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
- Full Text: false
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A value-driven approach for optimizing reliability-redundancy allocation problem in multi-state weighted k-out-of-n system
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2016
- Type: Text , Journal article
- Relation: Journal of Manufacturing Systems Vol. 40, no. (2016), p. 54-62
- Full Text: false
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- Description: This study concentrates on optimizing a multi-state weighted k-out-of-n system consisting of different types of reparable components. An optimization model is developed to decide upon both optimal redundancy allocation and best maintenance activities for reliability allocation. The optimization model is to maximize system reliability and minimize system cost simultaneously. To reach this goal, a financial view has been employed to estimate the system reliability, and combine it with system cost. The proposed model determines the number of each component type in the system, and the maintenance actions and the time at which they should be applied. Also, the model is programmed by MATLAB, and Genetic Algorithm is used to solve a practical case. (C) 2016 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
Application of fuzzy risk analysis for selecting critical processes in implementation of SPC with a case study
- Authors: Khorshidi, Hadi , Gunawan, Indra , Nikfalazar, Sanaz
- Date: 2016
- Type: Text , Journal article
- Relation: Group Decision and Negotiation Vol. 25, no. 1 (2016), p. 203-220
- Full Text: false
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- Description: Fuzzy risk analysis is widely used in risk assessment of components by linguistic terms. Fuzzy numbers are used to quantify the associated uncertainty. This study employs fuzzy risk analysis to evaluate processes for implementing statistical process control (SPC) in a specified manufacturing system. To reach this goal, fuzzy risk analysis has been applied based on both ranking and similarity of generalized trapezoidal fuzzy numbers in a stepwise procedure. Therefore, a new approach has been introduced for fuzzy risk analysis of processes to overcome the shortcomings of previous fuzzy risk analysis approaches. As a result, fuzzy risk analysis is used as a decision making technique to select critical processes under uncertainty. Also, the application of the proposed SPC implementation algorithm is illustrated in the manufacturing line of a car battery factory. © 2015, Springer Science+Business Media Dordrecht.
Applying UGF Concept to Enhance the Assessment Capability of FMEA
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2016
- Type: Text , Journal article
- Relation: Quality and Reliability Engineering International Vol. 32, no. 3 (Apr 2016), p. 1085-1093
- Full Text: false
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- Description: The purpose of this paper is to propose a modified version of Failure Mode and Effects Analysis (FMEA) to alleviate its drawbacks. FMEA is an important tool in risk evaluation and finding the priority of potential failure modes for corrective actions. In the proposed method, the Universal Generating Function (UGF) approach has been used to improve the assessment capability of the conventional Risk Priority Number (RPN) in ranking. The new method is named as URPN. It generates the most number of unique values in comparison with the previous methods and considers relative importance for the parameters while it is easy to compute. More unique numbers help to avoid from having the same priority level for different failure modes which represent various risk levels. A case study has been employed to demonstrate that the URPN not only can improve the shortcomings but also is able to provide accurate values for risk assessment. Copyright (c) 2015 John Wiley & Sons, Ltd.
Dynamic operation of liquid absorbent-based post-combustion CO2 capture plants
- Authors: Bui, Mai , Gunawan, Indra , Verheyen, Vincent , Meuleman, Erik
- Date: 2016
- Type: Text , Book chapter
- Relation: Absorption-Based Post-Combustion Capture of Carbon Dioxide (Woodhead Publishing Series in Energy) Chapter 24 p. 589-621
- Full Text: false
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- Description: Dynamic (or flexible) operation has been proposed as a strategy to reduce the impact of integrating post-combustion CO2 capture (PCC) into power plants. It provides a means for counteracting ongoing variations in the composition of flue gas and absorbent, and also accounts for dynamic variations in carbon and electricity pricing, and electricity demand. For example, in periods of low energy demand, electricity prices will be lower and capture rates may be ramped up accordingly. During high-demand periods, electricity prices will be higher, and capture may be turned down or switched off completely. Flexible PCC operation can also coordinate the balance between electricity demand and legislative requirements for CO2 emission reductions, to improve the economic feasibility of PCC. However, dynamic PCC operation imposes process disturbances when the CO2 capture plant is ramped up or turned down. The immediate and long-term effects of these disturbances are unclear. Thus, recent research is now focusing on the feasibility of flexible PCC operation on a technical basis. Dynamic modeling and pilot plant studies will improve our understanding of dynamic PCC behavior and enable process control to be optimized. © 2016 Elsevier Ltd All rights reserved.
