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Machine failures’ consequences – a classification model considering ultra-efficiency criteria
(2023)
To strive for a sustainable production, maintenance has to evaluate possible machine failure consequences not just economically but also holistically. Approaches such as the ultra-efficiency factory consider energy, material, human/staff, emission, and organization as optimization dimensions. These ultra-efficiency dimensions can be considered for analyzing not only the respective machine failure but also the effects on the entire production system holistically. This paper presents an easy to use method, based on a questionnaire, for assessing the failure consequences of a machine malfunction in a production system considering the ultra-efficiency dimensions. The method was validated in a battery production.
Urgent action is needed to keep the chance of limiting global warming to 1.5°C or even 2.0°C. Current outlooks by IPCC, and many other organisations forecast that this will be impossible at current pace of emission 'reductions' – Germany has already hit 1.5° warming this year. Across 2019, particularly during the UN New York Climate summit, numerous organisations declared their ambition to become net carbon neutral. Amongst these were investors and companies, including quite a number of German ones.
We apply a mixed methods approach, utilising data gathered from approx. 900 companies after Climate Week in context of the Energy Efficiency Index of German Industry (EEI), along with media research focusing on decarbonisation plans announced and initiatives pledging climate action.
With this, we analyse how German companies in the manufacturing sectors react to rising societal pressure and emerging policies, particularly what measures they have taken or plan to implement to reduce the footprint of their company, their products and their supply chain. In this, we particularly analyse whether and in what way energy- and resource consumption, as well as carbon emissions are considered in the development and lifecycle of goods manufactured. This is of huge relevance as these goods determine the future footprint of buildings, vehicles and industry.
Regarding the supply chain, current articles indicate that small and medium-sized enterprises (SME) are particularly challenged by increasing demands from their large corporate clients and an alleged lack of preparedness to be able to take and afford prompt decarbonisation action themselves (Buchenau et. al. 2019). Notably the automotive industry recently announced new models that will be 100% carbon neutral all the way through (ibid). We thus analyse if and how factors such as company size, energy intensity and sector affiliation influence a company’s plan to fully decarbonize. Ownership structure and corporate culture, it appears, significantly impact on the degree of decarbonisation action underway.
From the perspective of manufacturing companies, the political, media and economic discourse on decarbonisation in the recent years manifests itself as an increasing social expectation of action. In Germany, in particular, this discourse is also being driven forward by powerful companies, respectively sectors, most notably the automotive industry. Against this background, the present paper examines how German manufacturing companies react to rising societal pressure and emerging policies. It examines which measures the companies have taken or plan to take to reduce their carbon footprint, which aspirations are associated with this and the structural characteristics (company size, energy intensity, and sector) by which these are influenced. A mix methods approach is applied, utilising data gathered from approx. 900 companies in context of the Energy Efficiency Index of German Industry (EEI), along with media research focusing on the announced decarbonisation plans and initiatives. We demonstrate that one-size-serves-all approaches are not suitable to decarbonise industry, as the situation and ambitions differ considerably depending on size, energy intensity and sector. Even though the levels of ambition and urgency are high, micro and energy intensive companies, in particular, are challenged. The present research uncovers a series of questions that call for attention to materialise the ambitions and address the challenges outlined.
In increasingly complex production environments, tremendous efforts are being made to optimize the efficiency of a production system. An important efficiency factor is industrial maintenance, both influencing the cost and securing the technical availability of machines and components. Maintenance managers are required to deliver the necessary availability of the production system while minimizing the resources needed to do so. To make this possible, a method to evaluate the dependency between the technical availability of an entire production system and maintenance resources is necessary. This paper presents a systematic literature review of such methods is presented. In order to assess the methods proposed in the literature, first, requirements are developed, including a necessary focus on maintenance strategies within these methods. Including maintenance strategies is necessary since they provide the foundation for both the availability of a component and the maintenance resources needed. In total, 13 requirements are developed, and 21 different methods are evaluated. Only one of the proposed methods addresses all requirements, with others lacking possible combinations of maintenance strategies and the resulting influences on the production system.
Production systems are becoming increasingly complex, which means that the main task of industrial maintenance, ensuring the technical availability of a production system, is also becoming increasingly difficult. The previous focus of maintenance efforts on individual machines must give way to a holistic view encompassing the whole production system. Against this background, the technical availability of a production system must be redefined. The aim of this publication is to present different definition approaches of production systems’ availability and to demonstrate the effects of random machine failures on the key figures considering the complexity of the production system using a discrete event simulation.