This master thesis scrutinizes maintenance of production line made of two grinding machines used in bearing production. In the first section of the work, general principles of industrial maintenance are summarized. In the following practical section, maintenance of the production line is analysed. A calculation for determining production line downtime costs caused by machine failure is designed enabling an analysis of the effectiveness of investment into the diagnostic system of the machine. Lastly, possible measures for optimization of the production line’s maintenance are proposed.

Master thesis is focused on the study of effectiveness of selected machines in the company through indicators of Overall Equipment Effectiveness. The aim is to increase productivity of machinery by monitoring machine run. Analyses are performed on selected machines which are found out downtimes reducing machine run. Methods and tools of lean manufacturing are used for determine downtimes as a core part. Specifically, the implementation of the first phase of TPM – “Total Productive Maintenance” which is used in manufacturing, for determine current status of machines. Maintenance of machinery is also referred in the master thesis as important part of Overall Equipment Effectiveness. Individual factors of OEE are identified as a result of these analyses which are directly affected to productivity of machines. The output of these analyses is to design countermeasures against each downtime and system design of monitoring tools including technical and economical evaluation. Machine monitoring with automatic data collection based on calculated data is suitable option for the company.

För att kunna utföra energieffektiviserande åtgärder i en befintlig byggnad, och generera ett bra utfall, krävs goda kunskaper om projektet. Detta betyder att alla discipliner måste ha ett gott samarbete och att varje disciplin måste ta sitt ansvar för uppgiften. Det är inte alltid som utfallet blir det optimala. En sammanställning i tabellform kan tydligt påvisa de frekventa problemen. Detta har genom att belysa de problem som uppstår i samband med projektering, installation och drift av värmepumpar i tre olika fall genererat en sammanställd tabell. Resultatet visar att åtta olika problem förekommer och samtliga resultat förklaras och analyseras. Genom att påvisa svagheter, och ge förslag på möjliga åtgärder kan problem med projektering, installation och drift av värmepumpar minska. / In order to be able to perform energy efficiency measures in an existing building, and generate a good outcome, good knowledge of the project is required. This means that all disciplines must have a good cooperation and that each discipline must take responsibility for the task. It is not always that the outcome will be optimal. A summary in tabular form can clearly identify the frequent problems. This is done by highlighting the problems that arise in connection with the design, installation and operation of heat pumps in three different cases, generating a compiled table. The result shows that eight different problems occur and all results are explained and analyzed. By detecting weaknesses, and suggesting possible measures, problems with the design, installation and operation of heat pumps may decrease.

<p dir="ltr">Reverse osmosis (RO) is emerging as the world’s leading desalination technology due to its superior energy efficiency and the shift towards renewable electrification. However, RO systems need to further improve efficiency, increase operating flux, reach higher salinities (>7.5% w.t.), and minimize component complexity. Treating RO as a dynamical system, this dissertation invents new processes for high-efficiency desalination that achieve milestones for low downtime and high final salinity. It also introduces modeling methods that include more detail (e.g. salt retention, time-varying salinity, concentration polarization, salt transport, temporal multi-staging, etc.) and the first use of certain optimization methods in RO.</p><p dir="ltr">Batch RO is an unsteady, pressure driven process that efficiently desalinates a saline feed volume over time by continuously recirculating the brine through the membrane module. A tank houses the concentrating feed and mediates the streams entering and leaving the membrane module. Most studies so far have concentrated on the high-pressure tank design that requires finite downtime at the end of each stroke. A scalable pressure exchanger batch RO (PX-BRO) configuration using atmospheric tanks that practically has zero downtime and produces permeate even while flushing is first described in this dissertation.</p><p dir="ltr">To achieve high recovery at nominal RO pressures, osmotically assisted RO processes have both sides of the membrane saline and the streams usually in counterflow. The first unsteady osmotically assisted process based on the high-pressure piston tank design, batch counterflow RO (BCFRO) is introduced which dramatically reduces the energy needs. To address the issue of high component count in spatial multi-staging, the first “temporally multi-staged” BCFRO process is also introduced. The new process uses the pressure ex- changer and atmospheric pressure tank design for scalability and operational flexibility.</p><p dir="ltr">For membranes with low salt rejection, it becomes imperative to integrate the salt trans- port dynamics for deciding operating and initial conditions. Trajectory optimization is used to match salinity and volume between stages of temporally multi-staged BCFRO. Treating the process as an optimal control problem, a framework for obtaining time varying flux pro- files that minimize the specific energy consumption is also developed. Both reduced order and discretized models are developed to analyze these new batch RO configurations.</p>

