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Several risk assessment techniques have been presented and investigated in previous research, focusing mainly on the failure mode and effect analysis (FMEA). FMEA can be employed to determine where failures can occur within industrial systems and to assess the impact of such failures. This research proposes a novel methodology for hazard analysis and risk assessments that integrates FMEA with the bow-tie model. The proposed method has been applied and evaluated in a real industrial process, illustrating the effectiveness of the proposed method. Specifically, the bowtie diagram of the critical equipment in the adopted plant in the case study was built. Safety critical barriers are identified and each of these is assigned to industrial process with an individual responsible. The detection rating to the failure mode and the values of risk priority number (RPN) are calculated. The analysis shows the high values of RPN are 500 and 490 in this process. A global corrective actions are suggested to improve the RPN measure. Further managerial insights have been provided.

This paper describes the application of reliability-centered maintenance methodology to the development of maintenance plan for a steam-process plant. The main objective of reliability-centered maintenance is the cost-effective maintenance of the plant components inherent reliability value. The process-steam plant consists of fire-tube boiler, steam distribution, dryer, feed-water pump and process heater. Within this context, a maintenance program for the plant is carried out based on this reliability-centered maintenance concept. Applying of the reliability-centered maintenance methodology showed that the main time between failures for the plant equipments and the probability of sudden equipment failures are decreased. The proposed labor program is carried out. The results show that the labor cost decreases from 295200 $/year to 220800 $/year (about 25.8% of the total labor cost) for the proposed preventive maintenance planning. Moreover, the downtime cost of the plant components is investigated. The proposed PM planning results indicate a saving of about 80% of the total downtime cost as compared with that of current maintenance. In addition, the proposed spare parts programs for the plant components are generated. The results show that about 22.17% of the annual spare parts cost are saved when proposed preventive maintenance planning other current maintenance once. Based on these results, the application of the predictive maintenance should be applied.

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In this paper, a generalized mathematical model formulation for Cellular Manufacturing System (CMS) using Hierarchical Production Planning (HPP) approach, which is a methodology to introduce the planning process by a series of mathematical models, is proposed. Particularly, the main objective of the CMS is to obtain the optimum method and this optimum method helps to solve the problem of minimizing the variable production costs (production cost, cells setup cost, inventory holding cost and regular capacity cost). Subsequently, the model is applied to two different real case studies and is solved by using operation research optimization software (Lingo-12.0 program). The model is divided into three main steps as follows: data collection, mathematical model formula, and results. The proposed mathematical model of the optimization can solve the problems of the system under utilizing the limited resources in a production plan. To prove the applicability of the proposed model, two real case studies are introduced. The results show generally that the proposed mathematical model can be used to minimize manufacturing total costs of products for similar cases. Specifically, for the first case (Electric Water Heater with capacity 50 liter (EWH1)); the results show that the total cost decreases by 8.46 % for the optimum conditions. In addition, for the second case, (Electric Water Heater with capacity 80 liter (EWH2)); the results indicate that the total cost decreases by 3.7% for the optimum conditions.