Data-Driven System Reliability and Failure Behavior Modeling Using FMECA
- Khorshidi, Hadi, Gunawan, Indra, Ibrahim, Yousef
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2016
- Type: Text , Journal article
- Relation: IEEE Transactions on Industrial Informatics Vol. 12, no. 3 (2016), p. 1253-1260
- Full Text:
- Reviewed:
- Description: System reliability modeling needs a large amount of data to estimate the parameters. In addition, reliability estimation is associated with uncertainty. This paper aims to propose a new method to evaluate the failure behavior and reliability of a large system using failure modes, effects, and criticality analysis (FMECA). Therefore, qualitative data based on the judgment of experts are used when data are not sufficient. The subjective data of failure modes and causes have been aggregated through the system to develop an overall failure index (OFI). This index not only represents the system reliability behavior, but also prioritizes corrective actions based on improvements in system failure. In addition, two optimization models are presented to select optimal actions subject to budget constraint. The associated costs of each corrective action are considered in risk evaluation. Finally, a case study of a manufacturing line is introduced to verify the applicability of the proposed method in industrial environments. The proposed method is compared with conventional FMECA approach. It is shown that the proposed method has a better performance in risk assessment. A sensitivity analysis is provided on the budget amount and the results are discussed. © 2015 IEEE.
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2016
- Type: Text , Journal article
- Relation: IEEE Transactions on Industrial Informatics Vol. 12, no. 3 (2016), p. 1253-1260
- Full Text:
- Reviewed:
- Description: System reliability modeling needs a large amount of data to estimate the parameters. In addition, reliability estimation is associated with uncertainty. This paper aims to propose a new method to evaluate the failure behavior and reliability of a large system using failure modes, effects, and criticality analysis (FMECA). Therefore, qualitative data based on the judgment of experts are used when data are not sufficient. The subjective data of failure modes and causes have been aggregated through the system to develop an overall failure index (OFI). This index not only represents the system reliability behavior, but also prioritizes corrective actions based on improvements in system failure. In addition, two optimization models are presented to select optimal actions subject to budget constraint. The associated costs of each corrective action are considered in risk evaluation. Finally, a case study of a manufacturing line is introduced to verify the applicability of the proposed method in industrial environments. The proposed method is compared with conventional FMECA approach. It is shown that the proposed method has a better performance in risk assessment. A sensitivity analysis is provided on the budget amount and the results are discussed. © 2015 IEEE.
Development of a risk-based maintenance (RBM) strategy for sewerage pumping station network
- Masud, M., Chattopadhyay, Gopi, Gunawan, Indra
- Authors: Masud, M. , Chattopadhyay, Gopi , Gunawan, Indra
- Date: 2019
- Type: Text , Conference proceedings
- Relation: 2019 IEEE International Conference on Industrial Engineering and Engineering Management, IEEM 2019 p. 455-458
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- Description: Industries have been facing ever-increasing challenges to do more with less under ongoing budget constraints. They are pushing the boundary by challenging the OEM recommended maintenance intervals and relaxing or tightening based on where it is needed. This is also evident in water sector where industries are trying to do targeted maintenance based on balancing costs, performances and risks. The unexpected failures, the down time associated with such failures, the environmental overflows and, the increasing maintenance costs are major challenges all wastewater reticulation and distribution networks. Industries have been working hard to increase the availability of equipment and reduce the life-cycle cost without compromising safety and environmental targets. Risk-based maintenance (RBM) strategy is useful for allocation of maintenance resources where first allocation occurs to the highest risk item and progressively allocated till it reached budget limits. This paper is based on findings from a study covering 186 sewerage pumping stations of Townsville Water in North of Queensland in Australia. This study covered identifying the critical subsystems and mitigating the risks of failure of those subsystems. Implementation of risk based maintenance strategy was useful in further enhancing reliability and reduction of maintenance costs. © 2019 IEEE.
- Description: E1
- Authors: Masud, M. , Chattopadhyay, Gopi , Gunawan, Indra
- Date: 2019
- Type: Text , Conference proceedings
- Relation: 2019 IEEE International Conference on Industrial Engineering and Engineering Management, IEEM 2019 p. 455-458
- Full Text:
- Reviewed:
- Description: Industries have been facing ever-increasing challenges to do more with less under ongoing budget constraints. They are pushing the boundary by challenging the OEM recommended maintenance intervals and relaxing or tightening based on where it is needed. This is also evident in water sector where industries are trying to do targeted maintenance based on balancing costs, performances and risks. The unexpected failures, the down time associated with such failures, the environmental overflows and, the increasing maintenance costs are major challenges all wastewater reticulation and distribution networks. Industries have been working hard to increase the availability of equipment and reduce the life-cycle cost without compromising safety and environmental targets. Risk-based maintenance (RBM) strategy is useful for allocation of maintenance resources where first allocation occurs to the highest risk item and progressively allocated till it reached budget limits. This paper is based on findings from a study covering 186 sewerage pumping stations of Townsville Water in North of Queensland in Australia. This study covered identifying the critical subsystems and mitigating the risks of failure of those subsystems. Implementation of risk based maintenance strategy was useful in further enhancing reliability and reduction of maintenance costs. © 2019 IEEE.