Major drivetrain components of the Epiroc machines like axles, gearboxes, transmission, torqueconverter, clutch, and bearings are critical components which are focused upon in this thesis. Failure of these major component results in breakdown of the vehicle and if early fault detection is not existing, then this causes engineers and technicians to spend a substantial amount of time to identify the root cause of the failure. Due to this, the machine stands still until the problem is identified and repaired creating a negative impact on customer satisfaction. Thus, failure of these components results in costly downtime. Ways of improving the uptime of the machine have been an ongoing discussion due to costly downtime subjected to component failure. To improve uptime, reduce MTTR, and create acompetitive edge, a drivetrain sensor system is suggested to implement in this thesis that will monitor real-time operating data from these drivetrain components. In this way, the health of the drivetrain will be continuously monitored and if there is any degrade planned maintenance can be scheduled well in advance and spare parts inventory can be managed more efficiently. In addition, this will generate competitiveness for Epiroc products in the market. Epiroc being in competitive business, continuously aims to improve its products and services to satisfy customer needs, improve total cost of ownership, life cycle cost, and increase sales and profit. Epiroc is a leading productivity partner for the mining, infrastructure, and natural resource industries. It develops and manufactures innovative drilling rigs, quarrying, and construction equipment with state-of-the-art technology and provides world-class service and consumables. / Epiroc bedriver konkurenskraftiv verksamhet. Målet är att kontinuerligt förbättra sina produkter och tjänster för att tillgodose kundernas behov, förbättra den totala ägandekostnaden, livscykelkostnaden samt att öka försäljningen och vinsten. Epiroc är en ledandeproduktivitetspartner för gruv-, infrastruktur- och naturresursindustrin. Det utvecklar och tillverkar innovativa borriggar, stenbrott- och byggutrustning med toppmodern teknik och tillhandahåller service och förbrukningsvaror i världsklass. Att förbättra maskinens drifttid har alltid varit en kontinuerlig diskussion på grund av kostsamma stopp som orsakats av komponentfel. Om det uppstår större komponentfel som leder till att fordonet går sönder ochtidig feldetektering inte existerar, leder detta till att ingenjörer och tekniker måste spendera mycket tid på att identifiera orsaken till felet. På grund av detta står maskinen stilla tills problemet identifieras och repareras vilket skapar en negativ inverkan på kundnöjdheten. Viktiga drivkomponenter som axlar, växellådor, transmission, vridmomentomvandlare, koppling och lager är exempel på sådana kritiska komponenter vars fel resulterar i kostnadstopp. För att förbättra drifttiden, minska MTTR och skapa en konkurrensfördel för Epiroc-produkter, presenteras ett drivsystemsensorsystem i denna rapport som möjliggör övervakning av realtidsdata från dessa drivlinekomponenter. På detta sätt övervakas drivlinanshälsa kontinuerligt och om det uppstår någon försämring kan planerat underhåll planeras i godtid och reservdelslager hanteras effektivare. Dessutom kommer detta att skapa konkurrenskraft för Epiroc-produkter på marknaden.

