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Production and product service systems > Dugga > Flashcards

Dugga Flashcards

1
Q

What is servitization?

A
  • Creating value by shiftingfrom selling products to providing product-services
  • A ”product-service” is a mix of tangible products and intangible services that jointlyfulfils customer needs
  • A ”product-service system” (PSS) is the organizational structurethat provides the product-service to customers.
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2
Q

What is digitalization?

A
  1. From analog to digital (”digitization”)
  2. Impact on our business processes, services, economic models etc.
  3. Impact on our lives (e.g. employment and universal basic income)
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3
Q

What are the two main trends for servitization?

A
  1. From Ownership to accessibility
    The customer view:
    1. Value increasingly associated to the use of product, as opposed to ownership
    2. Product Technologies require increasingly specialized know-how
      1. Maintenance = business
  2. Transfer of responsibility
    1. Responsibility of products increasingly retained with manufacturer.
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4
Q

What are the implications of servitization for industry?

A
  • Use focus increase the importance of customer relationship through life
    • Availability of product functionality increase in importance
  • Increased ownership after produced come with risk and opportunity
    • Risk? Revenue from ”spare parts sales”
    • Opportunity?: maintain relationship with customer, and better control of ones technologies in the ”field” through lifecycle of product.
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5
Q

What is new supplu chain?

A
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6
Q

What consequences has the shift of the product ownership for the manufactureres?

A
  • Shifting to servitization impact
    • Business models- the way to offer solutions and ensure revenue
  • Shifting preferences and behaviour of users
    • Creates, and threatens, established products and business models, the changes is difficult to foresee which leads to that new risks appear
  • Obsolescence
    • Technology in products have largely different life cycles
      • New electronic production life, 4-7 years
        • Advanced products comprise of a mix if HW (hardware), SW (software) and electronics- services need to ensure functionality (upgrades, maintenance etc.)
      • Expected machine life, 25-30 years
        • Incentive for manufacturers to retain ownership through life
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7
Q

What is a product- service system (PSS)? and which three is the common types?

A

”Product Service Systems, put simply, are when a firm offers a mix of both product and services, in comparison to the tranditional focus on products”

  • Product- oriented PSS
    Ownership of the tangible product is transferred from the manufacturer to the customer (sold), while included in the original act of sale are additional services (e.g. maintenance, repair, re-use, recycling, training, consulting, etc.)
  • Use-oriented PSS
    Ownership of the tangible product is retained by the service provider. Functions of the product are sold via modifies distribution and payment systems. E.g. carpooling, enables drivers to offer the available seats in the car. Renting a car.
  • Result- oriented PSS
    Selling the result or capacity instead of a product. The producer maintains ownership pf the product and the customer pays only for the provision of agreed results. E.g.
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8
Q

What are the implications for manufacturers when having PSS?

A

Retained ownership of products

  • Increased responsibility through product life
    • May have a high economics impact and risk
  • Possibilities for re-manufacturing
    • Opening for ”smart” and ”circular” business
    • Where and how to remanufacture? Logistics, Design,..?
  • Changed revenue-streams
    • ”spare parts sales” not a good source of revenue
  • Opportunities for technology changes post-manufacturing
    • Can replace systematically obsolete or poor technologies
    • Can extent life through technology replacement and upgrades
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9
Q

What are the maintenance gererations?

A
  • Maintenance 1.0 (before 1950), Reactive actions
  • Maintenance 2.0 (1950-1975), Preventive maintenance, maintenance department created
  • Maintenance 3.0 (1975-2000), Academic interest, prevent effects of failures, condition-based maintenance, design for maintainability and collaboration
  • Maintenance 4.0 (20??), Design for eliminating failures, even more extensive collaboration, holistic view and IT solution
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10
Q

What is the definition of maintenance?

A

”A combination of all technical, administrative and managerial actions during the life-cycle of an item, and intended to remain it in, or restore it to a state in which it can preform the required function.”

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11
Q

What is OEE?

A

Overall equipment effectiveness

OEE = avilability * operatioan efficiency * quality rate

Low availability and operatinonal efficiency are two main contributors to OEE losses

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12
Q

What is reactive vs preventive maintenance?

