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- Al-Najjar, Basim, 1954-, et al.
(författare)
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A computerised model to enhance the cost-effectiveness of production and maintenance dynamic decisions : A case study at Fiat
- 2013
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Ingår i: Journal of Quality in Maintenance Engineering. - : Emerald Group Publishing Limited. - 1355-2511 .- 1758-7832. ; 19:2, s. 114-127
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Tidskriftsartikel (refereegranskat)abstract
- Purpose:– To develop and test a model and software-based support system for better understandingof the interactions between man-machine-maintenance-economy (MMME), and enable cost-effective decisions.Design/methodology/approach:– The study is based on published knowledge and experience within maintenance, maintenance organization and production, and a case study.Findings:– Development of a model describing interactions between man-machine-maintenance-economy interactions and MMME software module. MMME test shows its ability to identify, quantify, assess and follow up losses in production time which is necessary when planning effective maintenance actions.Research limitations/implications:– In the paper the focus is to quantify production time losses in order to identify the root causes of the problem. The case study is performed at a manufacturing plant for truck engines.Practical implications:– A systematic approach of how to quantify and evaluate losses in production time in order to identify problems and problem areas within the production. This approach is discussed and motivated with the aim of achieving more cost-effective decisions in maintenance.Originality/value:– The model and software application developed enables a structured way of analyzing production time losses in order to find cost-effective solutions to the problems. The model is very flexible enabling it to be customized for a wide spectrum of branches.
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| 2. |
- Al-Najjar, Basim, 1954-
(författare)
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A computerized model for assessing the return on investment in maintenance : following up maintenance contribution in company profit
- 2009
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Ingår i: Engineering asset lifecycle management. - : Springer. - 9781849960021
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Konferensbidrag (refereegranskat)abstract
- In order to reduce as much as possible the economic losses that are generated due to lack or inefficient maintenance, it is necessary to map, analyse and judge maintenance performance and act on deviations before it is too late. It is always necessary for a company to act for increasing profit and consequently enhance its competitiveness. In this paper, a software model (MainSave) has been developed for mapping, monitoring, analysis, following up and assessing the cost-effectiveness of maintenance (and maintenance investments). MainSave can be used for assessing savings and profit/losses due to maintenance performance, identify problem areas and primarily plan for new beneficial investments in maintenance. The module has been tested at Fiat/CRF in Italy. The major conclusion is; applying MainSave it would be possible to identify, assess and follow up maintenance contribution in company business.
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| 3. |
- Al-Najjar, Basim, 1954-
(författare)
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A Concept for Detecting Quality Deviation Earlier than when using Traditional Diagram in Automotive : A Case study
- 2001
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Ingår i: International Journal of Quality & Reliability Management. - : Emerald. - 0265-671X .- 1758-6682. ; 18:9, s. 917-940
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Tidskriftsartikel (refereegranskat)abstract
- The problem addressed in this paper is how to utilise the concept of total quality maintenance (TQMain) to develop an integrated VBM (vibration-based maintenance) for detecting deviations in the machine condition and product quality (technical specifications), before the machine starts manufacturing defective items. Concepts of TQMain and integrated VBM are discussed. A technical analysis is conducted to identify quality problem cause roots when manufacturing crankshafts in Volvo, Motor, Skövde, Sweden. A factorial experiment is conducted to assess the effect and significance of the suspected causes. Vibration measurements from 7 points are collected. The major conclusion of this study is; when using an effective, e.g. on the basis of TQMain concept, integrated VBM, deviations in product quality can be detected at an earlier stage than that when using usual quality control diagrams. Manufacturing defective items can be reduced dramatically (or prevented) which will eliminate bad quality- related losses.
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| 4. |
- Al-Najjar, Basim, 1954-, et al.
(författare)
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A Conceptual Model for Fault Detection and Decision Making for Rolling Element Bearings in Paper Mills
- 2001
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Ingår i: Journal of Quality in Maintenance Engineering. - : Emerald. - 1355-2511 .- 1758-7832. ; 7:3, s. 192-206
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Tidskriftsartikel (refereegranskat)abstract
- Rolling element bearing failures in paper mill machines are considered in relation to their critical role in the machine function. The use of expensive, sophisticated and highly automated equipment and machines and the intention to achieve higher quality products, longer machine life, higher machinery effectiveness and safer operating processes were the main driving force motivating efforts to improve maintenance concept during the last 50 years. In this paper, a conceptual model that integrates the available condition information, the deterministic models used in condition monitoring based upon mechanical theory and the probabilistic models used in the area of operational research is developed and its applicability is discussed. This models covers fault detection of a mechanical component such as a rolling element bearing, prediction of its vibration level in the near future, assessment of the probability of failure of a component over a finite period of time of interest.
