maintenance model for systems with phase-type distributed times to failure

Magdeburg, Univ., Fak. für Mathematik, Diss., 2010

Risk-based maintenance model for offshore oil and gas pipelines:a case study

Offshore oil and gas pipelines are vulnerable to environment as any leak and burst in pipelines cause oil/gas spill resulting in huge negative Impacts on marine lives. Breakdown maintenance of these pipelines is also cost-intensive and time-consuming resulting in huge tangible and intangible loss to the pipeline operators. Pipelines health monitoring and integrity analysis have been researched a lot for successful pipeline operations and risk-based maintenance model is one of the outcomes of those researches. This study develops a risk-based maintenance model using a combined multiple-criteria decision-making and weight method for offshore oil and gas pipelines in Thailand with the active participation of experienced executives. The model's effectiveness has been demonstrated through real life application on oil and gas pipelines in the Gulf of Thailand. Practical implications. Risk-based inspection and maintenance methodology is particularly important for oil pipelines system, as any failure in the system will not only affect productivity negatively but also has tremendous negative environmental impact. The proposed model helps the pipelines operators to analyze the health of pipelines dynamically, to select specific inspection and maintenance method for specific section in line with its probability and severity of failure.

Creating an open-books implementation framework for a maintenance-related value-based life-cycle model

This study is a qualitative action research by its nature with elements of personal design in the form of a tangible model implementation framework construction. Utilized empirical data has been gathered via two questionnaires in relation to the arranged four workshop events with twelve individual participants. Five of them represented maintenance customers, three maintenance service providers and four equipment providers respectively. Further, there are two main research objectives in proportion to the two complementary focusing areas of this thesis. Firstly, the value-based life-cycle model, which first version has already been developed prior to this thesis, requires updating in order to increase its real-life applicability as an inter-firm decision-making tool in industrial maintenance. This first research objective is fulfilled by improving appearance, intelligibility and usability of the above-mentioned model. In addition, certain new features are also added. The workshop participants from the collaborating companies were reasonably pleased with made changes, although further attention will be required in future on the model’s intelligibility in particular as main results, charts and values were all reckoned as slightly hard to understand. Moreover, upgraded model’s appearance and added new features satisfied them the most. Secondly and more importantly, the premises of the model’s possible inter-firm implementation process need to be considered. This second research objective is delivered in two consecutive steps. At first, a bipartite open-books supported implementation framework is created and its different characteristics discussed in theory. Afterwards, the prerequisites and the pitfalls of increasing inter-organizational information transparency are studied in empirical context. One of the main findings was that the organizations are not yet prepared for network-wide information disclosure as dyadic collaboration was favored instead. However, they would be willing to share information bilaterally at least. Another major result was that the present state of companies’ cost accounting systems will definitely need implementation-wise enhancing in future since accurate and sufficiently detailed maintenance data is not available. Further, it will also be crucial to create supporting and mutually agreed network infrastructure. There are hardly any collaborative models, methods or tools currently in usage. Lastly, the essential questions about mutual trust and predominant purchasing strategies are cooperation-wise important. If inter-organizational activities are expanded, a more relational approach should be favored in this regard. Mutual trust was also recognized as a significant cooperation factor, but it is hard to measure in reality.

