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Zennaro, Ilenia (2017) Total productive maintenance models and tools in flow line manufacturing systems. [Ph.D. thesis]

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Abstract (english)

Productive Plants Maintenance is a strategic function of industrial realities that aims to ensure the regular functioning and good conservation of productive equipment. (OSCE, 1993); in particular, it comprehends all technical and administrative techniques, including controlling activities, that aim to restore to and/or maintain an item in a condition in which it can performed the required function (UNI9910). A company, at in a first moment, decides to invest a part of its capital in new equipment for production, to reach its core business goals and gains success; in a second moment, anyway, it is necessary to invest resources and time to guarantee its correct functioning and conservation, to satisfy the productive expectation (Pay Back).
TPM (Total Productive Maintenance) is an industrial tool that comprehends all techniques and methods that aim to optimize industrial plants effectiveness, through equipment availability improvement and making downtime and failure decrease. TPM paradigm aims to increase productivity (Productive), involving all the staff (Total), through maintenance (Maintenance). TPM benefits are well known in our industries: companies that applied these techniques registered a reduction of failures of about 50%, a reduction of production loss of about 70%, the 60% of reduction of maintenance costs and, finally, 50-90% of reduction in set-up time.
However its implementation in industrial realities it is not always so easy: it is necessary to take care to some critical factors that might influence the success of the project. In the world of automatic production systems, where the human factor is reduced and often useless, to involve people in equipment maintenance might be hard. Moreover, to align production and maintenance requirements, in order to optimize equipment availability, means to plan together production downtime, looking to satisfy the demand that is becoming more and more variable and uncertain, with shortest lead time.
In this context, this work aims to carry out a useful framework to apply TPM in automatic production systems, in particular in Food & Beverage sector, focusing on the drivers that might influence its implementation. Food Industry, in addition to peculiarities related to the automation world, is characterized by factors related to security, safety, quality and sustainability. From literature review about many case studies of TPM Implementation it arises that the application of this paradigm on industrial realities requires a very long time and a lot of resources, and its benefits are slowly to arise. What is proposed in this work is different in the way it aims to maximize and to highlight TPM benefits in a faster way; the framework, in particular, is focused on carrying out productive equipment criticalities, through the use of various tools and techniques, to optimize and arise results. Therefore, it is propose the application of the framework to a real industrial case.
Then, a second part of this work is dedicated to micro downtime analysis in automatic production flow lines. In fact, as it arises from the case study, micro downtime is the greatest cause of inefficiency in these production systems. Micro downtime can be related to technical and/or design causes, or to the normal functioning of more machines working in series with different characteristics. Sometime micro downtime inefficiency could be solved with technical solutions, if they result convenient (efficiency

improvement compared to the investment proposed); in other cases it is required to evaluate the buffer size and allocation. In fact, in this sector, machines downtime might be related to lack of product in ingress ( the upstream machine is down – starving) or the excess of product in exit (the downstream machine is down – blocked).
The Ph.D. thesis structure is the follow:
1. State of the art analysis about factors that influence TPM implementation in automatic production systems and about food and beverage sector peculiarities; the core objective is to identify an innovative and structured framework for TPM implementation; what is new in the proposed framework is the focus on accelerated and visible benefits.
2. TPM framework application to a real industrial case, in particular a bottling line. During the framework implementation, micro downtime arise as the core inefficiency.
3. State of the art analysis about Downtime in automatic production systems, focusing on micro downtime impact on production efficiency and machines availability. Improvement for these inefficiencies are proposed as: technical solutions related to the improvement of equipment effectiveness (CPI – Cost Performance Indicator) or evaluation of buffer sizing and location through a simulative model (BAP – Buffer Allocation Problem);
4. Micro downtime analysis applied to a real case study; construction of the CPI, when possible, and of a new simulative model to evaluate buffer sizing and allocation. It is proposed a new simulative model based on ad hoc micro downtime probability distribution (Weibull Distribution for each micro downtime).
This Ph.D. Thesis has been carries out in strong collaboration with Acqua Minerale San Benedetto S.p.A., that made possible the framework implementation and data collection.