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| 5. |
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| 6. |
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| 7. |
- Al-Najjar, Basim, 1954-
(författare)
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A Maintenance Model for Identification, Quantification and Elimination of Losses in Companies Profitability : Application Examples
- 2009
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Ingår i: Proceedings of the 22nd international congress on condition monitoring and diagnostic engineering management. - Eibar : Fundación Tekniker. - 9788493206468
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Konferensbidrag (övrigt vetenskapligt/konstnärligt)abstract
- A production process includes several sub-processes, which may also be called working areas or disciplines that are responsible for performing the different tasks required to accomplish the mission of the process. It is crucial that the tasks performed in these sub-processes are synchronised with each other without unnecessary and uncontrollable gaps and overlapping, which in turn may lead to losses in production time and manpower. It is important to avoid a shortage of resources, unplanned stoppages and idle times that may arise due to the gaps. In this paper gaps are generated due to missing the tasks or inputs that are required because of deficiencies in planning, the lack of responsibilities or of knowledge and experience concerning these inputs. On the other hand, effective synchronising of production-different disciplines will enhance production process effectiveness as well as company profitability and competitiveness.The problem addressed in this paper is: How should maintenance be considered in conjunction with plant activities, such as production, quality and personnel competence, in order to easily and effectively identify and quantify company losses in profitability and competitiveness and consequently to eliminate underlying causes? In this paper the gaps and overlapping between maintenance, production, competence and quality are defined, identified and described through a technical analysis of the production sub-processes and their respective sub-organisations. The major result achieved in this study is the development of a new model (Maintenance Function Deployment (MFD)), for an easy and effective identification and quantification of company losses in profitability and competitiveness for cost-effective elimination of the root-causes. MFD can be applied through identifying:1. the requirements that are necessary to achieve and maintain company strategic goals,2. tools to maintain the condition of these requirements,3. activities for the effective utilisation of the tools above, and4. the factors required to support the integration of maintenance with plant business for enhancing production process effectiveness as well as company profitability and competitiveness.The structure of the quality house has been used as a platform for developing MFD model for effectively integrating maintenance with production, competence and quality. Two examples are conducted to demonstrate the possibility of applying the model and its potential for enhancing production processes profitably. The main conclusion is: applying MFD gives an enormous opportunity to continuously maintain the quality of the working areas under consideration, which makes MFD one of the company’s objective-driven tools for enhancing its profitability and competitiveness. Also, it implies the application of the PDCA cycle, which in turn improves the integration of relevant working areas cost-effectively and continuously.
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| 8. |
- Al-Najjar, Basim, 1954-
(författare)
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A Maintenance Model for Indentification, Quantification and Elimination of Losses in Companies Profitability : An Application Example
- 2009
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Ingår i: COMADEM 2009. - Eibar, Spain : Fundaci n Tekniker. - 9788493206468 ; , s. 45-53
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Konferensbidrag (refereegranskat)abstract
- A production process includes several sub-processes (working areas) that are responsible for performing the different tasks required to accomplish the mission of the process. Thus, it is important to avoid a shortage of resources, unplanned stoppages and idle times that may arise. The problem addressed in this paper is: How should maintenance be considered in conjunction with plant activities, such as production, quality and personnel competence for easily and effectively identifying and quantifying company losses in profitability and eliminating underlying causes? In this paper, the interactions between major working areas have been introduced and discussed. The major result achieved in this study is the development of a new model (Maintenance Function Deployment (MFD)), for an easy and effective identification and quantification of company losses in profitability. Four matrixes have been used for developing MFD model for effectively integrating maintenance with production, competence and quality. An application example is conducted to demonstrate the possibility of applying the model and its potential for enhancing production processes profitably. The main conclusion is: applying MFD gives an enormous opportunity to continuously maintain the quality of the working areas under consideration, which makes MFD one of the company’s objective-driven tools for enhancing its profitability and competitiveness.
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| 9. |
- Al-Najjar, Basim, 1954-
(författare)
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A method and an apparatus for predicting the condition of amachine or a component of the machine
- 2016
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Patent (populärvet., debatt m.m.)abstract
- The present invention relates to a methodand an apparatus for predicting the condition of a machine or a component of the machine based on measurements of a condition monitoring parameter. The apparatus comprising a data storage for storing a moving window including measurement values of the condition monitoring parameter, a monitoring module configured to determine whena measurement value exceeds a potential failure level at which damage of the machine or component is considered initiated, and to determine the point in time (tP) when the monitoring parameter exceeded the potential failure level, a data cleaning module configured to discarda new measurement value if it is smaller than the latest stored measurement value inthe moving window, to determine an expected value for the measurement based on a defined pattern for the condition monitoring parameter, which pattern reflects an expected behavior of the monitoring parameter after damage has been initiated, and the time elapsed since the point in time the monitoring parameter exceeded the potential failure level, and to discard the new measurement value if it deviates too much from the expected value, and to store not discarded measurement values in the moving window, and a prediction module configured to predict the level of the condition monitoring parameter at a future point in time based on the measurement
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| 10. |
- Al-Najjar, Basim, 1954-, et al.
(författare)
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A Model for Increasing Effectiveness and Profitability of Maintenance Performance : A Case Study
- 2018
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Ingår i: Engineering Asset Management 2016. - Cham : Springer. - 9783319622743 ; , s. 1-12
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Konferensbidrag (refereegranskat)abstract
- In today’s market, companies strive to achieve the competitive advantages. Failing in achieving these goals could threaten the companies’ existence. Failures in the operative level impact negatively on achieving these goals. In order to record these failures for better actions planning, special systems are often used for counting the number of failures, registering the duration of machines downtime and uptime for assessing the total downtime and classifying problems/failures in categories that are decided in advance. These categories can be Electrical, Electronic, Hydraulic, Mechanical, Pneumatics, Human error, and Miscellaneous. In this study, we develop a model to break down the contents of a company/machine failure databases, prioritize failures, assess economic losses due to failure impact on the competitive advantages and suggest a method of how maintenance actions should be rank-ordered cost-effectively. The model is tested using real data. The major results showed that losses aremainly due to two categories i.e. “Bad quality“ and “Less profit margin”, where failures of “Gear”, “Bearing” and “Raw materials quality” cause most of the losses. It is concluded that this model enables the user to quickly identify and prioritize maintenance and improvement efforts cost-effectively.
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