OEE improvement of thermoforming machines through application of TPM at Tibaldi Australasia
- Authors: Chundhoo, Vickram , Chattopadhyay, Gopinath , Gunawan, Indra , Ibrahim, Yousef
- Date: 2017
- Type: Text , Conference proceedings , Conference paper
- Relation: 2017 IEEE International Conference on Industrial Engineering and Engineering Management, IEEM 2017; Singapore, Singapore; 10th-13th December 2017 p. 929-933
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- Description: Overall Equipment Effectiveness (OEE) evaluates quantitatively how effectively a manufacturing operation is utilised. Total Productive Maintenance (TPM) was considered by Tibaldi, a leading food manufacturer in Australia for achieving OEE. This research project has identified performance gaps, developed plan and implemented it in Thermoforming area of the business. The developed methodology helped Tibaldi in improving productivity and quality through TPM involving machines, equipment, processes, and employees. This paper demonstrates how this can be achieved by reducing lead time and establishing lean environment. Productivity improvement through the devised methodology led to further enhancement of competitiveness of the organisation for domestic and international markets of processed food manufactured by Tibaldi Australia. Lessons learned from application of TPM in Thermoforming, a key asset area, is rolled out to other sections of the plat and results from this pilot study are presented in this paper.
A maintenance waste risk appraisal model based on modified failure mode and effect analysis (FMEA)
- Authors: Sutrisno, Agung , Gunawan, Indra , Vanany, Iwan , Khorshidi, Hadi
- Date: 2016
- Type: Text , Conference paper
- Relation: IEEE International Conference on Industrial Engineering and Engineering Management p. 1422-1425
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Improving reliability of service operation using FMEA Review and new opportunity for investigations
- Authors: Sutrisno, Agung , Gunawan, Indra
- Date: 2016
- Type: Text , Conference paper
- Relation: International Conference on Engineering and Technology for Sustainable Development, ICET4SD 2015; Yogyakarta; Indonesia; 11th-12th; IOP Conference Series: Materials Science and Engineering, Vol. 105 Vol. 105
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- Description: Despite its growing contribution to the global economy, investigation on the application status of service FMEA study to support realization of reliable service operation is very limited in literature. Motivated by such situation, the paper presented an initial survey on the status and research gaps in developing and applying FMEA in service sectors. Systematic preliminary survey using specific criteria are undertaken. Our study indicated that development and application of service FMEA are partially addressing the characteristics of service operations and it is still applied into the good deed and profit oriented operations. Opportunities for further investigation pertaining to advancement of its decision supporting tool for service risk appraisal, its modification to cope with sustainability related requirements and application of service FMEA in not for profit oriented operations are presented as new avenues for further investigation
A bi-objective dynamic model for multi-state weighted k-out-of-n system reliability
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2015
- Type: Text , Conference paper
- Relation: 25th European Safety and Reliability Conference, ESREL 2015; Zurich, Switzerland; 7th-10th September 2015 p. 2229-2234
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- Description: Nowadays, improving system reliability is becoming an important criterion for engineering industries. Many studies have been developed to evaluate the reliability of the systems which is the first step in system improvement. Most of these studies have been done in non-dynamic conditions in which the components have the constant reliability values during functioning periods. However, the components' reliability level varies over time due to both failures and maintenance actions. Therefore, time dimension should be added into system reliability evaluation. In this paper, a dynamic assessment is presented for multi-state weighted k-out-of-n systems. The k-out-of-n system is a popular structure in fault-tolerant systems in which n components work in parallel form with a pre-defined k as a condition. This dynamic assessment considers the reliability variation of the components over finite and discrete time periods. It provides an opportunity to assign decision variables for each functioning period, and analyze the impact of each decision on the whole system reliability. In addition, the income generated during each period is defined as an importance weight of the components. Therefore, the present value of the system is obtained by Universal Generating Function (UGF) and engineering economics' tools. Furthermore, an optimization model is developed to find optimal decisions based on system reliability and cost. Since the system reliability is estimated by money, the expected profit of the system can be as the objective function. As a result, the objective function can maximize system reliability and minimize system cost simultaneously. A Matlab programming is created for a numerical example to illustrate the proposed model. © 2015 Taylor & Francis Group, London.
