Inspection model development for production machines based on downtime record

In the production line, the main objective of the machines to provide the good quality of products at the time given and follow the customer requirement to accomplish customer’s satisfaction. To reach the objective, the production line should running in smooth flow without or less breakdown. Nevert...

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Main Author:	Nur Hazirah, Sa'ari
Format:	Thesis
Language:	English
Subjects:	Production machine Machine Preventive Maintenance (PM) Production machine > Analysis Production machine > Design and construction
Online Access:	http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/2/Full%20text.pdf
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spelling	my-unimap-412932016-04-13T04:45:58Z Inspection model development for production machines based on downtime record Nur Hazirah, Sa'ari Dr. Rosmaini Ahmad In the production line, the main objective of the machines to provide the good quality of products at the time given and follow the customer requirement to accomplish customer’s satisfaction. To reach the objective, the production line should running in smooth flow without or less breakdown. Nevertheless, the real production with the ineffective maintenance strategy becomes barrier to the production to achieving the objective. Reasonably, this problem contributes to high production lost, production defect due to reject product (if the breakdown occurs during the machine is operating) and increasing the maintenance cost. Inspection is one of the Preventive Maintenance (PM) strategies that can be used to reduce machines breakdown problem in the production line. Conversely, the application of inspection in term of how many times of the inspection should be done at the unit of time (such as per month) is the main issue. To answer this question, an adequate maintenance analysis based on inspection must be accomplished. Most of the existing study is focus to inspection of single machine at the state of constant failure rate. There is no consideration for machine in the state of decreasing and increasing failure rate. Hence, the inspection strategy introduce to the machine at decreasing failure rate state to give extra value to the production machines by reducing machines breakdown due to continuous monitoring the machine condition and do correction or maintenance if needed. In this research, an inspection model of maintenance analysis by considering the failure time of the machines is developed in order to determine the optimal inspection frequency of the critical machines in the production line. In addition, the inspection strategy that used can maximize the output of production machines in term of product and service. In order to confirm this model, a case study was carried out on the automotive industry in Malaysia. The result from failure analysis have identified that all the critical machines in the state of decreasing failure rate and the failure characteristic information was used for the next analysis. Result shows that the machine follows the Weibull distribution and for inspection modeling also used the Weibull function to identify the inspection frequency for the critical machines. Therefore, the result shows that have relationship between two inspection model base on profit and downtime. Universiti Malaysia Perlis (UniMAP) 2013 Thesis en http://dspace.unimap.edu.my:80/xmlui/handle/123456789/41293 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/1/Page%201-24.pdf 71c5473875b57926e6d613122277c7c8 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/2/Full%20text.pdf 4ee806be0708bbd059e90293c64a7541 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/3/license.txt 8a4605be74aa9ea9d79846c1fba20a33 Production machine Machine Preventive Maintenance (PM) Production machine -- Analysis Production machine -- Design and construction School of Manufacturing Engineering
institution	Universiti Malaysia Perlis
collection	UniMAP Institutional Repository
language	English
advisor	Dr. Rosmaini Ahmad
topic	Production machine Machine Preventive Maintenance (PM) Production machine -- Analysis Production machine -- Design and construction
spellingShingle	Production machine Machine Preventive Maintenance (PM) Production machine -- Analysis Production machine -- Design and construction Nur Hazirah, Sa'ari Inspection model development for production machines based on downtime record
description	In the production line, the main objective of the machines to provide the good quality of products at the time given and follow the customer requirement to accomplish customer’s satisfaction. To reach the objective, the production line should running in smooth flow without or less breakdown. Nevertheless, the real production with the ineffective maintenance strategy becomes barrier to the production to achieving the objective. Reasonably, this problem contributes to high production lost, production defect due to reject product (if the breakdown occurs during the machine is operating) and increasing the maintenance cost. Inspection is one of the Preventive Maintenance (PM) strategies that can be used to reduce machines breakdown problem in the production line. Conversely, the application of inspection in term of how many times of the inspection should be done at the unit of time (such as per month) is the main issue. To answer this question, an adequate maintenance analysis based on inspection must be accomplished. Most of the existing study is focus to inspection of single machine at the state of constant failure rate. There is no consideration for machine in the state of decreasing and increasing failure rate. Hence, the inspection strategy introduce to the machine at decreasing failure rate state to give extra value to the production machines by reducing machines breakdown due to continuous monitoring the machine condition and do correction or maintenance if needed. In this research, an inspection model of maintenance analysis by considering the failure time of the machines is developed in order to determine the optimal inspection frequency of the critical machines in the production line. In addition, the inspection strategy that used can maximize the output of production machines in term of product and service. In order to confirm this model, a case study was carried out on the automotive industry in Malaysia. The result from failure analysis have identified that all the critical machines in the state of decreasing failure rate and the failure characteristic information was used for the next analysis. Result shows that the machine follows the Weibull distribution and for inspection modeling also used the Weibull function to identify the inspection frequency for the critical machines. Therefore, the result shows that have relationship between two inspection model base on profit and downtime.
format	Thesis
author	Nur Hazirah, Sa'ari
author_facet	Nur Hazirah, Sa'ari
author_sort	Nur Hazirah, Sa'ari
title	Inspection model development for production machines based on downtime record
title_short	Inspection model development for production machines based on downtime record
title_full	Inspection model development for production machines based on downtime record
title_fullStr	Inspection model development for production machines based on downtime record
title_full_unstemmed	Inspection model development for production machines based on downtime record
title_sort	inspection model development for production machines based on downtime record
granting_institution	Universiti Malaysia Perlis (UniMAP)
granting_department	School of Manufacturing Engineering
url	http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/41293/2/Full%20text.pdf
_version_	1747836812770934784

Inspection model development for production machines based on downtime record

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