Total Productive Maintenance

In this first comprehensive departure from the time-and-motion dictums of Frederick Taylor's "Shop Management" that have influenced management practices for most of this century, Kiyoshi Suzaki offers a framework for successfully conducting business at its most crucial point-the shop floor Drawing on the principles of holistic management, where organizational boundaries are smashed and co-destiny is created, Suzaki demonstrates how modern shop floor management techniques -- focusing maximum energy on the front line -- can lead to dramatic improvements in productivity and valueadded-to-services The role of management today, Suzaki argues, is to eliminate its own responsibilities by thinking of the organization from the "genba, " or shop floor, point of view In this challenge, Suzaki claims, organizations need to collect the wisdom of people by practicing "Glass Wall Management," where organizations become transparent, enabling employees to contribute maximum creativity as opposed to blocking their potential with what he calls "Brick Wall Management" Further, to empower individuals to selfmanage their work and satisfy their customers, Suzaki asserts that they all should learn to manage their own "mini-company," where everybody is considered president of his or her area of responsibility Front-line supervisors, Suzaki shows, must develop a mission and goals and share them both up and downstream He cites examples of the "shop floor point of view" -- McDonald's Corporation's legal staff learning how to sell hamburgers and fix milkshake machines; Honda's human resource staff training on the assembly line -- that narrow the gap between top management and the shop floor By upgrading people's skills, focusing on empowerment, and streamlining processes, Suzaki illustrates that an organization will realize concrete improvements in quality, cost, delivery, safety, morale, and ultimately, its competitive position

The new shop floor management : empowering people for continuous improvement

Production rescheduling review: Opportunities for industrial integration and practical applications

Integrated product development is comprised of CAD, process planning and CNC code generation based on an integrated data structure. To make various CAD/CAM software solutions with different internal product data structures interoperable, it is necessary to realise reliable and robust information exchange capability in a manufacturing environment. To enable interoperability amongst integrated product development processes, management of collaboration of diverse CAD/CAM software packages is of outmost importance. In this article, the fundamental requirements for achieving interoperability and collaboration management in an integrated, enterprise-wide, product development process environment are discussed. Based on these requirements, the present prominent integrated, interoperable and collaborative CAD/CAM information system platforms are comparatively reviewed. There are two main paradigms for development of such platforms-viz. neutral-file based and procedure based. The merits and limitations of each paradigm are discussed. To overcome the limitations of the current present platforms, a three-layered integrated and interoperable platform, named INFELT STEP, for collaborative and interoperable product design/development using different and diverse CAD/CAPP/CAM/CNC software is proposed. This platform conjugates the capabilities of both main paradigms to eliminate their limitations. The layered structure of INFELT STEP caters for the requirements of an integrated, interoperable and collaborative computer-based manufacturing and supports the entire range of software packages in the CAD/CAPP/CAM product development chain. In this platform, each software package can send product data based on its own internal data structures to other packages that are linked to and communicate with this platform. Different layers of INFELT STEP convert software packages' processed data to its structured data models, which are based on the STEP standard-and then store them in its database. Conversely, INFELT STEP layers can retrieve structured data stored in its database and convert them to the format acceptable by a specific CAD/CAM/CAPP software package that is cooperating in a production workflow. This proposed platform manages the collaboration of CAD/CAM software packages, maintains the integration of CAD/CAM/CNC operations based on STEP data models, and also enables interoperability of such packages with different local data structures. The capabilities of INFELT STEP are demonstrated by using it in a prototype implementation.

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INFELT STEP: An integrated and interoperable platform for collaborative CAD/CAPP/CAM/CNC machining systems based on STEP standard

A new information exchange method named recursive propagation is proposed in order to solve job shop scheduling problems in decentralized manufacturing systems. Each machine only has to notify the change of its plan to other machines which are directly influenced by the change. The effect of the change in the plan is directly fed back to the machine which notified the change. The change in the plan is notified to all the machines concerned by simple one-to-one communication among the machines, and the influence of the change caused by its action can be reported to the initiator through the same communication path. The proposed method is applied to a 20×10 job shop scheduling problem, and the feasibility of this approach is verified by simulations.

Decentralized Job Shop Scheduling by Recursive Propagation Method

This paper deals with Flexible Manufacturing System (FMS) production rescheduling due to unavailability of cutting tools caused either of cutting tool failure or life time limit. The FMS consists of parallel identical machines integrated with an automatic material handling system and it runs fully automatically. Each machine has a same cutting tool configuration that consists of different geometrical cutting tool types on each tool magazine. The job usually takes two stages. Each stage has sequential operations allocated to machines considering the cutting tool life. In the real situation, the cutting tool can fail before the cutting tool life is reached. The objective in this paper is to develop a dynamic scheduling algorithm when a cutting tool is broken during unmanned and a rescheduling needed. The algorithm consists of four steps. The first step is generating initial schedule, the second step is determination the cutting tool failure time, the third step is determination of system status at cutting tool failure time and the fourth step is the rescheduling for unfinished jobs. The approaches to solve the problem are complete-reactive scheduling and robust-proactive scheduling. The new schedules result differences starting time and completion time of each operations from the initial schedule.