A
  • Previous estimations indicate a 70-30 ration towards reactive actions
  • OEE assessments indicates a positive trend: a 60-40 ratio
  • Cost of reactive actions = 3 times the cost of preventive actions
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13
Q

What does it mean with that mainteancne cannot colve all problems?

A
  • Maintenance department usually responsible for OEE in practice
  • Only direct impact on breakdowns and planned maintenance
  • Lack of systems perspective and need for: collaboration or integration, common goals.
  • Necessity for digitalized manufacturing.
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14
Q

What are the challenges for maintenance organizations?

A
  • Lack of system perspective
  • Preventive instead of reactive
  • Qualification of maintenance effects
  • Need for collaboration or integration
  • Need for common goals
  • Necessity for digitalized manufacturing
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15
Q

what are the challenges from a global perspective?

A

Connection to sustainability, ecological sustainability – energy consumption in production, economic sustainability.

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16
Q

What are the important solutions from the global perspective?

A
  • Standardization andmodularization
  • System levelthinking and criticalityanalysis (prioritization and a holistic view is crucial for smart production)
  • Increase importance of maintenance (technical know-how, closeness to equipment, availability to relevant data, from cost driver to cost driver to profit generator)
  • Flexiblemaintenance (adjust the maintenance organization to good and bad economy)
  • Smart maintenance (Data- driven planning, dynamic prioritization, attract and develop competence, from descriptive to predictive, quantify the effects of maintenance, real-time monitoring, maintenance strategies for the digital transformation)
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17
Q

W´why is there a increase importance for maintenance?

A

Technical know-how, closeness to equipment, availability of relevant data and from cost driver to profit generator.

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18
Q

What will the future maintenance be?

A
  • Data-driven maintenance planning
  • From descriptive to predictive
  • Dynamic prioritization
  • Attract and develop competence
  • Qualify the effects of maintenance
  • Real- time monitoring and remote maintenance
  • Create maintenance strategies for the digital transformation
  • Innovation, servitization and entrepreneurship
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19
Q

What is the production service system?

A

Production service activities aim to retain, restore and improve production systems relative inherent or agreed specifications during their entire life cycles. Reactive and preventive maintenance as well as improving activities are applied to increase system dependability and thereby economical, ecological and social sustainability.

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20
Q

What is the risk management methodology and tools?

A
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21
Q

What is it what if analysis?

A
  • What- If Analysis is based on creative, brainstorming for examination of a process or operation
  • It should be performed by a team, if the process is complex
  • It is powerful hazard identification technique if the analysis staff is Experiences
  • The result of a what-if analysis usually address potential accident situations implied by the questions and issues posed but the team
  • These questions and issues often suggest specific causes for the identified accident situations
  • The worksheet includes the What if, consequences(hazard and recommendation
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22
Q

What is hazard and operability study (HAZOP)?

A

It is a systematic method for identifying; potential hazards, operability deviations within the system and specifying the means by which wither the probability of their occurrence can be reduced or the consequences of the undesirable incidents can be minimised.

The worksheet includes: Guide Words, deviation, causes, consequences and recommendations

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23
Q

What is the Failure mode and effect analysis, FMEA?

A

FMEA evaluate the ways equipment can fail or be improperly operated and the effects these failures can have. In a FMEA, each individual failure is considered as an independent occurrence with no relation to other failures in the system. In short, FMEA identify single failure modes that either directly result in or contribute significantly to an accident.

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24
Q

What is the Risk priority number, RPN?

A

RPN is calculated as the product of severity, occurrence and detection. Since each of the factors in the range of 1-10, we have; 1<=RPN <=1000. The RPN is a basis for prioritization. High values indicate where action should be initiated. Low values should also examine whether any of these factors has a value of nine or ten. This is especially true if the failure probability or severity is high.

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25
Q

What is the fault tree analysis (FTA)?

A

Is a tool for; accident cause analysis, reconstruction of an accident and frequency/probability estimation of an accident

  • Is a graphical and logic technique
  • It is a backard method
  • Is used for cause analysis of a top event as an output of ”Hazard Identification”
  • It can be used for calculation of frequency of an incident

Boolean Algebra

P(A) = P(B or C) = Pb+Pc-PbPc = 1 - (1 - Pb)(1 - Pc)

P(A) = P(B and C) = Pb*Pc

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26
Q

What is the event tree analysis?

