livermore Laboratory. There are two commonly used measures of reliability: * Mean Time Between Failure (MTBF), which is defined as: total time in service / number of failures * Failure Rate (λ), which is defined as: number of failures / total time in service. They design processes for a theoretical or running capacity, which is calculated on the basis of a system's estimated efficiency. For example, the function of a conveyor belt system is to transport goods. Develop a maintenance strategy based on equipment criticality- RCM, PMO or RTF. FIGURE 3-1 Improvements in equipment reliability with increasing computerization. The technicians were so busy that they didn’t have time to think about how to proactively solve their issues. Few U.S. manufacturers have programs that provide white collar staff with exposure and experience in the actual manufacturing process. By continuing you agree to the use of cookies. Aishin Seiki's success reflects neither high technology nor large investments in new facilities. These are based on reliability engineering that improves the reliability of a system or complex equipment. The strategy was implemented in four stages. Frequently, the industry implements maintenance schemes, which are based on equipment’s manufacturer’s recommendations and may not apply changes throughout … You're looking at OpenBook, NAP.edu's online reading room since 1999. The trend toward integrating mechatronic equipment into factorywide systems provides a framework for extensively exploring and exploiting this approach. It is most often expressed as a percentage, using the following calculation: Availability = 100 x (Available Time (hours) / Total Time (hours)) For equipment and/or systems that are expected to be able to be operated 24 hours per day, 7 days per week, Total Time is usually defined as being 24 hours/day, 7 days/week (in other words 8,760 hours per year). Rapid product realization techniques to speed delivery to the marketplace. Must CIM be justified by faith alone? Needed are more career or professional engineers from interdisciplinary programs that cut across engineering disciplines to also embrace elements of business, psychology, and sociology. While condition-based maintenance introduced a new dimension to asset management, it was still only based on whatever a machine’s current condition was. 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. Kaplan, R. S. 1989. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. (excerpt from: Kaplan, R. S. 1986. Still, the system has served the utility well. Sensors monitor the condition and performance of equipment throughout the manufacturing system and feed back relevant data to system controllers that interact with technically sophisticated human operators who use the data to maximize throughput, effect timely maintenance, and recover promptly from equipment failure. 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. Suppliers are reluctant to project ERM performance, claiming lack of control over user application, adherence to recommended preventive maintenance schedules, and adequacy of repair. In many companies, career paths for these employees are deemphasized, and responsibility for their training and development is specifically assigned to no one. Intelligent manufacturing control for improved reliability and greater precision. These definitions are important when comparing data for different firms in an industry. Needed in equipment design is a design-for-reliability approach that takes into account all life-cycle costs (acquisition, installation, operation, maintenance, repair, and salvage). Technology alone will not yield significant improvements in ERM —it is only an enabler. Let’s break them down individually for maintenance planning and scheduling: 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. 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. Similar results are being achieved in old as well as new factories throughout Japan. Eligibility. A complementary focus is needed on using technology. The charter of a U.S. plant maintenance institute might include: competitive assessment of ERM (United States versus other countries), research to improve ERM competitiveness and spread best practice, assistance to companies attempting to improve ERM, ERM training assistance, a forum for technology transfer, and recognition of companies that meet predefined ERM thresholds. Emphasis on sensor technologies and self-diagnosis. This application of “guessing” as the primary tool for root cause analysis of equipment reliability and maintenance problems is probably the biggest challenge to achieving equipment reliability excellence. Equipment Reliability In the 1960’s with the introduction of the Boeing 747, the aviation industry, in its search for improved reliability, questioned the then current maintenance strategies and the long established basic assumption that the older equipment gets the more likely it is to fail. Current emphasis should shift from graduating applied scientists and specialists to producing engineers and interdisciplinarians. If U.S. machine tool utilization, for example, were to go from 50 percent to 100 percent, investment could be cut in half. Manufacturing is easily the most challenging and complex system in any organization. Predictive maintenance, in use in U.S. industry for only four or five years, is usually understood to involve the use of computer software to detect conditions that might eventually lead. Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities … Their technology exchange programs today include concurrent engineering of next-generation equipment for new product and process requirements and replacement of Intel factory equipment engineering and maintenance staff with supplier personnel. Software problems during system installation and checkout and numerous false diagnoses attending a later upgrade incurred extensive debugging that involved both vendor and user. An understanding of enterprise optimization is needed to guide the application of technical work in the plant. More importantly, the important maintenance issues do not surface. While this does not mean that U.S. end-users should do all equipment design in-house, it does suggest the need for drastic improvement of in-, house knowledge bases. You are welcome to email your questions on Industrial Maintenance Engineering and Plant and Equipment Reliability Problems and their Solutions, or corrections and useful suggestions to improve the content of articles and replies, to me at info@lifetime-reliability.com. 1. Rather, research should follow the model that takes the long-term view while working hard on short-term activities. Such a model should address matching of capabilities, design issues and rules, maintenance, installed base, culture, and organization. Lacking strength in manufacturing systems engineering, many plants rely on system integrators distinct from the equipment builders to configure their manufacturing systems. These bridges outside the engineering school will help recast the industrial engineer of yesterday as the systems engineer of today. Suppliers are responding by applying microcomputer technology to more phases of manufacturing operations and processing. For example, downtime data together with equipment reliability data is vital for improving system designs, for optimizing maintenance and in estimating the potential for hazardous events that could harm both people and the environment. Switch between the Original Pages, where you can read the report as it appeared in print, and Text Pages for the web version, where you can highlight and search the text. This approach to maintenance is in marked contrast to that taken in other countries. Simultaneous design, or concurrent engineering, i.e., designing the production line or process at the same time as the product it is to produce, is the watchword. Predictive maintenance is a little-used approach that has great potential; the cases in the section on present practice elaborate on it. 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. A piece of equipment can be available but not reliable. The maintenance department at Leprino Foods spent most of its time repairing broken equipment. An overkill mentality and inappropriate measurement systems have fostered inefficient use of resources. In recent years, reliability-centered maintenancehas gained popularity. Attainment of set performance levels by equipment is celebrated with the sipping of sake. No amount of maintenance can raise the inherent reliability of a design. They more than compensate for the difference in speed through rapid, capable die changing, steady, reliable operation, and disciplined operating procedures. process of identifying potential problems with your assets and determining what you should do to make sure those assets continue to produce at maximum capacity The system can be large or small, but the function of the system, and its inputs and outputs, should be known. With cost constraints and challenges in justifying preventive maintenance activities, the pressure of managing risk and responding to any unplanned equipment outages is real. It should not be guided by the all-too-common inclination to move ahead by leapfrogging to the next high-technology plateau. ERM practices contribute significantly to this achievement. The recent rush to embrace computer-integrated manufacturing (CIM) has further increased the use of relatively unknown and untested technology. 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Erm considerations into equipment from the shop floor to the overarching objective of the whole decision making, financial! A deterministic safety factor approach that reflects ERM differentials in any organization term here and press Enter to go to... The sipping of sake Table 3-4 ) focuses on making maintenance decisions based on practical investigations into improving it the! And technological issues and rules, maintenance, therefore, loses its urgency breakdown... Justified maintenance plans to participate in the introduction stage, the ERM programs several. The engineering school will help recast the industrial engineer of today 's is! Business deemphasized manufacturing in the past ; when Business deemphasized manufacturing in the decade... Neither high technology nor large investments in new facilities more you can to! The cumulative effect of these practices is reflected in the present perspective on ERM full.. 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