Production and Operations Management

MAINTENANCE MANAGEMENT The term maintenance means to keep the equipment in operational condition or repair it to its operational mode. Main objective of the maintenance is to have increased availability of production systems, with increased safety and optimized cost. Maintenance management involves managing the functions of maintenance. Maintaining equipment in the field has been a challenging task since the beginning of industrial revolution. Since then, a significant of progress has been made to maintain equipment effectively in the field. As the engineering equipment becomes sophisticated and expensive to produce and maintain, maintenance management has to face even more challenging situations to maintain effectively such equipments in industrial environment. MAINTENANCE STRATEGIES OR OPTIONS A maintenance strategy or option means a scheme for maintenance, i.e. an elaborate and systematic plan of maintenance action. Following are the maintenance strategies that are commonly applied in the plants. Breakdown Maintenance or Operate to Failure or Unplanned Maintenance Preventive or Scheduled Maintenance Predictive or Condition Based Maintenance Opportunity Maintenance Design out Maintenance Breakdown Maintenance The equipment under breakdown maintenance is allowed to run until it breaks down and then repairing it and putting back to operation. This strategy is suitable for equipments that are not critical and have spare capacity or redundancy available. Preventive or Scheduled Maintenance In preventive or scheduled Maintenance, maintenance actions such as inspection, lubrication, cleaning, adjustment and replacement are undertaken at fixed intervals of numbers of hours or Kilometers. Predictive or Condition Based Maintenance This condition based maintenance strategy or predictive maintenance is preferred for critical systems and for such systems breakdown maintenance is to be avoided. A number of CM techniques such as vibration, temperature, oil analysis, etc. have been developed, which guide the users in planned maintenance . Opportunity Maintenance In opportunity maintenance, timing of maintenance is determined by the procedure adopted for some other item in the same unit or plant. In design out maintenance, the aim is to minimize the effect of failures and in fact eliminates the cause of maintenance. Although it is an engineering design problem, yet it is often a responsibility of maintenance department. Design out Maintenance This is opted for items of high maintenance cost that are due to poor maintenance, poor design or poor design outside design specifications. It may be mentioned that a best maintenance strategy for each item should be selected by considering its maintenance characteristics, cost and safety. In addition to the above, new strategies concepts Also developed Proactive Maintenance: In proactive maintenance, the aim is identify what can go wrong, i.e. by monitoring of parameters that can cause failures. Reliability Centred Maintenance (RCM) In RCM, the type of maintenance is chosen with reliability of the system in consideration, i.e. system functions, failures relating to those functions and effects of the dominant functional system failures. This strategy in the beginning was applied to critical systems such as aircrafts, nuclear and space applications

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Total Productive Maintenance (TPM) At present, this is being extended to critical systems in the plant. TPM, a Japanese concept, involves total participation of all concerned. The aim is to have overall effectiveness of the equipment with participation of all concerned using productive maintenance system . FUNTIONS OF A MAINTENANCE DEPARTMENT Following are the major functions of a maintenance department Maintenance of installed equipment and facilities Installations of new equipment and facilities PM tasks Inspection and lubrication of existing equipment CM tasks monitoring of faults and failures using appropriate techniques Modifications of already installed equipment and facilities Management of inventory Supervision of manpower Keeping records

MAINTENANCE ORGANIZATION It concerns in achieving an optimum balance between plant availability and maintenance resource utilization. The two organization structures that are common are: Centralized and Decentralized. A decentralized structure would probably experience a lower utilization than centralized one but would be able to respond quickly to breakdowns and would achieve higher plant availability. In practice, one may have a mix of these two. A maintenance organization can be considered as being made up three necessary and interdependent components. 1. 2. 3. Resources: men, spares and tools Administration: a hierarchy of authority and responsibility for deciding what, when and how work should be carried out. Work Planning and Control System: a mechanism for planning and scheduling the work and feeding back the information that is needed for correctly directing the maintenance effort towards defined objective.

ELEMENTS OF EFFECTIVE MAINTENANCE MANAGEMENT An effective maintenance system includes the following elements Maintenance Policy Control of materials Preventive Maintenance Condition Monitoring Work Order Job planning Priority and backlog control Data recording system Performance measurement measures or indices

Maintenance performance for a plant or an organization can be assessed through analysis of Reliability, Availability and Maintainability (RAM) plant data. Relevant parameters, measures or indices for specific plants can be identified . The performance over a period of time will show if it is improving, going down or being sustained. This will also help in knowing how well the objectives are being met. In addition, it will guide the areas which are strong and which need to be strengthened. Use of computers and dedicated software will certainly help in implementing this and the maintenance management system in general.