Abstract (italian)

La Manutenzione degli Impianti Produttivi è una funzione strategica delle realtà industriali che ha l’obiettivo di assicurare il funzionamento regolare ed il buono stato di conservazione di questi sistemi (OSCE, 1993); in particolare, secondo la definizione UNI9910, essa comprende tutte le azioni tecniche ed amministrative, incluse le azioni di supervisione, volte a mantenere o a riportare un’entità in uno stato in cui possa eseguire la funzione richiesta. Se inizialmente un’azienda decide di investire una parte del proprio capitale nella costruzione ed avviamento di un nuovo impianto produttivo, successivamente è necessario investire tempo e risorse per il suo mantenimento, al fine di mantenere i requisiti richiesti e soddisfare le aspettative (Pay Back).
Il TPM (Total Productive Maintenance) consiste in un insieme di tecniche e strumenti che hanno la funzione di ottimizzare il mantenimento degli impianti produttivi, aumentandone l’affidabilità e riducendo fermi e guasti. Il TPM mira ad aumentare la produttività degli impianti (Productive), coinvolgendo tutto il personale (Total), attraverso la manutenzione (Maintenance). I benefici del TPM sono ormai ben noti nelle industrie: le aziende che hanno implementato tale paradigma hanno registrato una riduzione dei guasti del 50%, del 70% di produzione persa, del 60 % dei costi di manutenzione e tra il 50-90% dei tempi di set-up.
Tuttavia la sua implementazione non è sempre facile e diretta: è necessario porre attenzione ad alcuni fattori che possono pesantemente incidere sul successo del progetto. Per quanto riguarda il mondo degli impianti automatizzati, dove il fattore umano è ridotto e spesso estraneo, coinvolgere il personale nel mantenimento delle macchine può risultare difficoltoso. L’obiettivo di allineare esigenze produttive e manutentive, nell’ottica di ottimizzare l’affidabilità degli impianti, implica concordare fermi produttivi rispettando tempi di consegna sempre più ristretti con previsioni della domanda estremamente variabili; pertanto risulta evidente come ottimizzare la produzione attraverso la manutenzione possa essere un obiettivo ambizioso nelle realtà industriali.
In tale contesto si inserisce la presente trattazione, che ha l’obiettivo di proporre un framework di applicazione di tecniche di manutenzione nel contesto degli impianti automatizzati, in particolare legato al mondo del Food & Beverage. Tale settore, oltre alle peculiarità legate al mondo automatizzato, è caratterizzato da fattori di sicurezza alimentare, elevata qualità e obiettivi a sfondo ecosostenibile. Da quanto emerso in letteratura, il processo di applicazione del TPM è lungo ed impegnativo, e spesso i suoi benefici richiedono lunghi periodi per diventare tangibili. Quanto proposto in questo lavoro si differenzia dall’attuale stato dell’arte in quanto ambisce a massimizzare ed evidenziare i benefici di tale paradigma in tempi più ristretti; il framework proposto, in particolare, mira a focalizzarsi sulle criticità degli impianti produttivi, proponendo varie tecniche risolutive al fine di massimizzare i risultati e aumentarne la visibilità. E’ poi proposta l’applicazione di tale framework ad una vera realtà industriale, quale una linea di imbottigliamento.
Una seconda parte di tale lavoro è dedicata, invece, all’analisi delle micro fermate negli impianti automatizzati. Infatti, come emerso anche dal caso studio, esse rappresentano una rilevante fonte di inefficienza negli impianti automatizzati. Le microfermate possono essere di natura tecnica e/o di progetto oppure legate al normale funzionamento di più macchine con caratteristiche differenti che lavorano in sequenza. Tale inefficienza talvolta può essere risolta con soluzioni tecniche mirate e definitive, se opportunamente convenienti (recupero efficienza rispetto investimento proposto); talvolta invece è richiesta una rivalutazione del dimensionamento del Buffer tra le due stazioni di lavoro al fine di ridurre l’incisività delle micro fermate di una macchina sull’intera linea (fenomeni di starving and blocking). Nelle linee automatizzate è frequente che una macchina si trovi nelle condizioni di non poter operare per mancanza di input (starving) o per eccesso di output (blocking).
La tesi è suddivisa in quattro fasi:
1. Analisi dello stato dell’arte dei fattori che hanno influenzato l’implementazione della TPM nei sistemi automatizzati e delle peculiarità dell’industria alimentare al fine di identificare un modello di implementazione strutturato ed innovativo; la differenza dallo stato attuale è il focus su risultati accelerati e visibili.
2. Applicazione del modello ad un impianto di imbottigliamento; individuazione delle micro fermate come causa impattante di inefficienza produttiva.
3. Analisi dello stato dell’arte sui Downtime negli impianti automatizzati, focalizzandosi sull’impatto delle micro fermate sull’efficienza produttiva ed affidabilità del sistema. Proposte di miglioramento di tali inefficienze: Soluzione tecniche mirate con modello di recupero di efficienza produttiva (CPI – Cost Performance Indicator) o rivalutazione del dimensionamento dei buffer (BAP – Buffer Allocation Problem).
4. Analisi mirata delle micro fermate di una stazione di lavoro critica e relativa costruzione del modello simulativo per valutare il dimensionamento di un buffer. Tale modello risulta innovativo in quanto è basato su distribuzioni di Weibull personalizzate per ogni tipologia di micro fermata.
Tale progetto di ricerca è stato svolto grazie alla collaborazione con Acqua Minerale San Benedetto S.p.A., che ha reso possibile l’implementazione del modello e la raccolta dei dati.