Integrating SWOT analysis into the FMEA methodology to improve corrective action decision making
- Authors: Sutrisno, Agung , Kwon, Hyuckmoo , Gunawan, Indra , Eldridge, Stephen , Lee, Tzongru
- Date: 2016
- Type: Text , Journal article
- Relation: International Journal of Productivity and Quality Management Vol. 17, no. 1 (2016), p. 104-126
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- Description: Improving the method for selecting risk-based competing improvement strategies has equal importance with failure risk quantification inthe FMEA methodology. Nevertheless, there are few studies which focus on this issue. Furthermore, the influence of factors relating to the businessenvironment which may support or derail improvement efforts is not considered in previous studies. In order to address these limitations, a model is proposed in which the impact of environmental factors is considered byintegrating SWOT analysis into the FMEA method in order to support the appraisal of competing risk-based improvement efforts. The impact of SWOTvariables is deployed using a decision support model based upon the benefit, cost, opportunity, risk and organisational readiness index (BCOR2) approach inorder for the FMEA team to select from competing corrective actions. A case example from industry is provided in which the proposed model is applied. This example illustrates that this new model contributes successfully to good practice by identifying the most appropriate corrective action option to take andimproves upon the decisions provided by existing developments of the FMEA methodology.
Statistical process control application on service quality using SERVQUAL and QFD with a case study in trains' services
- Authors: Khorshidi, Hadi , Nikfalazar, Sanaz , Gunawan, Indra
- Date: 2016
- Type: Text , Journal article
- Relation: TQM Journal Vol. 28, no. 2 (2016), p. 195-215
- Full Text: false
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- Description: Purpose - The purpose of this paper is to implement statistical process control (SPC) in service quality using three-level SERVQUAL, quality function deployment (QFD) and internal measure. Design/methodology/approach - The SERVQUAL questionnaire is developed according to internal services of train. Also, it is verified by reliability scale and factor analysis. QFD method is employed for translating SERVQUAL dimensions' importance weights which are derived from Analytic Hierarchy Process into internal measures. Furthermore, the limits of the Zone of Tolerance are used to determine service quality specification limits based on normal distribution characteristics. Control charts and process capability indices are used to control service processes. Findings - SPC is used for service quality through a structured framework. Also, an adapted SERVQUAL questionnaire is created for measuring quality of train's internal services. In the case study, it is shown that reliability is the most important dimension in internal services of train for the passengers. Also, the service process is not capable to perform in acceptable level. Research limitations/implications - The proposed algorithm is practically applied to control the quality of a train's services. Internal measure is improved for continuous data collection and process monitoring. Also, it provides an opportunity to apply SPC on intangible attributes of the services. In the other word, SPC is used to control the qualitative specifications of the service processes which have been measured by SERVQUAL. Originality/value - Since SPC is usually used for manufacturing processes, this paper develops a model to use SPC in services in presence of qualitative criteria. To reach this goal, this model combines SERVQUAL, QFD, normal probability distribution, control charts, and process capability. In addition, it is a novel research on internal services of train with regard to service quality evaluation and process control. © 2016 Emerald Group Publishing Limited.
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
- Full Text: false
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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.