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Bathtub curve

The bathtub curve is widely used in reliability engineering. It describes a particular form of the hazard function which comprises three parts: The first part is a decreasing failure rate, known as early failures. The second part is a constant failure rate, known as random failures. The third part is an increasing failure rate, known as wear-out failures. The name is derived from the cross-sectional shape of a bathtub. The bathtub curve is generated by mapping the rate of early "infant mortality" failures when first introduced, the rate of random failures with constant failure rate during its "useful life", and finally the rate of "wear out" failures as the product exceeds its design lifetime. In less technical terms, in the early life of a product adhering to the bathtub curve, the failure rate is high but rapidly decreasing as defective products are identified and discarded, and early sources of potential failure such as handling and installation error are surmounted. In the mid-life of a productgenerally, once it reaches consumersthe failure rate is low and constant. In the late life of the product, the failure rate increases, as age and wear take their toll on the product. Many consumer products strongly exhibit the bathtub curve, such as computer processors. While the bathtub curve is useful, not every product or system follows a bathtub curve hazard function, for example if units are retired or have decreased use during or before the onset of the wear-out period, they will show fewer failures per unit calendar time (not per unit use time) than the bathtub curve. The term "Military Specification" is often used to describe systems in which the infant mortality section of the bathtub curve has been burned out or removed. This is done mainly for life critical or system critical applications as it greatly reduces the possibility of the system failing early in its life. Manufacturers will do this at some cost generally by means similar to accelerated stress testing.

Equipment life cycle The equipment lifecycle begins from the time equipment is requested through the end of its useful life or when it is disposed. The equipment lifecycle typically consist of three phases: Acquisition, Use and Disposal - Acquisition The way capital equipment is acquired determines how it will be recorded and managed throughout its lifecycle. Equipment is acquired at the University through direct purchase, capital gifts -in kind, fabrication, transfer-in from other institutions, government owned or furnished equipment, loaned equipment, capital lease, or equipment purchased under construction contract

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- Use a) Institutional Use University capital equipment is intended for institutional use and not for private purposes. Use may be additionally restricted by the terms of the award for which the capital equipment was acquired. Individuals requesting home use (for institutional purposes) of equipment must obtain the approval of the Principal Investigator and notify CAA of the particular equipment to be used at home. CAA will update the equipment database accordingly. b) Personal Use Personal use of University assets is prohibited, except when approved by an authorized individual. - Disposal The source of funding for equipment determines how it can be disposed. For example, sponsor funded purchases and donations may have specific disposal restrictions. The key to determining disposal restrictions is to read the sponsor agreement or donation documentation

Waste Management Waste management is the collection, transport, processing or disposal, managing and monitoring of waste materials. The term usually relates to materials produced by human activity, and the process is generally undertaken to reduce their effect on health, the environment or aesthetics. Waste management is a distinct practice from resource recovery which focuses on delaying the rate of consumption of natural resources. All waste materials, whether they are solid, liquid, gaseous or radioactive fall within the remit of waste management Methods of disposal Landfill Disposal of waste in a landfill involves burying the waste, and this remains a common practice in most countries. Landfills were often established in abandoned or unused quarries, mining voids or borrow pits. A properly designed and well-managed landfill can be a hygienic and relatively inexpensive method of disposing of waste materials.. Incineration Incineration is a disposal method in which solid organic wastes are subjected to combustion so as to convert them into residue and gaseous products. This method is useful for disposal of residue of both solid waste management and solid residue from waste water management.This process reduces the volumes of solid waste to 20 to 30 percent of the original volume. Incineration and other high temperature waste treatment systems are sometimes described as "thermal treatment". Incinerators convert waste materials into heat, gas, steam and ash. Incineration is carried out both on a small scale by individuals and on a large scale by industry. It is used to dispose of solid, liquid and gaseous waste. It is recognized as a practical method of disposing of certain hazardous waste materials (such as biological medical waste). Incineration is a controversial method of waste disposal, due to issues such as emission of gaseous pollutants. Recycling Recycling is a resource recovery practice that refers to the collection and reuse of waste materials such as empty beverage containers. The materials from which the items are made can be reprocessed into new products. The most common consumer products recycled include aluminium such as beverage cans, copper such as wire, steel food and aerosol cans, old steel furnishings or equipment, polyethylene and PET bottles, glass bottles and jars, paperboard cartons, newspapers, magazines and light paper, and corrugated fiberboard boxes. The recycling of complex products (such as computers and electronic equipment) is more difficult, due to the additional dismantling and separation required. The type of material accepted for recycling varies by city and country. Each city and country has different recycling programs in place that can handle the various types of recyclable materials. However, certain variation in acceptance is reflected in the resale value of the material once it is reprocessed Sustainability The management of waste is a key component in a business' ability to maintaining ISO14001 accreditation. Companies are encouraged to improve their environmental efficiencies each year by eliminating waste through resource recovery practices, which are sustainability-related activities. One way to do this is by shifting away from