A

Event Trees are suited for analysing initiating events that could result in a variety of outcomes

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27
Q

What is the risk evaluation- risk matrix?

A

Systematic hazard identification and risk assessment

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28
Q

What is the CE certification?

A

European Commission =By affixing the CE making to a product, a manufacturer declares that hte product meets all the legal requirements for CE marking and can be sold throughout the EEA.

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29
Q

What is the orgnaizations standard directive CE marking?

A
  • Directive set out the essential requirements
  • Harmonised standard provide technical information to meet these essential requirements
  • Product that meet essential Requirement must display CE marking
30
Q

What are the standard organisations, certifying organisations and other standards?

A

Standard Organisations

  • ISO- the international Organization for Standardization
  • CEN- the European Committee for Standardization
  • SIS- the Swedish Standards Institute

Certifying Organisations (Accreditation)

  • International Accreditation Forum
  • European co-operation for Accreditation
  • Swedac- Swedish Board for accreditation and conformity assessment

Other standards

  • US-FDA (Medical equipment), U(Pressure vessels)
  • Canada- DRP (Pressure vessels)
  • UL- Unwriteters laboratories (notified bodies)
31
Q

What is standard and its purpose?

A

A standard is a document that provides requirements, specifications, guidelines or characteristics that can be used consistently to ensure that materials, products, processes and services are fit for their purpose

Purpose:

  • International Standards are the backbone of our society, ensuring the safety and quality of products and services, facilitating international trade and improving the environment in which we live in.
  • Conformity to International Standards helps reassure consumers that products, systems and organizations are safe, reliable and good for the environment
  • International Standards are strategic tools and guidelines to help companies tackle some of the most demanding challenges of modern business. They ensure the business operations are efficient as possible, increase productivity and help companies access new markets.
  • Standards help business to:
    • Cut costs, though improves systems and processes
    • Increase customer satisfaction, through improved safety, quality and processes
    • Access new markets, through ensuring he compatibility of product and services
    • Reduce their impact on the environment
32
Q

What is standardization?

A
  • As a SIS member, your company or organization is entitled to participate on technical committees, enabling you to have an impact on future standards in your specific industry.
  • By participating, you have the chance to influence both future national and international standards, 17000 members.
  • No less than 4 4000 experts witching ca 330 committees were involved in SIS standardization activates in 2015.
  • Most standards that are implemented are international standards which have been developed within CEN or ISO
  • The standardization committee can start developing a standard from own initiative or from external partner. Anyone can contract SIS with suggestion regarding new or revised standard.
33
Q

What is the harmonized standards?

A
  • A harmonized standard is a European standard developed by a recognized European Standards Organization: CFN, CENEÖEC, or ETSI.
  • These standards meet the essential requirements or other provisions of relevant European Union harmonization legislation.
  • Compliance with harmonized standards provides a presumption of conformity with the corresponding requirements of harmonization legislation.
34
Q

What are the standard types?

A
  • A standards deals with basic safety concepts applicable to all types of machinery (SS-EN ISO 12100:2010)
  • B standard deals with one safety aspect that can be applies oo wide range of machinery
  • C standard deals with detailed safety requirements for specific (or group of) machines or safety components.
35
Q

What are the risk assessment SS-EN ISO 12100:2010 ?

A

Hazards/ Situations/ events:

Mechanical, electrical, terminal, noise, vibrations, radiation, material/ substance, ergonomic, associated with the environments where the machines is used and combinations

36
Q

What are the risk reduction according to the 3-step method?

A
  • Step 1: Elimination of the hazards on the basis of design measures (Inherently safe design measures)
  • Step 2: Risk reduction through application of technical and complementary protective measures
  • Step 3: Warning against residual risks
37
Q

What is the MD- Machinery Directive (2006/42/EC) ?

A

European commission

One of the main legislations governing the harmonisation of essential health and safety requirements of machinery at EU level is the Machinery Directive

The Machinery Directive has a dual objective: to permit the free movement of machinery within the European market whilst ensuring a high level of protection of health and safety.

38
Q

What is the risk cerifications that need to be considers for a production line?