A new modified FMEA model for ranking the risk of maintenance waste considering hierarchy of root causes and effects
- Authors: Sutrisno, Agung , Gunawan, Indra , Khorshidi, Hadi , Tangkuman, Stenly
- Date: 2015
- Type: Text , Journal article
- Relation: International Journal of Quality Engineering and Technology Vol. 5, no. 3-4 (2015), p. 217-237
- Full Text: false
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- Description: Implementing sustainable manufacturing practice requires efficiency of the resource utilisation and activities which add value to the operations. From this point of view, development of an improved methodology to access the criticality of non- Added value (waste) is important and believed to support the realisation of sustainable manufacturing operation. While previous studies on improving methodology to support sustainable operation from product and process design are abundantly available in the references, the contribution from maintenance field is in contrary. The goal of this study is to modify the quality improvement tool, failure mode and effect analysis (FMEA) to access the criticality of waste in maintenance operation. In an attempt to realise the above goal, an empirical study to propose the theoretical and actual maintenance waste from industrial practice is undertaken. In order to assist maintenance 218 A. Sutrisno et al. decision maker to quantify criticality of maintenance waste occurrence, a new model to rank waste maintenance mode, called the waste priority number (WPN) is given. Illustrative on using model for practical purpose is given.. © 2015 Inderscience Enterprises Ltd.
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
- Full Text: false
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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.
Analysis of education and practical relevance of project management topics in New Zealand
- Authors: Gunawan, Indra
- Date: 2015
- Type: Text , Journal article
- Relation: International Journal of Project Organisation and Management Vol. 7, no. 2 (2015), p. 174-183
- Full Text: false
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- Description: The objective of this paper is to analyse the education of project management (PM) and its practical relevance in New Zealand. The research has been done through a survey analysis of PM practitioners and academics. The PM practitioners were asked which PM topics are widely used in the industry. The academics were also asked through a parallel survey which PM topics are considered important at a tertiary level and taught to students. It can be seen from the results that contemporary education of PM has improved vastly and is relevant with its practice. The findings are important for both practitioners and academics to identify the gap between project management education and industry needs. Copyright © 2015 Inderscience Enterprises Ltd.
Evaluation of control system reliability using combined dynamic fault trees and Markov models
- Authors: Kolek, Levente , Ibrahim, Yousef , Gunawan, Indra , Laribi, Med Amine , Zegloul, Said
- Date: 2015
- Type: Text , Conference proceedings
- Full Text: false
- Description: In this paper, dynamic simulation methods for reliability evaluation of common industry-based control system architectures are investigated. Control system design often employs complex reliability structures in the forms of several levels of software and hardware redundancies, hot and cold standby systems. This is required in order to achieve certain plant availability and safety functions. Control system maintenance requires expert knowledge due to the complexity of troubleshooting steps involved with a hardware or software failures of a large system. Hence, it is crucial to understand the effect of recovery time on reliability and on overall availability in a critical control system. Dynamic Fault Tree Analysis (DFTA), Markov Chains and Reliability Block Diagrams (RBD) are presented and a block library is introduced for addressing the aforementioned modelling problems. In order to be able to evaluate dynamic fault trees and Markov Chains, Monte Carlo simulation has been used. An industry-based case study is presented, where critical failures of a redundant Programmable Logic Controller (PLC) system are identified by a Failure Mode and Effect Analysis (FMEA). The bottom up process of modelling control system reliability is discussed. © 2015 IEEE.
Notes on feasibility and optimality conditions of small-scale multifunction robotic cell scheduling problems with pickup restrictions
- Authors: Foumani, Mehdi , Gunawan, Indra , Smith-Miles, Kate , Ibrahim, Yousef
- Date: 2015
- Type: Text , Journal article
- Relation: IEEE Transactions on Industrial Informatics Vol. 11, no. 3 (2015), p. 821-829
- Full Text: false
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- Description: Optimization of robotic workcells is a growing concern in automated manufacturing systems. This study develops a methodology to maximize the production rate of a multifunction robot (MFR) operating within a rotationally arranged robotic cell. An MFR is able to perform additional special operations while in transit between transferring parts from adjacent processing stages. Considering the free-pickup scenario, the cycle time formulas are initially developed for small-scale cells where an MFR interacts with either two or three machines. A methodology for finding the optimality regions of all possible permutations is presented. The results are then extended to the no-wait pickup scenario in which all parts must be processed from the input hopper to the output hopper, without any interruption either on or between machines. This analysis enables insightful evaluation of the productivity improvements of MFRs in real-life robotized workcells. ©2014 IEEE.