El desarrollo de la presente tesis forma parte de un estudio realizado en una empresa que brinda servicios de mantenimiento y reparación de motores eléctricos para minería, industria y generación de electricidad. La tesis tiene como finalidad proponer un modelo de gestión que permita agilizar el tiempo de reparación de motores eléctricos de corriente continua, debido a que los clientes se vienen quejando por incumplimientos en la fecha de entrega del servicio, esto genera pérdida de credibilidad, imagen de la empresa y futuros negocios. Para remediar la problemática se utilizaron herramientas de mejora continua tales como análisis de Pareto, espina pescado, 5 por qué y matriz de priorización para determinar el estado actual del servicio de reparación de motores y determinar cuál será nuestro foco para la investigación, basado en este diagnóstico se ha establecido un estándar en la nomenclatura de actividades de un servicio completo de reparación de motor y se implementó un análisis de muestreo de trabajo para determinar el tiempo de estas actividades sin cabida a los tiempos improductivos. Una vez determinado los tiempos se implementó la Hoja de Ruta la cual sirve de fuente para el seguimiento y supervisión más exacta de las actividades durante la ejecución del servicio y de esta manera cumplir con el tiempo de entrega prometido al cliente. El modelo propuesto logra disminuir el tiempo de ejecución de un servicio completo de motor eléctrico del tipo CC en un 17%, así mismo se obtuvo un incremento significativo en nuestro indicador de cumplimiento con la fecha de entrega pactada y una disminución de quejas de los clientes. The development of this thesis is about of a company that provides maintenance and repair services of electric motors for mining, industry and electricity generation. The thesis aims to propose a management model that allows speed up the repair time DC electric motors, because customers have been complaining about violations on the date of delivery of the service, which entails loss of credibility, image of the company and future business. To remedy the problems we used quality tools such as Pareto analysis, fishbone, 5 why’s and prioritization matrix to determine the current state of the service engine repair and determine what will be our focus for research, based on this diagnosis it has set a standard in the nomenclature of activities of a full-service repair, also Work sampling was used to determine the time to accommodate these activities without downtime. Once determined the times we set the Roadmap which serves as a source for more accurate monitoring and supervision of the activities during the execution of the service and thus meet the promised delivery time to the customer was implemented. It managed to reduce the execution time of a full service type DC electric motor by 17%, also a significant increase was obtained in our indicator of compliance with agreed delivery date and a decrease in customer complaints.

The aims of this dissertation are to analyze the current state of process control, to identify the product range in selected organization and to design the process planning methodology to ensure an optimal implementation. Optimization is understood as costs minimization while keeping an acceptable continuity of supply. The dissertation contains a description of technological and non-manufacturing processes of brick products, as well as the summary and description of the basic tools of quality management.

The usage of information technology (IT) systems has become an integral part of assembly manufacturing. Supervisory control and data acquisition (SCADA) systems are widely used in order to control production cycles and monitor equipment such as conveyor belts. Other common IT systems are related to logistics, data analysis, or organizing of incoming and outgoing orders. In this thesis we create a model for the IT systems at the fuel pump and fuel injector manufacturer Scania XPI. One model is developed for the current state of the IT systems at Scania XPI, and one model is developed detailing the future state. The current state model consists of charts showing where in the production process that data is transmitted between which IT systems. This thesis utilizes the current state model in order to suggest improvements to the IT systems. These improvements are detailed in the model for the future state of IT systems at Scania XPI. Overall equipment efficiency (OEE) is a measurement of the performance of an industrial operation based on the percentage of up time running at full capacity compared to the available run time. Measurement of OEE requires that only downtimeduetointernal circumstances within the operation is taken into account, and that any potential quality deviations due to the operation are accounted for. Taking into account the variability of manufacturing processes, this thesis proposes solutions to issues in data processing required to measure the efficiency of operations in assembly manufacturing, such as identifying if process breakdowns are caused by external factors. The proposed solution is a system called "Process data analysis system" (PDAS), which uses the recorded machine statuses throughout operation in order to calculate process downtime and OEE. PDAS was implemented using the incremental waterfall model as a software development methodology. PDAS was evaluated by conducting four groups of experiments and a comparison to the PUS (processuppföljnings system) at Scania XPI. Automatically classifying downtime events as planned or unplanned allows PDAS to give an accurate view on the efficiency of the assembly production. The software can be used at Scania XPI and it’s functionality has been verified on assembly production running in ordinary conditions. We show that software can be developed to process industrial data in order to measure assembly line efficiency. Eventually, design and implementation of a downtime management system for assembly production is achieved as a final product of this thesis. / Användningen av informationsteknik (IT) system har blivit en viktig del av monteringstillverknings industrin. Supervisory control and data acquisition (SCADA) system är ofta implementerade i syfte att kontrollera produktionens takt och för att övervaka eller styra produktionens utrustning. Andra vanliga IT-system är relaterade till logistik, data analys, eller hantering av ingående och utgående beställningar. I detta examensarbete skapar vi en modell för IT-systemen på dieselpump och dieselinjektor tillverkaren Scania XPI. Denna modell visar både hur IT-systemen fungerar idag och hur de kan förbättras. Current state modellen består av diagram som visar var i produktionsprocessen som data skickas mellan IT-systemen. Vi använder oss av current state modellen i syfte att föreslå förbättringar till IT-systemen. Dessa förbättringar beskrivs i en modell för future stateäv IT-systemen hos Scania XPI. Overall equipment efficiency (OEE) är ett mått på prestandan på effektiviteten av industriell verksamhet baserat på procentandelen av drifttiden utan kvalitets avvikelser utan stopp jämfört med den totala drifttiden. Mätning av OEE kräver att driftstopp på grund av externa omständigheter ej tillräknas stopp tiden, och att kvalitets avvikelser kan mätas. Detta examensarbete föreslår lösningar på problem inom databehandling som krävs för att mäta produktionens effektivitet vid monteringstillverkning, exempelvis att identifiera om driftstopp som orsakas av externa omständigheter. Lösningen som presenteras är utveckling av Process Data Analysis System"(PDAS), som använder sig av automatiskt rapporterad maskinstatusdata för att beräkna stopp tid och OEE. PDAS implementerades med "incremental waterfall modelsom metodologi för mjukvaruutveckling. PDAS utvärderades genom att genomföra fyra grupper av experiment och med hjälp av en jämförelse med PUS (processuppföljnings system) hos Scania XPI. Genom att automatiskt klassificera planerad och oplanerad stopp tid ger PDAS en mer ackurat bild av effektiviteten för monterings produktionen. Mjukvaran kan användas av Scania XPI och funktionen av PDAS har verifierats för monteringstillverkningen under vanliga produktionsomständigheter. Vi visar att mjukvaran kan användas för att bearbeta industriell data i syfte att mäta effektiviteten av monterings tillverkningen. Slutligen uppnås design och implementation av ett system för stopptids hantering för monterings produktion som en produkt av denna uppsats.