https://iopscience.iop.org/article/10.1088/1757-899X/114/1/012052/pdf

An FMS Dynamic Production Scheduling Algorithm Considering Cutting Tool Failure and Cutting Tool Life

This paper deals with an object-oriented modeling of an autonomous distributed manufacturing system and its application to the production scheduling. The architecture of the autonomous distributed manufacturing systems is discussed from the viewpoint of information processing in the manufacturing system. An object-oriented modeling method is applied to describe the decision-making activities and the communication activities of the components, such as the manufacturing devices and the workpieces. The activities of the objects are discussed in detail from the viewpoint of the production scheduling. The contents of the objects are clarified, and the part-of relations and the is-a relations between the objects are also established. A distributed production scheduling method is proposed on the basis of the autonomous decision making of the individual components and their coordinations.

Design and Management of Autonomous Distributed Manufacturing System. Modeling and Application to Production Scheduling.

This paper presents overviews about reliability and maintainability of equipment especially for job-shop manufacturing systems. The job shop industry has the characteristics of a more dynamic production than flow shop industries, where products with a variety of great but small amounts. Its dynamic condition certainly contributes directly to the failure rate and reliability growth of equipment. Therefore, proper maintenance should be done as the reliability improvement. Stages of reliability improvement are reliability modeling, reliability analysis and maintenance optimization. This stage is based on reliability growth of equipment that is indicated the deterioration process of failure components, it can be build from maintenance data history or condition data monitoring.. Cost is often considered in points of a maintenance schedule. This cost was affected by minimizing the negative effects of maintenance and maximizing the benefit of production. The attention at reliability and maintenance optimization is a well researches area until now. This paper presents a brief review of existing reliability and maintenance research. Several reliable methods in this area are discussed and maintenance on job-shop industry as future prospects is investigated. It is shown in this paper that some aspect in the area of maintenance on job-shop industry steel needs to be deeply developed.

Maintenance on Job Shop Industry: Review and Analysis

This paper presents an object-oriented modelling approach to production scheduling for FMS. The purpose of this study is to prepare a simulation tool to try a method of production scheduling that allocates jobs to the machines and cutting tools in an FMS. This model is developed by using Pharo as the language software for object-oriented programming through UML system design. This model consists of three types of classes. The first type is the Equipment-class, which related to the physical equipment in the FMS, for example machining-centers, cutting tools, pallet stocker, stacker crane. The second type is the Product-class that related to the information how to process the product. This class has sub-class such as process plan, machining operation and required cutting tools. The third class is the Production Planning and Controlling (PPC) class, which related to create the schedule to equipment. The PPC-class has sub-classes such as the daily order or job, job sequence, job allocation on machine and scheduling methods. A numerical example is provided in this paper to show that the object-oriented model for FMS and production scheduling is verified. The FMS consist of four identical machining centers and eight jobs. Each job has a process plan that requires some specific cutting tool types. The method for production scheduling in this model is Shortest Processing Time (SPT). The production scheduling performance is measured in this model.

An Object-Oriented Modelling of Production Scheduling for Flexible Manufacturing System

The purpose of this study was to improve the accuracy of three-axis CNC Milling Vertical engines with a general approach by using mathematical modeling methods of machine tool geometric errors. The inaccuracy of CNC machines can be caused by geometric errors that are an important factor during the manufacturing process and during the assembly phase, and are factors for being able to build machines with high-accuracy. To improve the accuracy of the three-axis vertical milling machine, by knowing geometric errors and identifying the error position parameters in the machine tool by arranging the mathematical modeling. The geometric error in the machine tool consists of twenty-one error parameters consisting of nine linear error parameters, nine angle error parameters and three perpendicular error parameters. The mathematical modeling approach of geometric error with the calculated alignment error and angle error in the supporting components of the machine motion is linear guide way and linear motion. The purpose of using this mathematical modeling approach is the identification of geometric errors that can be helpful as reference during the design, assembly and maintenance stages to improve the accuracy of CNC machines. Mathematically modeling geometric errors in CNC machine tools can illustrate the relationship between alignment error, position and angle on a linear guide way of three-axis vertical milling machines.

https://iopscience.iop.org/article/10.1088/1757-899X/319/1/012015/pdf

Yatna Yuwana Martawirya

Papers

An FMS Dynamic Production Scheduling Algorithm Considering Cutting Tool Failure and Cutting Tool Life

Design and Management of Autonomous Distributed Manufacturing System. Modeling and Application to Production Scheduling.

Maintenance on Job Shop Industry: Review and Analysis

An Object-Oriented Modelling of Production Scheduling for Flexible Manufacturing System

Modeling of Geometric Error in Linear Guide Way to Improved the vertical three-axis CNC Milling machine’s accuracy