On reliability evaluation of multistate weighted k -out-of- n system using present value
- Authors: Khorshidi, Hadi , Gunawan, Indra , Ibrahim, Yousef
- Date: 2015
- Type: Text , Journal article
- Relation: Engineering Economist Vol. 60, no. 1 (2015), p. 22-39
- Full Text: false
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- Description: A new reliability evaluation methodology for multistate weighted k-out-of-n systems is presented in this article. The present value of the cash flow generated by the system components is used as a reliability value. We take a financial view of reliability and consider functioning periods and the time value of money in system reliability analysis. Two approaches, the universal generating function (UGF) and recursive algorithm, are applied to evaluate the reliability of the multistate weighted k-out-of-n system. An illustrative example is calculated based on the proposed system reliability evaluation methodology. It is shown that this evaluation method can also be used to find the value of the maintenance policy. Finally, the UGF and recursive algorithm approaches are compared with each other for large system reliability assessment. [ABSTRACT FROM AUTHOR] Copyright of Engineering Economist is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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
- Full Text: false
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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
- Full Text: false
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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.
Resolution of deadlocks in a robotic cell scheduling problem with post-process inspection system: Avoidance and recovery scenarios
- Authors: Foumani, Mehdi , Gunawan, Indra , Smith-Miles, Kate
- Date: 2015
- Type: Text , Conference proceedings
- Relation: 2015 IEEE International Conference on Industrial Engineering and Engineering Management, Singapore, 6th-9th December, 2015. p. 1107-1111
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- Description: The phenomenon of deadlock in robotic cells has been long ignored by most scheduling literature. A deadlock situation arises if a part cannot change its current state indefinitely since the destination machine is occupied by another part. The probability of the deadlock occurrence is likely to be large when the processing route cannot be predicted with certainty due to inspection processes. Our focus here is on a specific robotic cell with a post-process inspection system where the inspection is performed on an independent inspection machine. Avoidance and recovery policies are applied to overcome deadlocks originated from this cell. We develop these policies to prevent deadlock or alternatively resolve it during the online implementation of cycles. The former policy minimizes the storage cost, whereas the later policy minimizes the expected cycle time. An analysis of the scheduling problem that involves timings and costs is also carried out for comparing policies.
Stochastic scheduling of an automated two-machine robotic cell with in-process inspection system
- Authors: Foumani, Mehdi , Smith-Miles, Kate , Gunawan, Indra , Moeini, Ashgar
- Date: 2015
- Type: Text , Conference proceedings
- Relation: 45th International Conference on Computers and Industrial Engineering, CIE 2015; Universite de Lorraine, LCOMS Metz; France; 28th-30th October 2015. In Proceedings - CIE 45: 2015 International Conference on Computers and Industrial Engineering
- Full Text: false
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- Description: This study is focused on the domain of a two-machine robotic cell scheduling problem. Particularly, we propose the first analytical method for minimizing the partial cycle time of such a cell with a PC-based automatic inspection system to make the problem more realistic. It is assumed that parts must be inspected in one of the production machines, and this may result in a rework process. The stochastic nature of the rework process prevents us from applying existing deterministic solution methods for the scheduling problem. This study aims to develop an in-line inspection of identical parts using multiple contact/non-contact sensors. Initially, we present a heuristic method that converts a multiple-sensor inspection system into a single-sensor inspection system. Then, the expected sequence times of two different cycles are derived based on a geometric distribution, and finally the maximum expected throughput is pursued for each individual case.
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
- Full Text: false
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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
- Full Text: false
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