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EPrint type:Ph.D. thesis
Tutor:Battini, Daria
Ph.D. course:Ciclo 29 > Corsi 29 > INGEGNERIA MECCATRONICA E DELL'INNOVAZIONE MECCANICA DEL PRODOTTO
Data di deposito della tesi:28 January 2017
Anno di Pubblicazione:January 2017
Key Words:Microfermate / Microdowntime TPM: Total Productive Maintenance linee di produzione automatizzate / Automatic production lines Linea di imbottigliamento / bottling line Food and beverage
Settori scientifico-disciplinari MIUR:Area 09 - Ingegneria industriale e dell'informazione > ING-IND/17 Impianti industriali meccanici
Struttura di riferimento:Dipartimenti > Dipartimento di Tecnica e Gestione dei Sistemi Industriali
Codice ID:9957
Depositato il:02 Nov 2017 17:07
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Bibliografia

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Le url contenute in alcuni riferimenti sono raggiungibili cliccando sul link alla fine della citazione (Vai!) e tramite Google (Ricerca con Google). Il risultato dipende dalla formattazione della citazione.

Chapter 1 References Cerca con Google

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Chapter 2 References Cerca con Google

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[5] Andemeskel, Filmon. "Total Productive Maintenance Implementation Procedures in Manufacturing Organizations Using Axiomatic Design Principles." International Conference on Axiomatic Design, Worcester–June 27-28, 2013. ICAD, 2013. Cerca con Google

[6] Azzi A., Sgarbossa F., Battini D., Persona A., Akkerman R. (2011) "Manufacturing Execution Systems in the Food Proceedings" International Workshop on Food Supply Chain, June 26-29 Cerca con Google

[7] Baglee, David, and Michael Knowles. "Maintenance strategy development within SMEs: the development of an integrated approach." Control and Cybernetics 39.1 (2010): 275-303. Cerca con Google

[8] Bamber C.J., Sharp J.M., Hides M.T. (1999) "Factors affecting successful implementation of total productive maintenance; a UK manufacturing case study perspective" Journal of Quality in Maintenance Engineering, Vol. 5, No. 3 pp. 162-181. Cerca con Google

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[12] Catena, Marco, Alessandro Persona, and Bianca Rimini. "Accelerated TPM by simulation." SIMULATION SERIES 36.2 (2004): 3. Cerca con Google

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Chapter 3 References Cerca con Google

[1] Adam, Everett E., et al. "An international study of quality improvement approach and firm performance." International Journal of Operations & Production Management 17.9 (1997): 842-873. Cerca con Google

[2] Ahuja, I. P. S., and Pankaj Kumar. "A case study of total productive maintenance implementation at precision tube mills." Journal of Quality in Maintenance Engineering 15.3 (2009): 241-258. Cerca con Google

[3] Ahujia I.P.S., Khamba J.S. (2008) “Strategies and success factors for overcoming challenges in TPM implementation in Indian manufacturing industry”, Journal of Quality in Maintenance Engineering, Vol. 14, No. 2, pp. 123-147. Cerca con Google

[4] Ahujia I.P.S., Khamba J.S. (2008) “Total Productive Maintenance: literature review and directions” International Journal of Quality & Reliability Management, Vol. 25, No. 7, pp. 709-756. Cerca con Google

[5] Andemeskel, Filmon. "Total Productive Maintenance Implementation Procedures in Manufacturing Organizations Using Axiomatic Design Principles." International Conference on Axiomatic Design, Worcester–June 27-28, 2013. ICAD, 2013. Cerca con Google

[6] Azzi A., Sgarbossa F., Battini D., Persona A., Akkerman R. (2011) "Manufacturing Execution Systems in the Food Proceedings" International Workshop on Food Supply Chain, June 26-29 Cerca con Google

[7] Baglee, David, and Michael Knowles. "Maintenance strategy development within SMEs: the development of an integrated approach." Control and Cybernetics 39.1 (2010): 275-303. Cerca con Google