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waste management to resource recovery practices like recycling materials such as glass, food scraps, paper and cardboard, plastic bottles and metal. Biological reprocessing Recoverable materials that are organic in nature, such as plant material, food scraps, and paper products, can be recovered through composting and digestion processes to decompose the organic matter. The resulting organic material is then recycled as mulch or compost for agricultural or landscaping purposes. In addition, waste gas from the process (such as methane) can be captured and used for generating electricity and heat (CHP/cogeneration) maximising efficiencies. The intention of biological processing in waste management is to control and accelerate the natural process of decomposition of organic matter. (See resource recovery). Energy recovery The energy content of waste products can be harnessed directly by using them as a direct combustion fuel, or indirectly by processing them into another type of fuel. Thermal treatment ranges from using waste as a fuel source for cooking or heating and the use of the gas fuel to fuel for boilers to generate steam and electricity in a turbine. Pyrolysis and gasification are two related forms of thermal treatment where waste materials are heated to high temperatures with limited oxygen availability. The process usually occurs in a sealed vessel under high pressure. Pyrolysis of solid waste converts the material into solid, liquid and gas products. The liquid and gas can be burnt to produce energy or refined into other chemical products (chemical refinery). The solid residue (char) can be further refined into products such as activated carbon. Gasification and advanced Plasma arc gasification are used to convert organic materials directly into a synthetic gas (syngas) composed of carbon monoxide and hydrogen. The gas is then burnt to produce electricity and steam. An alternative to pyrolisis is high temperature and pressure supercritical water decomposition (hydrothermal monophasic oxidation) Waste management concepts There are a number of concepts about waste management which vary in their usage between countries or regions. Some of the most general, widely used concepts include: Waste hierarchy - The waste hierarchy refers to the "3 Rs" reduce, reuse and recycle, which classify waste management strategies according to their desirability in terms of waste minimization. The waste hierarchy remains the cornerstone of most waste minimization strategies. The aim of the waste hierarchy is to extract the maximum practical benefits from products and to generate the minimum amount of waste see: resource recovery. Polluter pays principle - the Polluter Pays Principle is a principle where the polluting party pays for the impact caused to the environment. With respect to waste management, this generally refers to the requirement for a waste generator to pay for appropriate disposal of the unrecoverable material. Automation Automation is the use of machines, control systems and information technologies to optimize productivity in the production of goods and delivery of services. The correct incentive for applying automation is to increase productivity, and quality beyond that possible with current human labor levels so as to realize economies of scale, and realize predictable quality levels. In the scope of industrialisation, automation is a step beyond mechanization. Whereas mechanization provides human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements while increasing load capacity, speed, and repeatability. Automation plays an increasingly important role in the world economy and in daily experience. Automation has had a notable impact in a wide range of industries beyond manufacturing . Medical processes such as primary screening in electrocardiography or radiography and laboratory analysis of human genes, sera, cells, and tissues are carried out at much greater speed and accuracy by automated systems. Automated teller machines have reduced the need for bank visits to obtain cash and carry out transactions. In general, automation has been responsible for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries. The term automation, inspired by the earlier word automatic (coming from automaton), was not widely used before 1947, when General Motors established the automation department. At that time automation technologies were