With the world economy becoming unpredictable, it has become a necessity for businesses to relook at the way they do business. The world has become competitive and companies that aim to become profitable have seen the need to find ways to improve efficiencies and increase productivity to stay relevant. There has been an adoption of strategies that are aimed at improving the efficiencies in companies such as Total Productive Maintenance (TPM). The strategy is aimed at improving equipment efficiencies and increase productivity through the transfer of certain skills from maintenance personnel to operators. The aim is that the operators perform some of the activities that the maintenance people used to do and they do the more complex tasks. By transferring these skills to operators there is constant cleaning, inspections and lubricating of equipment. This frees up time for maintenance people to do planning and other jobs that require time and higher skills levels. The implementation of these activities allows companies to tap into unused capacity that was always hidden by breakdowns and unplanned stops. The process however requires commitment from management and all stakeholders involved in the organisation. There are prescribed implementation processes that can be followed or companies can follow their own processes but the fundamentals of involving people from the onset must be followed. The involvement of stakeholders creates commitment at all levels and in order to sustain this initiative people must be committed to it. The inclusion of the activities transferred from maintenance people to operators, will reinforce the knowledge and habits required from operators and perhaps sustain the initiative. / MBA, North-West University, Potchefstroom Campus, 2015

With the world economy becoming unpredictable, it has become a necessity for businesses to relook at the way they do business. The world has become competitive and companies that aim to become profitable have seen the need to find ways to improve efficiencies and increase productivity to stay relevant. There has been an adoption of strategies that are aimed at improving the efficiencies in companies such as Total Productive Maintenance (TPM). The strategy is aimed at improving equipment efficiencies and increase productivity through the transfer of certain skills from maintenance personnel to operators. The aim is that the operators perform some of the activities that the maintenance people used to do and they do the more complex tasks. By transferring these skills to operators there is constant cleaning, inspections and lubricating of equipment. This frees up time for maintenance people to do planning and other jobs that require time and higher skills levels. The implementation of these activities allows companies to tap into unused capacity that was always hidden by breakdowns and unplanned stops. The process however requires commitment from management and all stakeholders involved in the organisation. There are prescribed implementation processes that can be followed or companies can follow their own processes but the fundamentals of involving people from the onset must be followed. The involvement of stakeholders creates commitment at all levels and in order to sustain this initiative people must be committed to it. The inclusion of the activities transferred from maintenance people to operators, will reinforce the knowledge and habits required from operators and perhaps sustain the initiative. / MBA, North-West University, Potchefstroom Campus, 2015