A
  • Every unit in you production should have undergone a Risk assessment and have the appropriate certification
  • The whole production line needs a separate assessment
  • The interfaces are especially put through the risk assessment
  • New technical documentation is needed
  • Difference between a new machine and an old machine
  • Three factor that determine of the existing process which has undergone an ”update” needs a new CE marking procedure
    • Large increase in performance
    • Different application (manufacturing of a new product)
    • Change regarding the line stability and/or strength
39
Q

What is CE cerification and the six steps that in contains?

A

The CE marketing is the manufacturers declaration that the product meets the requirements if the applicable EU Directives. There are two main benefits CE marking brings to business and consumers within the EEA.

  • Business know that products bearing the CE marking can be traded in the EEA without restrictions.
  • Consumers enjoy the same level of health, safety, and environmental production throughout the entire EEA.

Steps:

  1. Identify the applicable Directives and harmonized standards
  2. Identify the applicable requirements of the Directives
  3. Identify the appropriate route to conformity
  4. Assessment of the product conformity
  5. Compile the technical documentation
  6. Make the declaration and affix the CE marking
40
Q

What are the maintenance fundamentals?

A
  1. Definition of the maintenance objectives and KPI´s, Balance score card (BSC)
  2. Assets priority and maintenance strategy definition, Cristicaliy analysis (CA)
  3. Immediate intervention on high impact weak points, Failure root cause analysis (FRCA)
  4. Design of the preventive maintenance plans and resources, Reliability-centred maintenance (RCM)
  5. Preventive plan, schedule and resources optimization, Risk-cost optimization (RCO)
  6. Maintenance execution assessment and control, Reliability analysis (RA) and critical path method (CRM)
  7. Asset life cycle analysis and replacement optimization, Life cycle cost analysis (LCCA)
  8. Continuous improvement and new techniques utilization, Total productive maintenance (TPM), e-maintenance

Continuous improvements of phases

41
Q

What are the functions in maintenance?

A
  • Management
  • People professionalism
  • Administration and supply
  • Organization and support
  • Engineering
  • Health, safety and environment
42
Q

What is the cocept of depandability containing ?

A
  • Reliability
  • Maintainability
  • Maintenance support
43
Q

What is the definition of dependability?

A

A collective term used to describe the availability performance and its influencing factors: reliability performance, maintainability performance and maintenance support performance.

44
Q

What is the defintition of reliability?

A

Reliability is the ability of an item to perform a required function under given conditions for a given time interval. Reliability may also be defined as a probability that an equipment will perform its intended function without failure for a specific time under defined conditions. MTTF, MTBF

45
Q

What is the definition of maintainability?

A

Maintainability is the ability of an item under given conditions of use, to be retained in, or restored to, a state in which it can perform a required function, when maintenance is performed under given conditions and using stated procedures and resources. (Also used as a measure of maintainability performance and the time characteristic of maintainability is the active maintenance time). MTTR

46
Q

What is the definition of maintenace supportability?

A

The ability of having the right maintenance support at the necessary place to perform the required, maintenance activity at a given instant of time or during a given time interval. Maintenance support is the resources, service and management to perform a maintenance action. MTW

47
Q

What is inherent reliability?

A

The inherent reliability if a plant, system or device is the maximum achievable reliability based on configuration and component selection. If operated correctly, maintained correctly and inspected on appropriate intervals, it will be possible to attain the full inherent reliability If poor operated, poorly maintained or allowed to develop and retain defects, the reliability can be significantly less than the inherent reliability.

The reliability Management Process and the Maintenance Excellence Process go hand-in-hand. If maintenance work management processes are not done in manner that restores the inherent reliability, the reliability performance will continually degrade. If the reliability process is not working to provide an acceptable level of reliability, the maintenance processes will end up ”chasing-their-tail”, dealing with too-frequent and unexpected breakdowns.

48
Q

What is the path of failure?

A

The value of understanding the path of failure is knowing that both the failure mechanism and the defect can be discovered before failure, and that the failure can be prevented. Wise people also learn from failures, and they identify the three levels of cause in time to take corrective action.

In order o create Predictive Maintenance tasks, you need to understand the failure mechanism that ”are” at work and those that ”can be” at work. That is an important point to emphasize. Many people simply copy the PM tasks recommended by the manufacturer, and then perform them by rote without really understanding why they are doing them.

Predictive Maintenancetasks are intended to:

  1. Evaluate failure mechanisms that are known to be at work
  2. Identify failure mechanisms that can be at work
49
Q

What are the aim for failure analysis?