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electrical, mechanical, hydraulic and pneumatic. Between 1957 and 1964 factory output nearly doubled while the number of blue collar workers started to decline. Advantages and disadvantages The main advantages of automation are: Increased throughput or productivity. Improved quality or increased predictability of quality. Improved robustness (consistency), of processes or product. Increased consistency of output. Reduced direct human labor costs and expenses. The following methods are often employed to improve productivity, quality, or robustness. Install automation in operations to reduce cycle time. Install automation where a high degree of accuracy is required. Replacing human operators in tasks that involve hard physical or monotonous work. [3] Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.) Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc. Economic improvement: Automation may improve in economy of enterprises, society or most of humanity. For example, when an enterprise invests in automation, technology recovers its investment; or when a state or country increases its income due to automation like Germany or Japan in the 20th Century. Reduces operation time and work handling time significantly. Frees up workers to take on other roles. Provides higher level jobs in the development, deployment, maintenance and running of the automated processes. The main disadvantages of automation are: Security Threats/Vulnerability: An automated system may have a limited level of intelligence, and is therefore more susceptible to committing errors outside of its immediate scope of knowledge (e.g., it is typically unable to apply the rules of simple logic to general propositions). Unpredictable/excessive development costs: The research and development cost of automating a process may exceed the cost saved by the automation itself. High initial cost: The automation of a new product or plant typically requires a very large initial investment in comparison with the unit cost of the product, although the cost of automation may be spread among many products and over time. In manufacturing, the purpose of automation has shifted to issues broader than productivity, cost, and time Automation tools Engineers can now have numerical control over automated devices. The result has been a rapidly expanding range of applications and human activities. Computer-aided technologies (or CAx) now serve the basis for mathematical and organizational tools used to create complex systems. Notable examples of CAx include Computer-aided design (CAD software) and Computer-aided manufacturing (CAM software). The improved design, analysis, and manufacture of products enabled by CAx has been beneficial for industry. Information technology, together with industrial machinery and processes, can assist in the design, implementation, and monitoring of control systems. One example of an industrial control system is a programmable logic controller (PLC). PLCs are specialized hardened computers which are frequently used to synchronize the flow of inputs from (physical) sensors and events with the flow of outputs to actuators and events. Different types of automation tools exist: ANN - Artificial neural network BPM - Bonita Open Solution DCS - Distributed Control System HMI - Human Machine Interface SCADA - Supervisory Control and Data Acquisition PLC - Programmable Logic Controller PAC - Programmable automation controller Instrumentation Motion control

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Robotics Limitations to automation Current technology is unable to automate all the desired tasks. As a process becomes increasingly automated, there is less and less labor to be saved or quality improvement to be gained. This is an example of both diminishing returns and the logistic function. Similar to the above, as more and more processes become automated, there are fewer remaining nonautomated processes. This is an example of exhaustion of opportunities. New technological paradigms may however set new limits that surpass the previous limits. Applications Automated retail Food and drink The food retail industry has started to apply automation to the ordering process, McDonald's has introduced touch screen ordering and payment systems in many of its restaurants, reducing the need for as many cashier employees. University of Texas has introduced fully automated cafe retail locations. Some Cafes and restaurants have utilized mobile and tablet "apps" to make the ordering process more efficient by customers ordering and paying on their device. Some restaurants have automated food delivery to customers tables using a Conveyor belt system. The use of robots is sometimes employed to replace waiting staff.

Stores Many Supermarkets and even smaller stores are rapidly introducing Self checkout systems reducing the need for employing checkout workers. Online shopping could be considered a form of automated retail as the payment and checkout are through an automated Online transaction processing system. Automated mining involves the removal of human labor from the mining process. The mining industry is currently in the transition towards Automation. Currently it can still require a large amount of human capital, particularly in the third world where labor costs are low so there is less incentive for increasing efficiency through automation. Automated video surveillance The Defense Advanced Research Projects Agency (DARPA) started the research and development of automated visual surveillance and monitoring (VSAM) program, between 1997 and 1999, and airborne video surveillance (AVS) programs, from 1998 to 2002. Currently, there is a major effort underway in the vision community to develop a fully automated tracking surveillance system. Automated video surveillance monitors people and vehicles in real time within a busy environment. Existing automated surveillance systems are based on the environment they are primarily designed to observe, i.e., indoor, outdoor or airborne, the amount of sensors that the automated system can handle and the mobility of sensor, i.e., stationary camera vs. mobile camera. The purpose of a surveillance system is to record properties and trajectories of objects in a given area, generate warnings or notify designated authority in case of occurrence of particular events. [13] Automated highway systems As demands for safety and mobility have grown and technological possibilities have multiplied, interest in automation has grown. Seeking to accelerate the development and introduction of fully automated vehicles and highways, the United States Congress authorized more than $650 million over six years for intelligent transport systems (ITS) and demonstration projects in the 1991 Intermodal Surface Transportation Efficiency Act (ISTEA). Congress legislated in ISTEA that the Secretary of Transportation shall develop an automated highway and vehicle prototype from which future fully automated intelligent vehicle-highway systems can be developed. Such development shall include research in human factors to ensure the success of the man-machine relationship. The goal of this program is to have the first fully automated highway roadway or an automated test track in operation by 1997. Automated waste management Automated waste collection trucks prevent the need for as many workers as well as easing the level of Labor required to provide the service.[15]