- Description: E1
Dynamic modeling and validation of post-combustion CO2 capture plants in Australian coal-fired power stations
- Bui, Mai, Gunawan, Indra, Verheyen, Vincent, Artanto, Yuli, Meuleman, Erik, Feron, Paul
- Authors: Bui, Mai , Gunawan, Indra , Verheyen, Vincent , Artanto, Yuli , Meuleman, Erik , Feron, Paul
- Date: 2013
- Type: Text , Journal article
- Relation: Energy Procedia Vol. 37, no. (2013), p. 2694-2702
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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 while the PCC plant is ramped up, ramped down or turned off. This paper presents the preliminary development of a dynamic model for PCC in a brown coal-fired power plant using the process simulation software Aspen Plus Dynamics. Validation of the dynamic model will be against both steady state and dynamic data from the pilot plant. By gaining this understanding of the dynamic behavior, the technical and financial performance of PCC can be optimised.
- Authors: Bui, Mai , Gunawan, Indra , Verheyen, Vincent , Artanto, Yuli , Meuleman, Erik , Feron, Paul
- Date: 2013
- Type: Text , Journal article
- Relation: Energy Procedia Vol. 37, no. (2013), p. 2694-2702
- Full Text:
- Reviewed:
- 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 while the PCC plant is ramped up, ramped down or turned off. This paper presents the preliminary development of a dynamic model for PCC in a brown coal-fired power plant using the process simulation software Aspen Plus Dynamics. Validation of the dynamic model will be against both steady state and dynamic data from the pilot plant. By gaining this understanding of the dynamic behavior, the technical and financial performance of PCC can be optimised.
Dynamic operation of post-combustion CO2 capture in Australian coal-fired power plants
- Bui, Mai, Gunawan, Indra, Verheyen, Vincent, Meuleman, Erik, Feron, Paul
- 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.
- 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
- Full Text:
- Reviewed:
- 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
- Zhou, Leon, Gunawan, Indra, Jannise, Ricki, Suire, Casey, Eiman, Tyson
- 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.
- 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
- Full Text:
- Reviewed:
- 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.
Financial view and profitability evaluation on multistate weighted k-out-of-n:F system reliability
- Khorshidi, Hadi, Gunawan, Indra, Ibrahim, Yousef
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2014
- Type: Text , Journal article
- Relation: International Journal of Reliability and Safety Vol. 8, no. 2-4 (2014), p. 284-298
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- Description: A financial view is proposed for reliability evaluation of multi-state weighted k-out-of-n:F systems. Failure cost as the cost which is imposed on the components by failures is used to denote the importance weight of each component. The deterioration process of components over time is modelled by Markov chain. System failure behaviour is formulated by Universal Generating Function (UGF). Furthermore, the present value of system failure is calculated by considering time value of money. As a result, the system reliability is demonstrated as cost which is more sensible for managers. A numerical example is presented to illustrate the proposed approach. After that, a way is suggested to transform the system cost present value into system reliability value. MATLAB programming is developed to make a sensitivity analysis on example results. Therefore, the impact of maintenance activities is investigated to show how they can reduce system cost through improving the system reliability. Copyright © 2014 Inderscience Enterprises Ltd.
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2014
- Type: Text , Journal article
- Relation: International Journal of Reliability and Safety Vol. 8, no. 2-4 (2014), p. 284-298
- Full Text:
- Reviewed:
- Description: A financial view is proposed for reliability evaluation of multi-state weighted k-out-of-n:F systems. Failure cost as the cost which is imposed on the components by failures is used to denote the importance weight of each component. The deterioration process of components over time is modelled by Markov chain. System failure behaviour is formulated by Universal Generating Function (UGF). Furthermore, the present value of system failure is calculated by considering time value of money. As a result, the system reliability is demonstrated as cost which is more sensible for managers. A numerical example is presented to illustrate the proposed approach. After that, a way is suggested to transform the system cost present value into system reliability value. MATLAB programming is developed to make a sensitivity analysis on example results. Therefore, the impact of maintenance activities is investigated to show how they can reduce system cost through improving the system reliability. Copyright © 2014 Inderscience Enterprises Ltd.
