Effect of Failure Type on Downtime Duration for a Manufacturing Facility
Publication: Journal of Performance of Constructed Facilities
Volume 31, Issue 3
Abstract
Machinery infrastructure is usually prone to stoppage due to unexpected breakdowns. This paper analyzes possible failures root causes of manufacturing facilities, including machinery, to improve their performance. The research methodology utilizes a fact-driven statistical approach to investigate the statistical relationships between different affecting factors. These include failure modes, durations of downtime, working shifts, and products. Experimental designs models were employed in this paper, based on the analysis of variance (ANOVA) test and the Kruskal-Wallis test in combination with Tukey’s method for pairwise comparisons. ANOVA analysis identifies different downtime durations influenced by different types of failures. Similarly, the Kruskal-Wallis test results show that downtime durations are affected by different types of failures and not affected by different products and production lines. A case study was done on a dairy plant in Saudi Arabia where ten types of failures were identified. The results showed the top ranked failures to be finished product clearance, setup delay, raw material rejection, mechanical failure, and electrical failure. The findings help the management to develop learned lessons that help to minimize the cost and consequences of having frequent failures.
Get full access to this article
View all available purchase options and get full access to this article.
Acknowledgments
The authors thank King Fahd University of Petroleum and Minerals for the support and facilities that made this research possible.
References
Ahuja, I. P. S., and Khamba, J. S. (2008). “Total productive maintenance: Literature review and directions.” Int. J. Qual. Reliability Manage., 25(7), 709–756.
Al-Hinai, N., and ElMekkawy, T. Y. (2011). “Robust and stable flexible job shop scheduling with random machine breakdowns using a hybrid genetic algorithm.” Int. J. Prod. Econ., 132(2), 279–291.
Blanchard, B. S., Verma, D., and Peterson, E. L. (1995). Maintainability: A key to effective serviceability and maintenance management, Wiley, New York.
Bröchner, J. (2003). “Integrated development of facilities design and services.” J. Perform. Constr. Facil., 19–23.
Carper, K. L. (1987). “Failure information: Dissemination strategies.” J. Perform. Constr. Facil., 1–10.
Dweiri, F., and Meier, F. A. (1996). “Application of fuzzy decision-making in facilities layout planning.” Int. J. Prod. Res., 34(11), 3207–3225.
Evans, G. W., Wilhelm, M. R., and Karwowski, W. (1987). “A layout design heuristic employing the theory of fuzzy sets.” Int. J. Prod. Res., 25(10), 1431–1450.
Grobelny, J. (1987a). “On one possible fuzzy approach to facilities layout problems.” Int. J. Prod. Res., 25(8), 1123–1141.
Grobelny, J. (1987b). “The fuzzy approach to facilities layout problems.” Fuzzy Sets Syst., 23(2), 175–190.
Groenevelt, H., Pintelon, L., and Seidmann, A. (1992). “Production lot sizing with machine breakdowns.” Manage. Sci., 38(1), 104–123.
Gupta, M. C., Gupta, Y. P., and Evans, G. W. (1993). “Operations planning and scheduling problems in advanced manufacturing systems.” Int. J. Prod. Res., 31(4), 869–900.
Jones, K., and Sharp, M. (2007). “A new performance-based process model for built asset maintenance.” Facilities, 25(13–14), 525–535.
Karray, F., Zaneldin, E., Hegazy, T., Shabeeb, A. H., and Elbeltagi, E. (2000). “Tools of soft computing as applied to the problem of facilities layout planning.” IEEE Trans. Fuzzy Syst., 8(4), 367–379.
Kenne, J. P. (1999). “Experimental design in production and maintenance control problem of a single machine, single product manufacturing system.” Int. J. Prod. Res., 37(3), 621–637.
Liang, Z., He, Y., Wu, T., and Zhang, C. (2015). “An informative column generation and decomposition method for a production planning and facility location problem.” Int. J. Prod. Econ., 170, 88–96.
Minitab 17.3.0 [Computer software]. Minitab, Coventry, U.K.
Moua, B., and Russell, J. S. (2001). “Evolution of formal maintainability program for large manufacturing company.” J. Perform. Constr. Facil., 46–53.
Moubray, J. (2003). “21st century maintenance organization. Part I: The asset management model.” Maintenance technology, Applied Technology Publications, Barrington, IL.
Peters, B., and Yang, T. (1997). “Integrated facility layout and material handling system design in semiconductor fabrication facilities.” IEEE Trans. Semicond. Manuf., 10(3), 360–369.
Rabbani, M., Manavizadeh, N., and Hosseini Aghozi, N. S. (2015). “Robust optimization approach to production system with failure in rework and breakdown under uncertainty: Evolutionary methods.” Assembly Autom., 35(1), 81–93.
Raman, D., Nagalingam, S. V., and Lin, G. C. (2009). “Towards measuring the effectiveness of a facilities layout.” Rob. Comput. Integr. Manuf., 25(1), 191–203.
Singh, S. P., and Sharma, R. R. (2006). “A review of different approaches to the facility layout problems.” Int. J. Adv. Manuf. Technol., 30(5-6), 425–433.
Swanson, L. (2001). “Linking maintenance strategies to performance.” Int. J. Prod. Econ., 70(3), 237–244.
Xiong, J., Xing, L. N., and Chen, Y. W. (2013). “Robust scheduling for multi-objective flexible job-shop problems with random machine breakdowns.” Int. J. Prod. Econ., 141(1), 112–126.
Yang, T., and Hung, C. C. (2007). “Multiple-attribute decision making methods for plant layout design problem.” Rob. Comput. Integr. Manuf., 23(1), 126–137.
Yin, R. K. (2009). Case study research: Design and methods, 4th Ed., Sage, Thousand Oaks, CA.
Zhang, Y., Wu, X., and Zhou, X. (2013). “Stochastic scheduling problems with general position-based learning effects and stochastic breakdowns.” J. Scheduling, 16(3), 331–336.
Information & Authors
Information
Published In
Journal of Performance of Constructed Facilities
Volume 31 • Issue 3 • June 2017
Copyright
©2016 American Society of Civil Engineers.
History
Received: Jan 16, 2016
Accepted: Sep 19, 2016
Published online: Nov 28, 2016
Discussion open until: Apr 28, 2017
Published in print: Jun 1, 2017
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.