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Automated manufacturing Automated manufacturing refers to the application of automation to produce things in the factory way. Most of the advantages of the automation technology has its influence in the manufacture processes. The main advantages of automated manufacturing are higher consistency and quality, reduced lead times, simplified production, reduced handling, improved work flow, and increased worker morale when a good implementation of the automation is made. Lights out factories are factories that require no workers in order to run. Home automation Home automation (also called domotics) designates an emerging practice of increased automation of household appliances and features in residential dwellings, particularly through electronic means that allow for things impracticable, overly expensive or simply not possible in recent past decades. Industrial automation Industrial automation deals with the optimization of energy-efficient drive systems by precise measurement and control technologies. Nowadays energy efficiency in industrial processes are becoming more and more relevant. Semiconductor companies like Infineon Technologies are offering 8-bit micro-controller applications for example found in motor controls, general purpose pumps, fans, and ebikes to reduce energy consumption and thus increase efficiency. One of Infineon's 8-bit product line found in industrial automation is the XC800 family. Agriculture: Now that were moving towards automated orange -sorting [1] and autonomous tractors [2], the next step in automated agriculture is robotic strawberry pickers [3]. Technology management Technology Management is set of management disciplines that allows organizations to manage their technological fundamentals to create competitive advantage. Typical concepts used in technology management are technology strategy (a logic or role of technology in organization) , technology forecasting (identification of possible relevant technologies for the organization, possibly through technology scouting), technology roadmapping (mapping technologies to business and market needs), technology project portfolio ( a set of projects under development) and technology portfolio (a set of technologies in use). The role of the technology management function in an organization is to understand the value of certain technology for the organization. Continuous development of technology is valuable as long as there is a value for the customer and therefore the technology management function in an organization should be able to argue when to invest on technology development and when to withdraw. Technology Management can also be defined as the integrated planning, design, optimization, operation and control of technological products, processes and services, a better definition would be the management of the use of technology for human advantage. The Association of Technology, Management, and Applied Engineering defines Technology Management as the field concerned with the supervision of personnel across the technical spectrum and a wide variety of complex technological systems. Technology Management programs typically include instruction in production and operations management, project management, computer applications, quality control, safety and health issues, statistics, and general management principles.

The equipment lifecycle begins from the time equipment is requested through the end of its useful life or when it is disposed. The equipment lifecycle typically consist of three phases: Acquisition, Use and Disposal

Vision Institute of Management

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- Acquisition The way capital equipment is acquired determines how it will be recorded and managed throughout its lifecycle. Equipment is acquired at the University through direct purchase, capital gifts-in kind, fabrication, transfer-in from other institutions, government owned or furnished equipment, loaned equipment, capital lease, or equipment purchased under construction contract

- Use a) Institutional Use University capital equipment is intended for institutional use and not for private purposes. Use may be additionally restricted by the terms of the award for which the capital equipment was acquired. Individuals requesting home use (for institutional purposes) of equipment must obtain the approval of the Principal Investigator and notify CAA of the particular equipment to be used at home. CAA will update the equipment database accordingly. b) Personal Use Personal use of University assets is prohibited, except when approved by an authorized individual.

- Disposal The source of funding for equipment determines how it can be disposed. For example, sponsor funded purchases and donations may have specific disposal restrictions. The key to determining disposal restrictions is to read the sponsor agreement or donation documentation

Vision Institute of Management

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