A

Find, assess, reduce and eliminate both causes and effects for failure. Use weibull distribution to determine the probability of failure.

50
Q

What is the bath-tub curve?

A
51
Q

In the bath-tube curve what is the infant mortaility failure period?

A

In the early life, an item population exhibits a high failure rate, due mainly to manufacturing weakness, including; poor joints and connections, damaged components, chemical impurities, dirt and contamination and assembly errors.

52
Q

In the bath-tube curve what is the useful life failure period?

A

The failure rate remains substantially constant, and, although some failures may still arise from manufacturing weakness or wear-out, the majority of failures are caused by the opening stress to which the item is subject in its particular application (e.g. temperature, electrical and environmental stresses) and occur randomly (without any time-dependent pattern). During this period, when the failure rate is considered to be constant, the negative exponential distribution descries the time to failure.

The period is the interval of the most interest from a reliability prediction standpoint because, if a rigorous reliability programme is applied throughout a project lifetime, is its assumed that:

  • The majority of early life failures will normally be eliminated before an item enters service
  • An in-service maintenance policy will ensure that item are replaced before wear out becomes a significant problem.
53
Q

In the bath-tube curve what is the wear-out failure period?

A

During the wear-out failure period, the failure rate increases due mainly to deterioration of the item though prolonged expose to operating and environmental stresses, which may include; insulation breakdown, wear of fatigue, corrosion or oxidation. Normally, wear out failures are avoided by replacing an item, either on the basis of fixed life replacement or on-condition monitoring. Even so, eventually the system become troublesome in use and is probably best replaced.

54
Q

What is the exponential distrubution?

A
  • Simples of all the life models
  • One parameter, landa
  • PDF, f(t) =landa*e^(-landa*t)
  • CDF, F(t) = 1- e^(landa*t) and R(t) = e^(landa*t)
  • Hazard function,h(t)=landa i.e. constant
  • MTBF = 1/ and failure rate = landa
  • 1/ is the 63 rd percentile i.e. time at which 63% of population will have failed
  • Hazard function: constant line, Survival function, exponential decreasing
55
Q

What is the weibull distrubution?

A
  • Most useful lifetime in reliability analysis
  • 2 parameter weibull; shape beta, and scale n
  • When beta<1 decresing hazard function
  • When beta>1 increasing hazard function
  • When beta=1 constant hazard function
  • n is the characteristic life, 63 rd percentile
56
Q

What is the probability plotting and assumptions?

A
  • Graphical estimation method
  • Based on cumulative distribution function CDF –F(t)
  • Probability papers for parametric distributions, e.g. Weibull
  • Axis is transformed so that the true CDF plots as a straight line
  • If plotted data fits a straight line hen the data fits the appropriate distribution
  • Parameter estimation ‘

Assumptions:

  • Data most be independently identically distributed (IID), no casual relationship, no trend, same distribution
  • Non-repaired items
  • Repaired items with no trend in the time between failures
57
Q

What is the maintenance concepts?

A

Is an overall model for how to plan, control and improve maintenance- ”how to do maintenance”. TRM, RCM and CBM are the three most common maintenance concepts and widely used in industry, they are completing each other.

58
Q

What is the total productive maintenance and the parts that it consists?

A

Origin from Japanese manufacturing industry to support lean production (JIT,TQM and TPM)

Productive =The most economic maintenance that raises equipment productivity

Total = the entire company is involved

  • Autonomous Maintenance
    • Operator maintenance
    • Fostering operator ownership
    • Cleaning, lubricating, tightening, adjustment, inspection, readjustment
  • Focused Maintenance
    • Elimination of equipment losses
    • Improve system efficiency
    • Improve OEE
    • Collaboration with other functions
  • Planned Maintenance
    • Plan PM (TBM, CBM etc.)
    • Improve MTTR, MTBF
  • Quality Maintenance
    • Zero defects
    • Track equipment problems and root causes
  • Education and Training
    • Technical, quality, interpersonal skills
    • Multi-skilled employees
  • Safety, health and environment
    • Ensure safe working environment
    • Eliminate accidents and injuries
    • Standard operating procedures
  • Office TPM:
    • Reduce cost-related issues
    • 5S in office
    • Improve collaboration between functions
  • Development Management
    • Maintenance prevention
    • Early Equipment management
    • Maintenance in design phase
    • Very important, often neglected!!

