<p>The decision making processes in today's manufacturing systems represent very complex and challenging tasks. The desired flexibility in terms of the functionality of a machine adds more components to the machine. The real time monitoring and reporting generates large streams of data. However the intelligent and real time processing of this large collection of system data is at the core of the manufacturing decision support tools. </p> <p>This thesis outlines the use of Frequent Episodes in Event Sequences and Hidden Markov Modeling of throughput, quality and maintenance data to model the deterioration of performance in the components that make up the manufacturing system. The thesis also introduces the concept of decision points and outlines how to integrate the total cost function in a business model. </p> This thesis deals with the following three topics: <p>First, the component-based data structure of the manufacturing system is outlined especially throughput, quality and maintenance data. In this approach, the manufacturing system is considered as a group of components that interact with each other and with raw materials to produce the manufactured product. This interaction creates a considerable amount of data which can be associated with the relevant components of the system. The relations between the manufacturing components are established on a physical and logical basis. The components properties are clearly defined in database tables specifically created for this application. The thesis also discusses the web services in manufacturing systems and the portable technologies used in plant decision support tools. </p> <p>Second, the thesis presents a novel application of Frequent Episodes in Event Sequences to identify patterns in the deterioration of performance in a component using frequent episodes of operational failures, quality failures and maintenance activities. A Hidden Markov Model (HMM) is used to model each deterioration episode to estimate the states of performance and the transition rates between the states. The thesis compares the results generated by this model to other existing models of component performance deterioration while emphasizing the benefits ofthe proposed model through the use of the plant data.</p> <p>Finally the thesis presents a methodology usmg HMM probability distributions and Bayesian Decision theory framework to provide a set of decisions and recommendations under the condition of data uncertainty. The results of this analysis are then integrated in the plant maintenance business model.</p> <p>It is worthwhile mentioning that to develop the techniques and validate the results in this research; a Manufacturing Execution System (MES) was developed to operate in an automotive engine plant. All the data and results in this research are based on the plant data. The MES which was developed in this research provided significant benefits in the plant and was adapted by many other GM plants around the world.</p> / Thesis / Doctor of Philosophy (PhD)

Este trabalho apresenta um estudo da instrumentalização de software em Redes de Sensores Sem Fio, complementado pela aplicação, em um estudo de caso, de uma instrumentalização. A proposta da instrumentalização visa ampliar o conhecimento sobre essas redes em termos de desempenho, permitindo ao usuário tomar decisões suportadas pelo instrumento. Nesse sentido, foi realizada a abordagem conceitual em termos de Redes de Sensores Sem Fio, da tendência de padronização para essas redes e de instrumentalização por meio de software. Para a comprovação dos benefícios da adoção da utilização do conceito de instrumentalização de software nessas redes, foi desenvolvida uma rede de sensores utilizando esses conceitos, na qual foi possível avaliar o perfil dos aspectos temporais e da manutenção da qualidade da conexão. Os resultados obtidos evidenciam que é possível conhecer, com maiores detalhes, o comportamento da rede, o que melhora a qualidade da tomada de decisão do usuário em relação à sua utilização em aplicações com restrições temporais, nas quais os tempos de resposta envolvidos devem respeitar os limites máximos permitidos. / This thesis aims at the study of software instrumentation handling in terms of wireless sensor networks which is supplemented with the its application in a case study. The instrumentation purposes go towards the networks knowledge extension concerning its performance by allowing the user to make decisions based on software instrument reading. In this sense, a conceptual approach was performed which takes the wireless sensor network into account as well as the trend of standardization for these networks and the software instrumentation itself. In order to confirm the benefits on adopting the usage of software instrumentation concept on these networks, a wireless sensor network was developed using these concepts. In this sense, it was possible to evaluate the timing aspects profile and the link quality maintenance. The results show that is possible to know about the behavior of the network in details. By doing this, the quality of the users decision-making regarding their use in applications with time constraints, in which response time involved should respect the maximum allowable limits, has been improved.

Este trabalho apresenta um estudo da instrumentalização de software em Redes de Sensores Sem Fio, complementado pela aplicação, em um estudo de caso, de uma instrumentalização. A proposta da instrumentalização visa ampliar o conhecimento sobre essas redes em termos de desempenho, permitindo ao usuário tomar decisões suportadas pelo instrumento. Nesse sentido, foi realizada a abordagem conceitual em termos de Redes de Sensores Sem Fio, da tendência de padronização para essas redes e de instrumentalização por meio de software. Para a comprovação dos benefícios da adoção da utilização do conceito de instrumentalização de software nessas redes, foi desenvolvida uma rede de sensores utilizando esses conceitos, na qual foi possível avaliar o perfil dos aspectos temporais e da manutenção da qualidade da conexão. Os resultados obtidos evidenciam que é possível conhecer, com maiores detalhes, o comportamento da rede, o que melhora a qualidade da tomada de decisão do usuário em relação à sua utilização em aplicações com restrições temporais, nas quais os tempos de resposta envolvidos devem respeitar os limites máximos permitidos. / This thesis aims at the study of software instrumentation handling in terms of wireless sensor networks which is supplemented with the its application in a case study. The instrumentation purposes go towards the networks knowledge extension concerning its performance by allowing the user to make decisions based on software instrument reading. In this sense, a conceptual approach was performed which takes the wireless sensor network into account as well as the trend of standardization for these networks and the software instrumentation itself. In order to confirm the benefits on adopting the usage of software instrumentation concept on these networks, a wireless sensor network was developed using these concepts. In this sense, it was possible to evaluate the timing aspects profile and the link quality maintenance. The results show that is possible to know about the behavior of the network in details. By doing this, the quality of the users decision-making regarding their use in applications with time constraints, in which response time involved should respect the maximum allowable limits, has been improved.

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