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Reliability-Centered Maintenance Methodology and Application: A Case Study  [PDF]
Islam H. Afefy
Engineering (ENG) , 2010, DOI: 10.4236/eng.2010.211109
Abstract: This paper describes the application of reliability-centered maintenance methodology to the development of maintenance plan for a steam-process plant. The main objective of reliability-centered maintenance is the cost-effective maintenance of the plant components inherent reliability value. The process-steam plant consists of fire-tube boiler, steam distribution, dryer, feed-water pump and process heater. Within this context, a maintenance program for the plant is carried out based on this reliability-centered maintenance concept. Applying of the reliability-centered maintenance methodology showed that the main time between failures for the plant equipments and the probability of sudden equipment failures are decreased. The proposed labor program is carried out. The results show that the labor cost decreases from 295200 $/year to 220800 $/year (about 25.8% of the total labor cost) for the proposed preventive maintenance planning. Moreover, the downtime cost of the plant components is investigated. The proposed PM planning results indicate a saving of about 80% of the total downtime cost as compared with that of current maintenance. In addition, the proposed spare parts programs for the plant components are generated. The results show that about 22.17% of the annual spare parts cost are saved when proposed preventive maintenance planning other current maintenance once. Based on these results, the application of the predictive maintenance should be applied.
Identifica??o e avalia??o de variáveis críticas no processo de produ??o da cana-de-a?úcar
Campos, Cassiano M.;Milan, Marcos;Siqueira, Luiz F. F.;
Engenharia Agrícola , 2008, DOI: 10.1590/S0100-69162008000300016
Abstract: the sugarcane is one of the most economically important crops in brazil, presenting a perspective of cultivated areas expansion for the next years. in reason of the increasing at the demanding, there is a need of maintenance and increasing field yield, optimizing the already available resources. one of the alternatives for the yield increasing is the improvement of agricultural operations involved in the production. it is necessary, because of the operational issues and involved cost, to identify those of more importance and establish the patterns to be attend by then. this way the objective of this work was to identify and evaluate the critical variables that are present in the sugarcane production process. the work was developed in two stages. the first one consisted of the identification of the critical variables through fmea "failure mode and effect analysis". the second one was carried out in the field, in order to evaluate the most critical variable and determined the capacity of the process through the cpk index. seventeen variables were identified and among them the irregular spacing between furrows was considered as the most critical. the furrows systems guide, manual and automatic, are not capable of attending the tolerance limits adopted by the sugarcane mill. it is necessary to review these limits and/or analyze alternatives to improve the systems in order attend the wanted patterns.
Aplica??o sistêmica do modo de análise de falhas e efeitos (FMEA) para o desenvolvimento de indicadores de desempenho de empresas de pequeno porte
Matos, Roselane Biangaman de;Milan, Marcos;
Revista árvore , 2009, DOI: 10.1590/S0100-67622009000500020
Abstract: the brazilian forestry sector employs directly and indirectly 6,5 millions of people. there are, out of these, 2,5 million allocated in the mechanized processed wood sub sector. the industrial park, for the production of sawn wood, has approximately 10.000 units. most of them are small size enterprises and 74,6% of them have less than 10.000 m3 year-1 of installed capacity. the small size enterprises are present low technology level, workers with poor qualification and difficulties of establishing control items which allow the efficient management of the productive process. considering their social and economical importance, the managing difficulties of small and medium size enterprises and the use of indices of critical performance in order to improve the management system, this work aims at defining the indices of critical performance of the production process of small size enterprises in wood business. for such, the fmea methodology was used to identify the potential failures and, as a result, to develop the performance indices. there were 24 types of failure identified, all of them considered as critical. they were analyzed and monitored. it was observed that there is a potential to improve the process.
Prevenzione dell’eventuale cardiotossicita’ della terapia antipsicotica tramite l’esecuzione di procedure preliminari alla sua impostazione utilizzando la metodica FMEA
Barbera V.,Cavarra S.,Podestà P.,Sartore F.
Working Paper of Public Health , 2012,
Abstract: Obiettivi: il progetto si propone di elaborare una procedura da implementarsi obbligatoriamente prima della impostazione di qualsiasi terapia antipsicotica alla luce della potenziale cardiotossicità dei farmaci antipsicotici di 1° e 2° generazione;Metodologia: gruppo di lavoro formato dall’equipe medica e infermieristica, avvalendosi della metodologia FMEA;Risultati: l’elaborazione di una scheda FMEA;Conclusioni: il documento prodotto ha suscitato nel gruppo di lavoro notevoli discussioni e riflessioni sulla metodologia adottata.
Assessment and Risk Management of Potential Hazards by Failure Modes and Effect Analysis (FMEA) Method in Yazd Steel Complex  [PDF]
Mehrzad Ebrahemzadih, G. H. Halvani, Behzad Shahmoradi, Omid Giahi
Open Journal of Safety Science and Technology (OJSST) , 2014, DOI: 10.4236/ojsst.2014.43014
Abstract: Background: Failure mode and effect analysis (FMEA) is a widely used quality improvement and risk assessment tool in manufacturing. The aim of this study is to assess potential hazards by failure modes and effect analysis (FMEA) method in Yazd Steel Complex. Methods: In this descriptive study, we evaluated the risks in different parts of the complex by using FMEA method and by using FMEA Worksheets (PFMEA) derived from the standard (MIL_STD-882). Failure modes and the various components and effects as using quantitative score to the risk priority (RPN) were obtained. PFMEA worksheets were completed and, we reevaluated the weaknesses part of the system. Activities related to each from the different parts of Yazd Steel Complex by using the scores risk priority (RPN) were evaluated. Then the results obtained by using SPSS software were performed by evaluation and analysis. Results: The findings showed that the steel maker lime unite and steel making ingot casting achieved the highest of RPN before and after corrective actions measures (490, 168) and environmental health unite and roll styles unite achieved the lowest of RPN before and after corrective actions measures (28, 20). Conclusions: The results show that the FMEA technique can identify a higher number of hazards than any other technique. The important point is that selection of an appropriate technique plays an important role in identifying a higher number of hazards.