An investigation on imperialist competitive algorithm for solving reliability-redundancy allocation problems
- Authors: Khorshidi, Hadi , Gunawan, Indra , Sutrisno, Agung , Nikfalazar, Sanaz
- Date: 2015
- Type: Text , Conference paper
- Relation: 2015 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM); Singapore, Singapore; 6th-9th December 2015 p. 1041-1045
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- Description: Reliability-redundancy allocation problems (RRAPs) are optimization models that try to find the optimal number of redundant components and their reliability levels simultaneously. Many studies have been developed to solve RRAPs in recent years. There are some specific RRAP models for various system structures to maximize system reliability subject to cost, volume and weight constraints. Different meta-heuristic algorithms have been used in order to reach the best objective function value. In this study, an investigation is done on imperialist competitive algorithm (ICA) to maximize models for series and bridge systems. ICA is used by adjusting different values to algorithm's parameters. This investigation recognizes which combination is the most suitable for solving the RRAPs by ICA. Each combination has been run for 35 times. Therefore, the combinations are compared by descriptive statistics' measures and analysis of variance (ANOVA). Furthermore, the best obtained solution is compared with the previous studies.
Quantifying the impact of using multi-function robots on productivity of rotationally arranged robotic cells
- Authors: Foumani, Mehdi , Ibrahim, Yousef , Gunawan, Indra
- Date: 2015
- Type: Text , Conference paper
- Relation: 2013 IEEE International Conference on Industrial Engineering and Engineering Management , Bangkok, 2013 p. 1194-1198
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- Description: This paper investigates the scheduling of a rotationally arranged robotic cell with the Multi-Function Robot (MFR). The earlier known robotic study in this area assumed that the robot only moves the part between machines. We lift this assumption on robot tasks and assumed a special class of robots which is also able to perform a special operation in transit. The aim is to find a minimum cycle time for identical part production. Considering additive and constant travel-time, the distance between any two machines is varying or constant based on the robot acceleration/deceleration for incompact and compact cells. The lower bound of the cycle time is deduced to evaluate the optimality of two practical permutations namely uphill and downhill. It also identifies the regions where using a Multi-Function Robotic Cell (MFRC) is more economical than a Single-Function Robotic Cell (SFRC).
Reliability centered maintenance using system dynamics approach
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2015
- Type: Text , Conference paper
- Relation: 2015 IEEE International Conference on Industrial Technology (ICIT) p. 1932-1936
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- Description: This paper presents a system dynamic modeling technique for reliability centered maintenance (RCM). It provides a simulation model to analyze the impact of maintenance strategies such as preventive and corrective maintenance on system availability. Also, maintenance cost is associated with the model to have an optimization view for a manufacturing system. As a result, the optimal decisions can be made based on the results of the model. In addition, sensitivity analysis has been conducted for various parameters in the simulation model. The results were compared and discussed for various conditions.
System dynamics modeling for multi-state systems
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2015
- Type: Text , Conference paper
- Relation: 25th European Safety and Reliability Conference, ESREL 2015; Zurich, Switzerland; 7th-10th September 2015 p. 925-930
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- Description: In this paper, the dynamic behavior of the system reliability is modeled by system dynamics approach. Since the reliability levels of the components and systems changes during functioning periods, this variability should be considered in reliability assessment. System dynamics has been used to simulate the dynamic interactions of the phenomena in different areas such as economics, environment, social, humanity, management, and engineering. In system dynamics, Causal Loop Diagrams (CLDs) and stock and flow structures are employed to both represent the elements and model their interactions in order to predict the future status of the system. Due to the capability of the system dynamics in capturing the dynamic behavior of complex systems, it is used for a dynamic assessment of system reliability. The components in this system are multi-state so that they have more performance levels than failure and working states. A case of a multi-state weighted k-out-of-n system is simulated in this study. Software iThink is used to develop the dynamic model for the case study. The results of the system dynamics approach are compared with the outputs of the dynamic availability assessment by mathematical modeling. In addition, the associated cost of maintenance activities is added in the model. Therefore, different scenarios can be evaluated in terms of cost and reliability with the intention of finding optimal decisions. Finally, a sensitivity analysis has been conducted under various conditions in the simulation model. © 2015 Taylor & Francis Group, London.