MQFD: A Model for Synergizing TPM and QFD

This thesis presents the methodology of linking Total Productive Maintenance (TPM) and Quality Function Deployment (QFD). The Synergic power ofTPM and QFD led to the formation of a new maintenance model named Maintenance Quality Function Deployment (MQFD). This model was found so powerful that, it could overcome the drawbacks of TPM, by taking care of customer voices. Those voices of customers are used to develop the house of quality. The outputs of house of quality, which are in the form of technical languages, are submitted to the top management for making strategic decisions. The technical languages, which are concerned with enhancing maintenance quality, are strategically directed by the top management towards their adoption of eight TPM pillars. The TPM characteristics developed through the development of eight pillars are fed into the production system, where their implementation is focused towards increasing the values of the maintenance quality parameters, namely overall equipment efficiency (GEE), mean time between failures (MTBF), mean time to repair (MTIR), performance quality, availability and mean down time (MDT). The outputs from production system are required to be reflected in the form of business values namely improved maintenance quality, increased profit, upgraded core competence, and enhanced goodwill. A unique feature of the MQFD model is that it is not necessary to change or dismantle the existing process ofdeveloping house ofquality and TPM projects, which may already be under practice in the company concerned. Thus, the MQFD model enables the tactical marriage between QFD and TPM.First, the literature was reviewed. The results of this review indicated that no activities had so far been reported on integrating QFD in TPM and vice versa. During the second phase, a survey was conducted in six companies in which TPM had been implemented. The objective of this survey was to locate any traces of QFD implementation in TPM programme being implemented in these companies. This survey results indicated that no effort on integrating QFD in TPM had been made in these companies. After completing these two phases of activities, the MQFD model was designed. The details of this work are presented in this research work. Followed by this, the explorative studies on implementing this MQFD model in real time environments were conducted. In addition to that, an empirical study was carried out to examine the receptivity of MQFD model among the practitioners and multifarious organizational cultures. Finally, a sensitivity analysis was conducted to find the hierarchy of various factors influencing MQFD in a company. Throughout the research work, the theory and practice of MQFD were juxtaposed by presenting and publishing papers among scholarly communities and conducting case studies in real time scenario.

Estágio na empresa SPECMAN para a prática de técnicas de controlo da condição

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Aplicação da filosofia Lean management:caso de estudo, aplicado à manutenção de edifícios

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia da Manutenção

Luotettavuuskeskeisen kunnossapidon soveltaminen vaneriteollisuuden koneille

Diplomityön tarkoituksena on tutkia luotettavuuskeskeisen kunnossapidon soveltamista Raute Oyj:n vanerikoneille. Työn tavoitteena on luoda suunnitelma luotettavuuskeskeisen kunnossapidon soveltamiseksi Raute Oyj:llä. Tavoitteena on myös kehittää malli ennakkohuoltosuunnitelmien sekä kriittisten huoltojen ja varaosien määrittelyyn päälinjoille. Kunnossapitoliiketoiminta on Rautella voimakkaasti kasvava liiketoiminta-alue. Voimakkaan kasvun seurauksena on yritykseen syntynyt kunnossapitotoimintojen kehitystarve. Luotettavuuskeskeistä kunnossapitoa hyödyntämällä on tarkoitus kehittää vanerikoneiden kunnossapitoa ja luoda Rautelle kunnossapitotuotteita. Työssä on tutkittu luotettavuuskeskeisen kunnossapidon soveltamista va-neriteollisuuden koneille laitevalmistajan näkökulmasta. Työssä on käsitelty kirjallisuuden pohjalta vanerin valmistusprosessia, vanerikoneita, kunnossapitoa sekä luotettavuuskeskeistä kunnossapitoa. Lisäksi on selvitetty vanerikoneiden kunnossapidon nykytilaa Raute Oyj:llä ja sen asiakkaiden vaneritehtaissa. Työn tuloksena syntyi toimintaehdotus luotettavuuskeskeisen kunnossapidon soveltamiseksi Rauten tuotteille. Ennakkohuoltosuunnitelmien luomiseen ja kehittämiseen työssä syntyi kunnossapitomalli, jonka pohjalta työssä luotiin xy-pöllinkeskittäjälle luotettavuuskeskeiseen kunnossapitoon perustuva ennakkohuoltosuunnitelma sekä määritettiin kriittiset varaosat.

