 Failure – The termination of ability of an item to perform a required function. Reliability: The reliability of the machine is a very important if the machine has to find the huge market in the business. The Japanese are succeeding at this because they have an integrated view of manufacturing as a system. Hence the right at the time of designing reliability and durability should be given priority. While this does not mean that U.S. end-users should do all equipment design in-house, it does suggest the need for drastic improvement of in-, house knowledge bases. One factor that can influence a test score is the test taker’s alertness and concentration on the day of the test. Procurement specifications have been upgraded to require that all key process equipment suppliers have a basic level of ERM expertise. 3. Additional capacity can be made available in many cases by increasing equipment utilization rates rather than by adding units of equipment. The ERM programs of several U.S. and Japanese manufacturers are outlined in the following paragraphs. Similar results are being achieved in old as well as new factories throughout Japan. Die change time, which necessarily represents scheduled machine downtime, is a critical element of overall operating performance, and rapid, efficient die changing is a key basis of competition in stamping operations. At the early design stage, Reliability Predictions enable you to perform an assessment of likely failure rate characteristics. If few numbers of machines are to be manufactured then expensive materials and high production costs can be considered, but for the mass production economy of the machine should be top priority. Results of these performance comparisons are published in the trade press. Japanese efforts in this area have dramatically improved quality, lowered cost, and reduced plant breakdowns from 10 percent to as little as 1 percent of previous levels within three years. Restoration of apprenticeship programs and manufacturing laboratories. They more than compensate for the difference in speed through rapid, capable die changing, steady, reliable operation, and disciplined operating procedures. A Strategic Industry at Risk. An overkill mentality and inappropriate measurement systems have fostered inefficient use of resources. Click here to buy this book in print or download it as a free PDF, if available. Light weight and minimum dimensions: The machine elements and machine should be strong, rigid and wear resistant with minimum weight and least dimensions. maximum applied pure bending stress. U.S. aircraft engine manufacturers, for example, focused on ERM to achieve greater reliability requested by the customers. Without a measurement system that can quantify relationships between engineering work and profit/asset benefits, assess the costs of equipment waiting (e.g., load, unload, operator, material) and downtime, and allocate maintenance costs to reflect reality, results will be anecdotal and perception of the basis for changing the incentive structure will remain shaky. Sensors monitor the condition and performance of equipment throughout the manufacturing system and feed back relevant data to system controllers that interact with technically sophisticated human operators who use the data to maximize throughput, effect timely maintenance, and recover promptly from equipment failure. The optimal maintenance and reliability program for a plant provides the right maintenance on the right assets at the right time. This in turn requires design-out maintenance. Software maintenance and lack of skills have emerged as major contributors to the perception that mechatronic equipment is less reliable than electromechanical equipment. A machine running 24/7 might experience the failure mode of fatigue as it nears the end of its life. Present problems need to be resolved at a practical level, while high-technology approaches to ERM are developed in the next generation of equipment. It should not be guided by the all-too-common inclination to move ahead by leapfrogging to the next high-technology plateau. The final, or establishment, stage calls for (1) making the new ERM strategy the norm for conducting business and (2) providing a process for continuous improvement. Executive management awareness of present ERM practice in the United States and abroad, and its importance for competitiveness. Effective management of ERM requires realistic awareness of the benefits of and necessary decisions related to ERM, the technical knowledge that will permit managers to make appropriate. This is true even of smaller companies. One relates to people, the other to equipment (Table 3-4). They will not begin to address these issues, however, unless they are convinced of the importance of ERM for competitiveness. The number of faults presents in the software 2. The task will require a major departure from the traditional lines of demarcation between the trades necessitating, in essence, a cultural change—probably the most difficult problem U.S. industry faces. Lacking strength in manufacturing systems engineering, many plants rely on system integrators distinct from the equipment builders to configure their manufacturing systems. Reliability, availability, and serviceability - RAS, for short - are considered to be important aspects to design into any system. ERM issues will not be addressed unless management chooses to address them. Results in trial fabrication plants for both wafer etch and implanter equipment show a substantial increase in average monthly uptime and increased predictability by reducing the range of monthly. As a result, it is difficult to make comparisons, share results and good practices among cooperating operations, and measure ERM performance trends in any one factory in a universally credible way. Durability : The longer the life of the machine more it develops the reputation of being the dependable machine and more will be its sale. In contrast to design engineers who, because they are charged in most cases directly to a product, are viewed as contributors, manufacturing engineers and skilled workers are considered manufacturing overhead and, hence, as opportunities for cost reduction. A standard methodology for measuring the performance of ERM is needed, as is a way to quantify the benefits of ERM for top management. There are two commonly used measures of reliability: * Mean Time Between Failure (MTBF), which is defined as: total time in service / number of failures To search the entire text of this book, type in your search term here and press Enter. In 1989 alone, 51 companies were recognized by the Japan Institute for Plant Maintenance for achieving a level of performance in total productive maintenance that placed them on par with the Nishio factory. effectively promote ERM, a clear and strong initiative is needed to identify what needs to be changed, what the objective should be, and how to make the change, in order to have an immediate and significant impact with lasting effects. The panel has ranked research needs in ERM within two broad categories. Show this book's table of contents, where you can jump to any chapter by name. Number of machines to be built: Designing of the machine will depend a lot on the number of machines to be manufactured. The Japanese have done it by adhering to the basic principles of motivation, commitment and understanding, and training and discipline. The strategy was implemented in four stages. Many books are written about machine design. Reliability:This highlights performance of product or system within a known set of parameters. Reliability is a measure of the probability that an item will perform its intended function for a specified interval under stated conditions. In firms whose management understands facility issues, including the implications of ERM efforts, just-in-time (JIT)1 is less a measure of inventory than an indication that all processes are under control. Of JIT to realize the potential benefits of using simulation methodology during process design reliability... 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