Flexible operation of CSIRO's post-combustion CO2 capture pilot plant at the AGL Loy Yang power station
- Bui, Mai, Gunawan, Indra, Verheyen, Vincent, Feron, Paul, Meuleman, Erik
- Authors: Bui, Mai , Gunawan, Indra , Verheyen, Vincent , Feron, Paul , Meuleman, Erik
- Date: 2016
- Type: Text , Journal article
- Relation: International Journal of Greenhouse Gas Control Vol. 48, no. (May 2016), p. 188-203
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- Description: Flexible operation has the potehtial to significantly improve the economic viability of post-combustion CO2 capture (PCC). However, the impact of disturbances from flexible operation of the PCC process is unclear. The purpose of this study was to investigate the effects of flexible operation in a PCC pilot plant by implementing step-changes for improved dynamic data reliability. The flexible operation campaign was conducted at the CSIRO PCC pilot plant at AGL Loy Yang using monoethanolamine (MEA) absorbent. The pilot plant was operated under a broad range of transient conditions (changing flue gas flow, liquid absorbent flow and steam pressure) to capture the dynamics of a PCC process during flexible operation. The study demonstrated that the dynamics of flue gas flow rate was faster than absorbent flow rate. The greatest CO2 removal% was achieved at the lowest flue gas flow rate or at the highest absorbent flow rate; however, the latter provided improved energy efficiency. The steam pressure parameter could adjust the temperature of all columns simultaneously which can be used to compensate for effects from ambient conditions or heat losses. These results verify the technical feasibility of flexible PCC operation and provide a suitable dataset for dynamic model validation. (C) 2015 Elsevier Ltd. All rights reserved.
- Authors: Bui, Mai , Gunawan, Indra , Verheyen, Vincent , Feron, Paul , Meuleman, Erik
- Date: 2016
- Type: Text , Journal article
- Relation: International Journal of Greenhouse Gas Control Vol. 48, no. (May 2016), p. 188-203
- Full Text:
- Reviewed:
- Description: Flexible operation has the potehtial to significantly improve the economic viability of post-combustion CO2 capture (PCC). However, the impact of disturbances from flexible operation of the PCC process is unclear. The purpose of this study was to investigate the effects of flexible operation in a PCC pilot plant by implementing step-changes for improved dynamic data reliability. The flexible operation campaign was conducted at the CSIRO PCC pilot plant at AGL Loy Yang using monoethanolamine (MEA) absorbent. The pilot plant was operated under a broad range of transient conditions (changing flue gas flow, liquid absorbent flow and steam pressure) to capture the dynamics of a PCC process during flexible operation. The study demonstrated that the dynamics of flue gas flow rate was faster than absorbent flow rate. The greatest CO2 removal% was achieved at the lowest flue gas flow rate or at the highest absorbent flow rate; however, the latter provided improved energy efficiency. The steam pressure parameter could adjust the temperature of all columns simultaneously which can be used to compensate for effects from ambient conditions or heat losses. These results verify the technical feasibility of flexible PCC operation and provide a suitable dataset for dynamic model validation. (C) 2015 Elsevier Ltd. All rights reserved.
Implementation of lean manufacturing through learning curve modelling for labour forecast
- Authors: Gunawan, Indra
- Date: 2009
- Type: Text , Journal article
- Relation: International Journal of Mechanical & Mechatronics Engineering Vol. 9, no. 10 (2009), p. 46-52
- Full Text:
- Reviewed:
- Description: In this paper, an implementation of lean manufacturing through learning curve modelling for labour forecast is discussed. First, various learning curve models are presented. Then the models are analyzed in terms of their advantages and limitations. As a case study, the learning curve modelling is presented with the data derived from a production company. With the application of the learning curve, labour need can be more accurately predicted and scheduled on time.
- Authors: Gunawan, Indra
- Date: 2009
- Type: Text , Journal article
- Relation: International Journal of Mechanical & Mechatronics Engineering Vol. 9, no. 10 (2009), p. 46-52
- Full Text:
- Reviewed:
- Description: In this paper, an implementation of lean manufacturing through learning curve modelling for labour forecast is discussed. First, various learning curve models are presented. Then the models are analyzed in terms of their advantages and limitations. As a case study, the learning curve modelling is presented with the data derived from a production company. With the application of the learning curve, labour need can be more accurately predicted and scheduled on time.
Improving reliability of service operation using FMEA Review and new opportunity for investigations
- Sutrisno, Agung, Gunawan, Indra
- 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
- Full Text:
- Reviewed:
- 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
- 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
- Full Text:
- Reviewed:
- 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
OEE improvement of thermoforming machines through application of TPM at Tibaldi Australasia
- Chundhoo, Vickram, Chattopadhyay, Gopinath, Gunawan, Indra, Ibrahim, Yousef
- 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
- Full Text:
- Reviewed:
- 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.
- 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
- Full Text:
- Reviewed:
- 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.
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