* Starting from Need* Evolution of the Toyota Production System* Further Development* Genealogy of the Toyota Production System* The True Intention of the Ford System* Surviving the Low-Growth Period

Toyota production system : beyond large-scale production

Machinery health prognostics: A systematic review from data acquisition to RUL prediction

It is considered by many that for industry to prosper into the 1990s it must adopt the principles of total quality control. These principles offer the opportunity to tap previously unused brainpower within an organisation, and to achieve what our potential overseas customers expect of us, that is, a guaranteed 100 per cent good product. This paper presents one company's ideas and methods of implementation. Tqc is very much a people thing, and requires employees at all levels to become familiar with, and practise basic charting and problem solving techniques. Economics do not allow us to load up our organisations with service departments. Quality must be controlled by the people at the workface (a).

Total quality control

The geometric error in the surface grinding process is mainly affected by the thermal effect and the stiffness of the grinding system. For minimizing the geometric error, the selection of grinding parameters is very important. This paper presented an application of Taguchi and response surface methodologies for the geometric error. The effect of grinding parameters on the geometric error was evaluated and optimum grinding conditions for minimizing the geometric error were determined. A second-order response model for the geometric error was developed and the utilization of the response surface model was evaluated with constraints of the surface roughness and the material removal rate. Confirmation experiments were conducted at an optimal condition and selected two conditions for observing accuracy of the developed response surface model.

Application of Taguchi and response surface methodologies for geometric error in surface grinding process

Prognostics and health management is an emerging discipline to scientifically manage the health condition of engineering systems and their critical components. It mainly consists of three main aspects: construction of health indicators, remaining useful life prediction, and health management. Construction of health indicators aims to evaluate the system’s current health condition and its critical components. Given the observations of a health indicator, prediction of the remaining useful life is used to infer the time when an engineering systems or a critical component will no longer perform its intended function. Health management involves planning the optimal maintenance schedule according to the system’s current and future health condition, its critical components and the replacement costs. Construction of health indicators is the key to predicting the remaining useful life. Bearings and gears are the most common mechanical components in rotating machines, and their health conditions are of great concern in practice. Because it is difficult to measure and quantify the health conditions of bearings and gears in many cases, numerous vibration-based methods have been proposed to construct bearing and gear health indicators. This paper presents a thorough review of vibration-based bearing and gear health indicators constructed from mechanical signal processing, modeling, and machine learning. This review paper will be helpful for designing further advanced bearing and gear health indicators and provides a basis for predicting the remaining useful life of bearings and gears. Most of the bearing and gear health indicators reviewed in this paper are highly relevant to simulated and experimental run-to-failure data rather than artificially seeded bearing and gear fault data. Finally, some problems in the literature are highlighted and areas for future study are identified.

Prognostics and Health Management: A Review of Vibration Based Bearing and Gear Health Indicators

https://web.iitd.ac.in/~mskulkarni/Papers/Divya/DP_2011_CIE.pdf

A methodology for joint optimization for maintenance planning, process quality and production scheduling

Combined Taguchi and dual response method for optimization of a centerless grinding operation

Weibull accelerated failure time regression model for remaining useful life prediction of bearing working under multiple operating conditions

Performance of a manufacturing system depends on its ability to simultaneously meet several requirements such as: quick response to market demand, high product quality, low manufacturing costs and timely deliveries; which in turn strongly depend on performance at the shop floor level. In the past, the shop floor level operational policies in the context of scheduling, maintenance and quality have been examined in isolation. However, it is hypothesised that these three aspects of operations planning may also have some interaction effect and hence joint consideration of various policy options pertaining to quality, maintenance and scheduling on the performance of the manufacturing system is an important area for investigation. In this paper, a review of literature addressing the joint consideration of these three aspects is presented and research gaps are highlighted. As a preliminary work, some numerical investigations are also presented to highlight the importance of joint consideration of these three aspects. Finally, a conceptual methodology is presented that can lead to further developments in this field. Some potential research areas in this context are identified.

https://web.iitd.ac.in/~mskulkarni/Papers/Divya/DP_2010_IJAOM.pdf

Makarand S. Kulkarni

Papers

A methodology for joint optimization for maintenance planning, process quality and production scheduling

Combined Taguchi and dual response method for optimization of a centerless grinding operation

Weibull accelerated failure time regression model for remaining useful life prediction of bearing working under multiple operating conditions

Joint consideration of production scheduling, maintenance and quality policies: a review and conceptual framework

Bearing diagnosis based on Mahalanobis–Taguchi–Gram–Schmidt method