An unreliability analysis for k-out-of-n: F system
- Authors: Ibrahim, Yousef , Gunawan, Indra , Khorshidi, Hadi
- Date: 2014
- Type: Text , Conference paper
- Relation: Proceedings of 6th Asia-Pacific International Symposium on Advanced Reliability and Maintenance Modeling (APARM 2014): Advanced Reliability and Maintenance Modeling VI p. 208-215
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Dynamic operation of post-combustion CO2 capture in Australian coal-fired power plants
- Authors: Bui, Mai , Gunawan, Indra , Verheyen, Vincent , Meuleman, Erik , Feron, Paul
- Date: 2014
- Type: Text , Conference paper
- Relation: 12th International Conference on Greenhouse Gas Control Technologies, GHGT 2014 p. 1368-1375
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- Description: Flexible operation of post-combustion CO2 capture (PCC) plants can improve efficiency through coordinating the balance between consumer demands for electricity and CO2 emission reductions. This strategy however, will impose process disturbances and the immediate and long term impact is unclear. There is a justified need for the development of accurate dynamic PCC models, as well as practical experience in dynamic operation of PCC pilot plants. This paper presents CSIRO PCC pilot plant data from the 2012 and 2013 dynamic campaigns using MEA solvent. The step-change approach to dynamic plant operation was implemented and the use of density meters to instantaneously measure CO2 loading instantaneously was investigated.
Enhanced multizone single-trip sand-control system successfully treats six zones in offshore Indonesia well
- Authors: Zhou, Leon , Gunawan, Indra , Jannise, Ricki , Suire, Casey , Eiman, Tyson
- Date: 2014
- Type: Text , Conference paper
- Relation: Offshore Technology Conference Asia: Meeting the Challenges for Asia's Growth, OTC ASIA 2014 p. 1799-1808
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- Description: Although multiple-zone, downhole sand-control tool systems have been in use since the early 1990s, these systems had been designed for jobs that only required low-pump-rates with low-pressure differentials. Multiple-zone systems capable of high fracturing pump rates and the associated differentials only recently have been introduced to the oilfield. Although these jobs are becoming more common, most of the completions have been limited to four or five treated zones. This paper presents a case history from Indonesia in which six discrete zones in an offshore deployment were treated successfully in a single trip. The challenges for this completion were numerous. Manufacturing lead time was very short, and the system would have to be adapted to the unique requirements of the completion design and the use of new components. Since the proppant and pump rating for these systems was based on five zones, rigorous analysis was necessary to ensure that a high pump rate, high differential pressure-rated single-trip, multiple-zone sand-control tool system was capable of treating six zones and that the crossover tool would survive the erosive effects of these extreme conditions. To provide assurance of the elastomeric seal integrity of the service tool, a testing program was executed for treatments to provide tracking and verification of conditions. Procedures were prepared, and equipment was retained on hand to replace the service tools, if any leaks were evident. Since system installation experience was limited in this area, gathering sufficient knowledge and experience for system deployment had to be addressed quickly. This would require sharing of lessons learned, use of experienced personnel from previous installations, and conducting of detailed training discussions between subject matter experts and service personnel. Deployment challenges and solutions, successes experienced at the well site, and the actual performance of the operations are discussed in this paper.
Train unloading facility defect elimination program
- Authors: da Costa Cunha, Cristiano , Gunawan, Indra
- Date: 2014
- Type: Text , Conference paper
- Relation: Asset Management Conference
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- Description: A total of 4% of availability increase was achieved in an Iron Ore Train Unloader facility. A Six Sigma approach, supported by statistical techniques such as Pareto and Jackknife, is used to identify the main causes of loss and implement corrective actions, based on repetitive data collected within the time usage model accounting system. A classification method was utilised to separate production delays into different categories and target the focus of the defect elimination program in a staged approach. Via root cause analysis and fishbone diagrams, effective defect elimination tasks are identified to eliminate process outliers. Prioritisation tools and effective resource allocation are utilised to achieve an increased value adding defect elimination strategy. A control process of ongoing monitoring and data analysis is implemented to maintain sustainability of the program throughout the lifecycle of the asset and continuously improve availability. A total of 3.3 Mt of increased iron ore productivity within the Iron Ore Train Unloader facility was the result observed in the last 12 months.