[8] Bamber C.J., Sharp J.M., Hides M.T. (1999) "Factors affecting successful implementation of total productive maintenance; a UK manufacturing case study perspective" Journal of Quality in Maintenance Engineering, Vol. 5, No. 3 pp. 162-181. Cerca con Google

[9] Barberá, Luis, et al. "Advanced model for maintenance management in a continuous improvement cycle: integration into the business strategy."International Journal of System Assurance Engineering and Management 3.1 (2012): 47-63. Cerca con Google

[10] Ben-Daya M. (2000) "You may need RCM to enhance TPM implementation" Journal of Quality in Maintenance Engineering, Vol. 6, No. 2 pp. 82-85. Cerca con Google

[11] Blanchard B.S. (1997) "An enhanced approach for implementing total productive maintenance in the manufacturing environment" Journal of Quality in Maintenance Engineering, Vol. 3, No. 2 pp. 69-80. Cerca con Google

[12] Catena, Marco, Alessandro Persona, and Bianca Rimini. "Accelerated TPM by simulation." SIMULATION SERIES 36.2 (2004): 3. Cerca con Google

[13] Chan F.T.S., Lau H.C.W., Ip R.W.L., Chan H.K., Kong S. (2005) "Implementation of total productive maintenance: A case study" International Journal of Production Economics, 95 pp. 71-94. Cerca con Google

[14] Chand, G., and B. Shirvani. "Implementation of TPM in cellular manufacture." Journal of Materials Processing Technology 103.1 (2000): 149-154. Cerca con Google

[15] Cigolini R., Turco F. (1997) "Total Productive Maintenance: a survey in Italy" Journal of Quality in Maintenance Engineering, Vol. 3, No. 4 pp. 259-272. Cerca con Google

[16] Co H.C., Patuwo B.E., Hu M.Y. (1998) "The human factor in advaced manufacturing technology adoption; an empirical analysis", International Journal of Operations & Production Management, Vol. 18, No. 1, pp. 87-106. Cerca con Google

[17] Cooke F.L. (2000) "Implementing TPM in plant maintenance: some organizational barriers", International Journal of Quality & Reliability Management, Vol. 17, No. 9, pp. 1003-1016. Cerca con Google

[18] Crosio D. (2007) "TPM in una linea di imbottigliamento; strategie, implementazione e realizzazione", Manutenzione, Tecnica e Management - Maggio 2007. Cerca con Google

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Chapter 5 References Cerca con Google

[1] Adebiyi, K. A., Ojediran, J. O., & Oyenuga, O. A. (2004). An appraisal of maintenance practice in food industries in Nigeria. Journal of food engineering,62(2), 131-133. Cerca con Google

[2] Al-Hawari, T., Aqlan, F., Al-Buhaisi, M. A., & Al-Faqeer, Z. (2010, January). Simulation-based analysis and productivity improvement of a fully automatic bottle-filling production system: a practical case study. In Computer Modeling and Simulation, 2010. ICCMS'10. Second International Conference on (Vol. 4, pp. 195-199). IEEE. Cerca con Google

[3] Andersson, C., & Bellgran, M. (2015). On the complexity of using performance measures: Enhancing sustained production improvement capability by combining OEE and productivity. Journal of Manufacturing Systems, 35, 144-154. Cerca con Google

[4] Arturo Garza-Reyes, J., Eldridge, S., Barber, K. D., & Soriano-Meier, H. (2010). Overall equipment effectiveness (OEE) and process capability (PC) measures: a relationship analysis. International Journal of Quality & Reliability Management, 27(1), 48-62. Cerca con Google

[5] Battini, Daria, Alessandro Persona, and Alberto Regattieri. "Buffer size design linked to reliability performance: A simulative study." Computers & Industrial Engineering 56.4 (2009): 1633-1641. Cerca con Google

[6] Battini, Daria, et al. "Buffer design for availability: a new simulative study in case of infant and random failures." International Journal of Services and Operations Management 14.2 (2013): 157-174. Cerca con Google

[7] Brah, S. A., & Chong, W. K. (2004). Relationship between total productive maintenance and performance. International Journal of Production Research,42(12), 2383-2401. Cerca con Google

[8] De Carlo, F., Arleo, M. A., & Tucci, M. (2014). OEE Evaluation of a Paced Assembly Line through Different Calculation and Simulation Methods: A Case Study in the Pharmaceutical Environment. International Journal of Engineering Business Management, 6. Cerca con Google