Sähkönsiirtoyritysten kunnossapidon taloudellinen malli

Sähkönsiirtoyritysten kunnossapidon taloudellinen malli eli SKUTMA, on sähköverkkoyhtiöille suunniteltu luotettavuuspohjainen kunnossapitomalli, mikä priorisoi ja ajoittaa sähkönjakeluverkon komponenttien huolto- ja investointiajankohdat. Malli hyödyntää dynaamisen optimoinnin algoritmia kustannusminimien löytämiseksi tarkastelujaksolta ja simuloi komponenttien rappeutumasta rappeutumismallin avulla. Tässä diplomityössä on kehitetty kunnossapito-ohjelma SKUTMA-mallin pohjalta, minkä avulla tutkitaan mallin toimivuutta oikeilla johtolähdöillä ja sen hyödyntämistä sähköverkkojen kunnossapidon suunnittelussa. Työssä käydään läpi myös kunnossapitoohjelman laskenta metodiikkaa ja sen ominaisuuksia. Tämän työn lopputuloksena saadaan selkeä kuva mallin toiminnasta, käytettävyydestä ja jatkokehityspotentiaalista.

Avaliação do impacto dos diferentes tipos de veículos no custo de manutenção rodoviária no Rio Grande do Sul

O presente trabalho permite avaliar, em valores monetários, o impacto, ou responsabilidade, dos diferentes tipos de veículos nos custos totais de manutenção das rodovias. O objetivo é alcançado através do desenvolvimento de um conjunto sistematizado de procedimentos que quantificam todos os custos, não só os impostos pelos veículos aos pavimentos, como também todos demais decorrentes da conservação dos demais elementos que constituem a rodovia. O trabalho esta organizado numa estrutura que divide os custos envolvidos na manutenção rodoviária em dois grandes grupos, designados, de acordo com os conceitos econômicos, de custos fixos e custos variáveis. Dessa forma, os procedimentos desenvolvidos correlacionam o produto final de uma rodovia, as viagens realizadas pelos veículos, com os custos decorrentes de seu desgaste, dividindo-os em duas parcelas, uma que não se altera com o nível de uso, chamada parcela fixa, e outra, sensível ao nível de utilização da rodovia, chamada parcela variável. A partir dessa divisão e com o emprego de fatores que relacionam os níveis de ocupação e degradação da via pelos veículos, são determinados os valores monetários que representam quanto cada um desses veículos deve ser responsabilizado nos custos totais necessários à manutenção rodoviária. No desenvolvimento do trabalho foram utilizados os conceitos e definições das operações de conservação descritas nos manuais técnicos do Departamento Nacional de Estradas de Rodagem - DNER. Os dados referentes aos custos e às características das rodovias foram retirados de pesquisas realizadas no Estado do Rio Grande do Sul, e as deteriorações decorrentes do uso com seus respectivos custos foram obtidas através de simulações com o uso do Highway Design and Maintenance Model - HDM III.

Stochastic stability for Markovian jump linear systems associated with a finite number of jump times

This paper deals with a stochastic stability concept for discrete-time Markovian jump linear systems. The random jump parameter is associated to changes between the system operation modes due to failures or repairs, which can be well described by an underlying finite-state Markov chain. In the model studied, a fixed number of failures or repairs is allowed, after which, the system is brought to a halt for maintenance or for replacement. The usual concepts of stochastic stability are related to pure infinite horizon problems, and are not appropriate in this scenario. A new stability concept is introduced, named stochastic tau-stability that is tailored to the present setting. Necessary and sufficient conditions to ensure the stochastic tau-stability are provided, and the almost sure stability concept associated with this class of processes is also addressed. The paper also develops equivalences among second order concepts that parallels the results for infinite horizon problems. (C) 2003 Elsevier B.V. All rights reserved.

