Failure Modes and Effects Analysis (FMEA) of Computerized Numerical Control (CNC) Turning Center

Patil, Rajkumar Bhimgonda; Kothavale, B. S.

doi:10.15866/ireme.v12i1.14156

Cited by 8 publications

(8 citation statements)

References 12 publications

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“…Dedimas et al [15] researched at Ethiopia textile Share Company, using FMEA method, as a result, the company could reduce downtime and saving cost 11,466,168.00 ETB annually. FMEA methodology was used by CNC turning producer to analyze the risk involved in the operation of CNC turning center in India, by identifying critical failure modes, components and sub-systems in order to increase the quality and reliability of CNC turning center [16]. The Pareto chart is used as an important tool to identify the most significant defects by giving priority [17].…”

Section: Figure 1 World Car Sales 2015-2018mentioning

confidence: 99%

Increasing Overall Equipment Effectiveness in Automotive Company Using DMAIC and FMEA Method

Rozak¹,

Jaqin²,

Hasbullah³

2020

JESA

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Cylinder Block Machining Line in Indonesian automotive company has launched a worldclass company, but this company still has intention to increase the OEE value. The aim of this research was to show the application of Failure Mode and Effect Analysis (FMEA) for increasing OEE value using the DMAIC cycle (Define, Measure, Analyze, Improve and Control). Others tool to analyze this problem were Pareto Diagram and Cause and Effect Diagram. Before improvement condition, the availability average value was 90.5% from the total of production loading time. FMEA was one of tool to select the priority of the production problem that should be taken action, so it could improve the industrial operating system from the long time and frequent breakdown equipment base on highest FMEA Risk Priority Number, by additional critical components check point and feedback system to others machine for similar problem. Thus, the ITS-0015 machine that selected as observed machine could reduce the machine breakdown time from 111 became 85 minutes/month and breakdown quantity from 4.7 became 3.5 times/month. Finally, we could increase the availability value from 90.8% became 96.0% and the impact was increasing OEE value from 87% became 92%. Keywords:overall equipment effectiveness, availability, failure mode and effect analysis, DMAIC cycle, pareto diagram, cause and effect diagram Journal Européen des Systèmes Automatisés

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Section: Figure 1 World Car Sales 2015-2018mentioning

confidence: 99%

Increasing Overall Equipment Effectiveness in Automotive Company Using DMAIC and FMEA Method

Rozak¹,

Jaqin²,

Hasbullah³

2020

JESA

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“…In this paper, a PHM solution for a machine tool hydraulic unit was presented. Despite the hydraulic unit being one of the most critical part of machine tools, 1,3,36 scientific literature was still lacking in this research field. The unavailability of a large amount of faulty data in the life of a machine tool brought about the decision to implement a digital twin of the hydraulic unit.…”

Section: Discussionmentioning

confidence: 99%

“…In manufacturing systems, productivity targets are demanding to ensure maximum reliability and availability of machine tools, 1 while breakdowns and failures need to be fully avoided. 2,3 Due to these requirements and increased system complexity, preventive maintenance represents a conspicuous fraction of the total costs in an industrial scenario. 4 Consequently, the attractiveness of Prognostics and Health Management (PHM) solutions rises.…”

Section: Introductionmentioning

confidence: 99%

“…The hydraulic unit is one of the most critical parts and the cause of unexpected breakdowns and downtimes. 1,3 From a reliability analysis of 10 CNC lathes from 2009 to 2014, the hydraulic subsystem showed the highest failure rate (22.9% of the total failures). 1 A similar project on 12 machining centres between 2005 and 2010 confirmed the result.…”

Section: Introductionmentioning

confidence: 99%

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A novel prognostics solution for machine tool sub-units: The hydraulic case

Bernini

Waltz

Albertelli

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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A novel prognostic approach was developed and applied to a machine tool hydraulic unit. Three components were considered: pump, sensor and valve. The proposed methodology exploited a digital twin of the system to perform simulations of the healthy and faulty machine. The digital twin was properly validated through experiments. This approach dealt with the need to carry out time-consuming and expensive experimental campaigns, that is, run-to-failures – not affordable in many industrial applications. The diagnosis module was trained on digital twin simulations and fulfilled the fault detection, isolation and quantification phases. The challenge related to the variability of the operating conditions of the machine was addressed through a robustness analysis of the methodology. The solution successfully dealt with both stationary and non-stationary working conditions. A dedicated classification model was designed for each faulty component, maximising the associated classification rate. The testing procedure consisted of the application of a 10-fold cross-validation to compute the mean classification rates for stationary and non-stationary working conditions. Diagnosis performance results were excellent for the pump, whereas they were lower for the sensor and valve, reaching 79.75% and 74.93% accuracy respectively for the most challenging working cycle. The prognosis directly exploited the output of diagnostics, allowing for experimental effort reduction. Prognosis predictions were built starting from the updated health status provided by the diagnosis output. In order to test the prognosis module, mean and standard deviation of the prediction errors (less than 1.176%) were computed through a Monte Carlo approach. The conceived methodology allowed one of the critical goals of prognostics to be handled: the Remaining Useful Life probability density function estimation.

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“…FTA and FMEA as a method to improve the quality of large industrial products at the end consumer level [9]. FTA and FMEA as a method to identify modes, components, and sub-systems of critical failures in CNC systems [10]. FTA and FMEA as a method for analyzing failure modes and effects on power plant boilers.…”

Section: Introductionmentioning

confidence: 99%

The analysis of failure and reliability factors of impressed current cathodic protection (ICCP) design toward underwater line of warship (Case study in kri kcr-40 type)

Putra¹,

Bura²,

Aritonang³

et al. 2019

Eng. Appl. Sci. Lett.

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Corrosion at the bottom of a ship's water line can result in personnel and material safety risks. There are 2 (two) ways to protect against corrosion, they are passive protection (by painting) and active protection (by cathodic protection method). In the KRI with KCR-40 type, the design of the bottom line of the ship's waterline protection has been carried out with ICCP, but the value of its failure risk and reliability is unknown, both functional and designs, so that the design of the tool cannot be used maximally. This research aimed to determine the factors of failure and reliability value of the design-based ICCP (Reliability by Design) with the FTA and FMEA approach, the FTA aimed to identify the risks that contribute to the failure. The main factors causing failure in the design of ICCP tools occur in the component of Steel potential indicator and rectifier indicator with a failure mode not pointing to the correct number, this will result in corrosion control which is expected to be uncontrolled properly and correctly due to incorrect data input. After analyzing the FTA, the reliability value was 33%. Mitigation of tool components that have a high level of risk among other things in the indicator of steel potential and rectifier indicators: the first was to redesign the laying of some components of the tool compilers to pay attention to the circulating circulation in the box so that the tool works more optimally, the second was to carry out periodic control while the device was operating, and third was to ensure that the electrical power used was stable so there were no problems with the ICCP device while the ICCP device was operating.

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Failure Modes and Effects Analysis (FMEA) of Computerized Numerical Control (CNC) Turning Center

Cited by 8 publications

References 12 publications

Increasing Overall Equipment Effectiveness in Automotive Company Using DMAIC and FMEA Method

Increasing Overall Equipment Effectiveness in Automotive Company Using DMAIC and FMEA Method

A novel prognostics solution for machine tool sub-units: The hydraulic case

The analysis of failure and reliability factors of impressed current cathodic protection (ICCP) design toward underwater line of warship (Case study in kri kcr-40 type)

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