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[12] Huang, S. H., Dismukes, J. P., Shi, J., Su, Q., Razzak, M. A., Bodhale, R., & Robinson, D. E. (2003). Manufacturing productivity improvement using effectiveness metrics and simulation analysis. International Journal of Production Research, 41(3), 513-527. Cerca con Google

[13] Huang, S. H., Dismukes, J. P., Shi, J., Su, Q., Wang, G., Razzak, M. A., & Robinson, D. E. (2002). Manufacturing system modeling for productivity improvement. Journal of Manufacturing Systems, 21(4), 249-259. Cerca con Google

[14] Liberopoulos, G., & Tsarouhas, P. (2005). Reliability analysis of an automated pizza production line. Journal of Food Engineering, 69(1), 79-96. Cerca con Google

[15] Manzini, Riccardo, and Alberto Regattieri. Manutenzione dei sistemi di produzione. Società Editrice Esculapio, 2008. Cerca con Google

[16] Ohunakin, O. S., & Leramo, R. O. (2012). Total productive maintenance implementation in a beverage industry: A Case Study. Journal of Engineering and Applied Science, 7(2), 128-133 Cerca con Google

[17] Patti, A. L., & Watson, K. J. (2010). Downtime variability: the impact of duration–frequency on the performance of serial production systems.International Journal of Production Research, 48(19), 5831-5841. Cerca con Google

[18] Rahman, C. M., Hoque, M. A., & Uddin, S. M. (2014). Assessment of Total Productive Maintenance Implementation through Downtime and Mean Downtime Analysis (Case study: a Semi-automated Manufacturing Company of Bangladesh). Assessment, 4(09). Cerca con Google

[19] Regattieri, A., Manzini, R., & Battini, D. (2010). Estimating reliability characteristics in the presence of censored data: A case study in a light commercial vehicle manufacturing system. Reliability Engineering & System Safety, 95(10), 1093-1102. Cerca con Google

[20] S. Al-Chalabi, H., Lundberg, J., Wijaya, A., & Ghodrati, B. (2014). Downtime analysis of drilling machines and suggestions for improvements. Journal of Quality in Maintenance Engineering, 20(4), 306-332. Cerca con Google

[21] Tsarouhas, P. (2007). Implementation of total productive maintenance in food industry: a case study. Journal of Quality in Maintenance Engineering, 13(1), 5-18. Cerca con Google

[22] Tsarouhas, P. H. (2013). Equipment performance evaluation in a production plant of traditional Italian cheese. International Journal of Production Research,51(19), 5897-5907. Cerca con Google

[23] Tsarouhas, P. H. (2013). Evaluation of overall equipment effectiveness in the beverage industry: a case study. International Journal of Production Research,51(2), 515-523. Cerca con Google

[24] Tsarouhas, P. H., & Arvanitoyannis, I. S. (2010). Assessment of operation management for beer packaging line based on field failure data: A case study.Journal of food engineering, 98(1), 51-59. Cerca con Google

[25] Tsarouhas, P. H., & Arvanitoyannis, I. S. (2014). Yogurt production line: reliability analysis. Production & Manufacturing Research, 2(1), 11-23. Cerca con Google

[26] Tsarouhas, P. H., Arvanitoyannis, I. S., & Ampatzis, Z. D. (2009). A case study of investigating reliability and maintainability in a Greek juice bottling medium size enterprise (MSE). Journal of food engineering, 95(3), 479-488. Cerca con Google

[27] Tsarouhas, P. H., Arvanitoyannis, I. S., & Varzakas, T. H. (2009). Reliability and maintainability analysis of cheese (feta) production line in a Greek medium-size company: A case study. Journal of Food Engineering, 94(3), 233-240. Cerca con Google

[28] Tsarouhas, P. H., Arvanitoyannis, I. S., & Varzakas, T. H. (2009). Reliability and maintainability analysis of cheese (feta) production line in a Greek medium-size company: A case study. Journal of Food Engineering, 94(3), 233-240. Cerca con Google

[29] Tsarouhas, P. H., Varzakas, T. H., & Arvanitoyannis, I. S. (2009). Reliability and maintainability analysis of strudel production line with experimental data–a case study. Journal of food engineering, 91(2), 250-259 Cerca con Google

[30] Xie, X., & Li, J. (2012). Modeling, analysis and continuous improvement of food production systems: A case study at a meat shaving and packaging line.Journal of food engineering, 113(2), 344-350. Cerca con Google

[31] Zhu, X. (2011, September). Analysis and improvement of enterprise's equipment effectivenessbased on OEE. In Electronics, Communications and Control (ICECC), 2011 International Conference on (pp. 4167-4171). IEEE. Cerca con Google

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