Determination of Factors and Quality Control of Car Painting Based on FMEA and SPC.V2  [PDF]
Masud Rana, Xinmin Zhang, Sayed Abdul Akher
Modern Mechanical Engineering (MME) , 2018, DOI: 10.4236/mme.2018.82011
Abstract: The global automotive industry demands world-class levels of product quality, productivity, and competitiveness as well as continual improvement. To achieve this goal,?many vehicle manufacturers companies use?quality control tools to improve the quality of the product with zero defects and highly satisfied to the customer. Nowadays, there are a lot of quality tools applied to solve the problem quickly but it’s still the fact to find out good and efficient solving way. The study emphasizes the identification of potential failure which failures may have encountered in the production process and it will lead to car scrap, rework and influence of the internal production and quality target. After the complete study of the manufacturing process and production data-failure causes, failure rate and data etc. FMEA discover the weak processes in the form of higher risk priority number in the manufacturing of the car painting process, which required reducing by identifying and implementing of the defects and this will improve the process quality of the painting surface of the car. To analysis, the improvement of the car surface defects SPC (Statistical Process Control) tools are more efficient where can easily visible the defects trends. SPC chart is chronological graphs of process data that are used in manufactures industries to help understand, control and improve the process and that although based on statistical theory area easy for practitioners to use and interpret. In order to orient goal of zero defects of the car, surface uses the PFMEA technique to prioritizethe defects and statistically analyze the roots cause of the defect and control the defects through continues improvements process.
Utiliza??o do método FMEA para avalia??o do risco ambiental
Zambrano, Tatiane Fernandes;Martins, Manoel Fernando;
Gest?o & Produ??o , 2007, DOI: 10.1590/S0104-530X2007000200008
Abstract: the objective of this article is to present a method to evaluate environmental impacts during the productive process of small companies. a survey was conducted concerning the inputs and outputs of each stage of the productive process. the outputs which showed environmental impacts were analyzed using the fmea method. case studies were done in six small companies in s?o carlos- sp. the companies, where the research was done, belong to the following sectors: mechanical-metal, food, textile, plastics, a company of diagnosis kits for clinical analyses laboratories and a company which sells marble.
Avalia??o da preven??o de falhas em processos utilizando métodos de tomada de decis?o
Aguiar, Dimas Campos de;Salomon, Valério A. P.;
Produ??o , 2007, DOI: 10.1590/S0103-65132007000300008
Abstract: this work presents an investigation about the use of process fmea (failure mode and effect analysis) with the exhibition of identified irregularities for its correct use. the ahp (analytic hierarchy process) and the fuzzy sets are applied in the study of current practices for the fmea use. ahp is applied to prioritize the irregularities as for the gravity of its occurrence. the fuzzy sets are applied for performance evaluation of the fmea use in some automotive companies. as result, there are the acceptance of eight and the not acceptance of tree forms fmea discovered.
Comparison Between two FMEA Analysis Applied to Dairy
Amanda de Cássia Nogueira,Alexandre de Paula Peres
Engenharia Ambiental : Pesquisa e Tecnologia , 2010,
Abstract: The FMEA (Failure Mode and Effect Analysis) is a methodology that has been used in environmental risk assessment during the production process. Although the environmental certification means strengthening corporate image and ensuring their stay in the market, it is still very costly, particularly for small and medium businesses. Given this, the FMEA can be a benchmark for companies to start to diagnose the environmental risk caused by them. This methodology was used to diagnose differences in environmental concern and environmental controls exercised in two dairy plants from Lavras. By applying this method, one can observe different applications on the tables found in business: diagnosis and confirmation of the risks of controls taken.
Shipbuilding pipeline production quality improvement
T. Buksa,D. Pavletic,M. Sokovic
Journal of Achievements in Materials and Manufacturing Engineering , 2010,
Abstract: Purpose: The pipeline production is one of major processes in shipbuilding industry. Quality improvement and risk assessment in this process can yield significant savings, both in terms of internal quality costs as well as in terms of customer satisfactions.Design/methodology/approach: Shipbuilding pipeline production quality improvement has been carried out by application of FMEA (Failure Mode and Effect Analysis) method. For the successful implementation of FMEA method it is necessary to identify process failure modes or possibility of the appearance of non-compliance, as well as their possible causes. For qualitative analysis of key input variables of the process, in the paper is used Ishikawa diagram and p-chart.Findings: It is shown that proposed approach to risk assessment in shipbuilding pipeline production is applicable to real casa scenario. The analysis has identified the points in the process with the highest probability of occurrence of nonconformities, or the highest risk for error.Research limitations/implications: As the experimenting has been conducted in shipyard, within production process, research schedule must have been set in accordance with production pace. Also, due to character of production process the data collecting was adopted to the production plan in that particular moment.Practical implications: Dealing with causes of potential nonconformities in the process can significantly contribute to the reliability and robustness of the process. Corrective actions that have been taken based on results of analysis significantly contributed to the level of quality in the pipeline production process.Originality/value: The pepper is dealing with a well known method applied in different production environment that are mostly conservative in production approach. It was shown that successful application of proposed approach can yield benefits especially in improved quality of produced pipelines within shipbuilding industry.
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