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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.
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.
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.