Triassic reservoir characteristics of the Bird's Head, New Guinea, Indonesia : New insight from provenance study
- Authors: Gunawan, Indra , Hall, Robert , Sapiie, Benyamin
- Date: 2014
- Type: Text , Conference paper
- Relation: International Petroleum Technology Conference 2014, IPTC 2014 p. 3109-3117
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- Description: The Bird's Head area of New Guinea is underlain by Australian continental crust and has relatively complete Palaeozoic to Recent stratigraphic record. One of the siliciclastic formations of the Bird's Head is the Tipuma Formation. Its age has been estimated as Triassic to Jurassic and is a potentially important hydrocarbon reservoir. New fieldwork was carried out, complemented by analysis of light and heavy minerals, U-Pb zircon geochronology, and quartz CL luminescence study. The Tipuma Formation was previously dated only by its stratigraphic position and was suggested to have been deposited in a continental passive margin. This study shows sandstones and conglomerates were sourced from acid volcanic, metamorphic, and recycled sedimentary rocks to the north, and from the North Australian Craton. Cathodoluminescence study on detrital quartz supports the importance of the important of volcanic quartz. The quartz provenance of sandstones from the Lower, Middle and Upper Members of the Tipuma Formation are dominated by low-T metamorphic and volcanic with little plutonic origin and there is some variation with stratigraphic position and in the Middle Member the abundance of volcanic quartz declines. The youngest zircon ages indicate it was deposited in the Triassic. Permo-Triassic (205-275 Ma), Neoproterozoic (c. 975 Ma), Early Mesoproterozoic (1.4-1.6 Ga), and Paleopro-terozoic (1.8-2.0 Ga) populations, with a few grains of Archaean age (2.8-3.2 Ga) characterized most Tipuma Formation sandstones. The Tipuma Formation was probably not deposited in a simple continental block setting and was influenced by volcanic activity in the Bird's Head during its deposition. The long-lived Palaeozoic volcanic activity interpreted to indicate subduction of the palaeo-Pacific oceanic plate under the Australian continent associated with an Andean-type active margin. The decline of the abundance of volcanic quartz, Permo-Triassic zircons, and increase in Carboniferous and Proterozoic zircons within the Middle Member indicate a reduced contribution of sediment from the arc and an increased contribution of sediment from northern Australia.
Cyclic production for robotic cells served by multi-function robots with resumable processing regime
- Authors: Foumani, Mehdi , Ibrahim, Yousef , Gunawan, Indra
- Date: 2013
- Type: Text , Conference paper
- Relation: 2013 IEEE International Conference on Industrial Engineering and Engineering Management, Bangkok, (10 - 13 December 2013) p. 551-555
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- Description: This paper addresses the problem of finding the optimal robot move cycle to minimise the cycle time of two-machine cells. The earlier robot's function was mainly moving parts between machines in a manufacturing process. We lift this assumption on robot tasks and assumed a special robot, namely multi-function, which performs a unique operation in transit. This robot starts performing this operation after unloading a part from input buffer and finishes it before loading the part to the output buffer. The processing mode on robot is “stop resume”. Thus, regardless of the gap interrupts during the operation, the robot continues processing on part when it is reloaded to the robot without any loss in time. The focus of this study is on one-unit cycles since they are very popular in industry. The cycle time of two possible one-unit cycles is obtained, and the optimality condition of them is determined.