5S

Seiri (sort), Seiton (straighten), Seiso (shine), Seiketsu (standardize) and Shitsuke (sustain)

59
Q

What is the TPM standards for OEE?

A

TPM standards: Availability = 90%, Performance = 95%, Quality =99% and OEE=85% (50-60% in Swedish industry)

60
Q

What is the advantages and disadvantages with TPM?

A

Advantages:

  • Holistic view company-wide integration
  • Simple and effective (e.g. autonomous maintenance)
  • Continuous improvement

Disadvantages:

  • Long and difficult implementation process
  • No detailed PM planning method
61
Q

What is the Reliability- centered maintenance (RCM)?

A

From aviation industry. Questioned why and how maintenance should be done. Maintenance so expensive because of the effect according to the bathtub curve.

According to RCM: Do only what must be done and reduce unnecessary maintenance Reliability is out in the centre. 4 basic features of RCM:

  1. Preserve functions
  2. Identify failure modes that can defeat the function
  3. Prioritize function need
  4. Select applicable and effective PM tasks for high priority failure modes.

Applicable = if the task is performed, it will accomplish one of three reasons for preventive maintenance (prevent or mitigate failure, detect one set of a failure, discover hidden failure)

Effective = we are willing to spend the resources to do it

62
Q

What dicitions can you take based on the wear out curves?

A
63
Q

What is RCM IIs 7 questions?

A

RCM II = RCM outside aciation industry 7 questions

  1. What are the functions and associated performance standards of the asset in its present operating context?
  2. In what ways does it fail to fulfil its function?
  3. What causes each functional failure?
  4. What happens when each failure occurs?
  5. In what way does each failure matter?
  6. What can be done o predict or prevent each failure?
  7. What should be done if the suitable proactive task cannot be found?
64
Q

What are the advantages and disadvantages with RCM?

A

Advantages

  • Reduction of maintenance cost
  • Documentation and traceability
  • Cross-functional team work
  • Emphasis on hidden failure modes
  • Improved safety

Disadvantages:

  • Time consuming (therefore expensive)
  • Subjective, and requires experience
  • Easy to misss dominant failure modes
65
Q

What is Condition based maintenance (CBM)? and the advantages and disadvantages?

A

Monitor system performance, system health root causes of failures, forecasting remaining useful life. CBM unitizes Condition Monitoring, e.g. in production equipment’s; vibration, thermography, oil analysis and ultrasonic. Is not only about sensors.

  1. Diagnostics = Finding the fault after occurring, or in the process of the fault occurring (fault not equal to failure)
  2. Prognostics = Predicting future failures by analysing current and previous history.

PF curve- the heart of CBM, describes equipment’s failure behaviour.

Advantages:

  • Prevents failures
  • Prevents unnecessary preventive maintenance
  • Very useful in critical equipment

Disadvantages:

  • Expensive monitoring equipment’s (but this is changing rapidly)
  • No failure elimination
66
Q

What is the oppertunities and challenges for digitalisation for product- service systems?

A

Opportunities:

  • Entirely new product-services by bonding hardware and software functionality
  • Tangible products + intangible services + digital architectures (e.g. platforms)
  • In-use product information (feedback to R&D and feed forward by real-time provision of services)
  • ”Data is the new oil”

Challenges:

  • Digital infrastructure
  • Security, privacy and ownership of data
  • Competence gap (difficult to attract talent)
  • ” Digital giants” and ”super firms”

For high value, long life cycle products- much of this revolves around maintenance!

67
Q

What are the oppertunities and challanges for digitalised manufacturing?

A

Data, robustness, real-time control, integration, autonomous production, competence, education, work environment, business models, services and legislation

Not just technological, but also social!

68
Q

What is defining “smart manufacturing”?

A

Four principles:

  • Data-driven decision-making
  • Human capital resource
  • Internal integration
  • External integration
69
Q

What are the contextual factors?

A
  • Change context
    • Leadership, corporate culture, algorithm interpretability
  • Investment context
    • ICT capital investments, complementary investments, quantifying the value of maintenance
  • Interface context
    • Digital platforms, openness, IT-security
70
Q
A

Production and product service systems (1 decks)

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