Stoichiometric and kinetic characterisation of Nitrobacter in mixed culture by decoupling the growth and energy generation processes

The growth, maintenance and lysis processes of Nitrobacter were characterised. A Nitrobacter culture was enriched in a sequencing batch reactor (SBR). Fluorescent in situ hybridisation showed that Nitrobacter constituted 73% of the bacterial population. Batch tests were carried out to measure the oxygen uptake rate and/or nitrite consumption rate when both nitrite and CO2 were in excess, and in the absence of either of these two substrates. The results obtained, along with the SBR performance data, allowed the determination of the maintenance coefficient and in situ cell lysis rate of Nitrobacter. Nitrobacter spends a significant amount of energy for maintenance, which varies considerably with the specific growth rate. At maximum growth, Nitrobacter consume nitrite at a rate of 0.042 mgN/mgCOD(biomass)center dot h for maintenance purposes, which increases more than threefold to 0.143 mgN/mgCOD(biomass)center dot h in the absence of growth. In the SBR, where Nitrobacter grew at 40% of its maximum growth rate, a maintenance coefficient of 0.113 mgN/mgCOD center dot h was found, resulting in 42% of the total amount of nitrite being consumed for maintenance. The above three maintenance coefficient values obtained at different growth rates appear to support the maintenance model proposed in Pirt (1982). The in situ lysis rate of Nitrobacter was determined to be 0.07/day under aerobic conditions at 22 C and pH 7.3. Further, the maximum specific growth rate of Nitrobacter was estimated to be 0.02/h (0.48/day). The affinity constant of Nitrobacter with respect to nitrite was determined to be 1.50 mgNO(2)(-)-N/L, independent of the presence or absence of CO2. (c) 2006 Wiley Periodicals, Inc.

New Operation Model for Maintenance Material Logistics in Paper Industry

This research report illustrates and examines new operation models for decreasing fixed costs and transforming them into variable costs in the field of paper industry. The report illustrates two cases - a new operation model for material logistics in maintenance and an examination of forklift truck fleet outsourcing solutions. Conventional material logistics in maintenance operation is illustrated and some problems related to conventional operation are identified. A new operation model that solves some of these problems is presented including descriptions of procurement and service contracts and sources of added value. Forklift truck fleet outsourcing solutions are examined by illustrating the responsibilities of a host company and a service provider both before and after outsourcing. The customer buys outsourcingservices in order to improve its investment productivity. The mechanism of how these services affect the customer company's investment productivity is illustrated.

Value added logistics in supply and demand chain : COSTFIX : New operation model for maintenance material logistics in paper industry

This research report illustrates and examines new operation models for decreasing fixed costs and transforming them into variable costs in the field of paper industry. The report illustrates two cases – a new operation model for material logistics in maintenance and an examination of forklift truck fleet outsourcing solutions. Conventional material logistics in maintenance operation is illustrated and some problems related to conventional operation are identified. A new operation model that solves some of these problems is presented including descriptions of procurement and service contracts and sources of added value. Forklift truck fleet outsourcing solutions are examined by illustrating the responsibilities of a host company and a service provider both before and after outsourcing. The customer buys outsourcing services in order to improve its investment productivity. The mechanism of how these services affect the customer company’s investment productivity is illustrated.

A simulation model of the optimal maintenance strategy: conceptual agent-based approach

In this Master’s thesis agent-based modeling has been used to analyze maintenance strategy related phenomena. The main research question that has been answered was: what does the agent-based model made for this study tell us about how different maintenance strategy decisions affect profitability of equipment owners and maintenance service providers? Thus, the main outcome of this study is an analysis of how profitability can be increased in industrial maintenance context. To answer that question, first, a literature review of maintenance strategy, agent-based modeling and maintenance modeling and optimization was conducted. This review provided the basis for making the agent-based model. Making the model followed a standard simulation modeling procedure. With the simulation results from the agent-based model the research question was answered. Specifically, the results of the modeling and this study are: (1) optimizing the point in which a machine is maintained increases profitability for the owner of the machine and also the maintainer with certain conditions; (2) time-based pricing of maintenance services leads to a zero-sum game between the parties; (3) value-based pricing of maintenance services leads to a win-win game between the parties, if the owners of the machines share a substantial amount of their value to the maintainers; and (4) error in machine condition measurement is a critical parameter to optimizing maintenance strategy, and there is real systemic value in having more accurate machine condition measurement systems.