Reliability prediction and spare parts analysis of a fielded system
- Authors: Nhlapo, Masopha , Gunawan, Indra , Ibrahim, Yousef
- Date: 2013
- Type: Text , Conference paper
- Relation: 17th Asset Management Conference, 2013: Asset Management Practices for Essential Resources.Hawthorn, Vic, p. 1-15
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Application of Markov process technique for optimal maintenance in a power station
- Authors: Patel, Deepak , Gunawan, Indra
- Date: 2012
- Type: Text , Conference paper
- Relation: Asset Management Conference Vol. 1, p. 99-104
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- Description: Maintenance, reliability and availability of Pulverised Fuel Mills are of vital importance for the effective and efficient running of boiler at any brown coal power station. Achieving these targets become more critical when the unit boiler and turbine have been upgraded with no major upgrade on mills. Mill redundancy play major role in overall boiler operation and performance. In this paper, present mill operating strategy at Loy Yang Power station is challenged and revised strategy is proposed with strong evidences proved with the application of Markov Processes. Markov analysis is done at mill system level to establish the facts about the effects of mill operation on system availability. Short term and long term benefits of revised strategy are also discussed. Management is now convinced and actual trials have started. Mill maintenance strategies shall be reviewed and revised based on this work. It is also expected to gain considerable savings on mill maintenance costs in coming years if proposed operating strategy is adopted.
Cost reduction strategies for a paint manufacturing plant
- Authors: Gunawan, Indra , Karan, Ajay
- Date: 2012
- Type: Text , Conference paper
- Relation: ICOMS Asset Management Conference 2012
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Analysis of product recall in New Zealand
- Authors: Gunawan, Indra
- Date: 2011
- Type: Text , Conference paper
- Relation: Proceedings of the 17th Annual International Conference on Industry, Engineering, and Management Systems
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- Description: 2014061019
Challenges of recovering by-passed condensate in Al-Raja field utilizing MBO method
- Authors: Gunawan, Indra , Al-Abbasi, Omar
- Date: 2011
- Type: Text , Conference paper
- Relation: SPE Asia Pacific Oil and Gas Conference and Exhibition 2011 p. 998-1017
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- Description: This paper presents a case study on a reservoir simulation modeling of recycling gas condensate using Modified Black Oil formulation (MBO) to identify and recover the by-passed condensate in Al-Raja Field. Al-Raja field is a good candidate to utilize MBO formulation instead of fully compositional due to following reasons (1) Gas injection/recycling is able to maintain the reservoir pressure above or at the dew point pressure in Al-Raja Field. (2) by keeping reservoir pressure above dew point pressure, gas injection will prevent any Retrograde Liquid Deposit (RLD) occured in the reservoir. It was well accepted methodology that MBO can be used in lean to medium rich gas condensate reservoir under gas cycling above dew point. Al-Raja field is located in the Eastern part of the Marib-AlJawf Basin Republic of Yemen. The field has a moderate-size medium rich gas condensate reservoir with an average gas production rate of 750 MMscf/D from 18 wells. The lean gas is being re-injected back into the reservoir using line-drive pattern wells. Some make up gas from nearby fields was provided to replace fuel and shrinkage volumes. The high vertical relief of the field structure leads to significant temperature gradient that resulted in challenges to model the oil-gas ratio (Rv). The primary objective of the study is (1) to evaluate the current gas recycling performance at well and field level, (2) identify the location of current by-passed condensate (3) utilize the model to improve and optimize the liquid recovery through several options of optimum field developments (infill wells). To achieve the objectives, 3-D Static and Dynamic models with 4 components MBO definition were constructed. In this study, we will show how to generate PVT Modified Black Oil (MBO) properties such as solution gas-oil ratio (Rs), oil-gas ratio (Rv), oil formation volume factor (Bo), and gas formation factor (Bg), from PVT-EOS. Whitson and Torp procedures were selected to calculate MBO properties from PVT experimental data of gas condensate. The use of the MBO approach enabled us to perform faster field performance history matching compared with the compositional. This approach preserves less run time to conduct the Al-Raja prediction including infill drilling optimization. The condensate-gas ratio distribution achieved after the history match process guided us to locate the optimum infill well locations in by-passed area for the future development. Moderate condensate areas were located, and several wells have been drilled and proved to be successful. More infill wells were recommended to raise the field production and recover the remaining reserve.
Application of design structure matrix in project management
- Authors: Gunawan, Indra , Singh, Darius
- Date: 2008
- Type: Text , Conference paper
- Relation: Proceedings of the 17th International Conference on Management of Technology
- Full Text: false
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