Paul M. Gibbons

A Systems Approach Towards Reliability-Centred Maintenance (RCM) of Wind Turbines☆

Abstract Wind turbines are a proven source of clean energy with wind power energy harvesting technologies supplying about 3% of global electricity consumption. However there is an increasing demand on maintenance and operational improvements since turbines have been plagued with downtime problems of major components e.g. gearboxes and generators, especially with offshore turbines which are difficult to access. Reliability Centric Maintenance (RCM) is a way of capturing the potential causes of downtime and poor performance by preventing failures and having a proactive approach to operations and maintenance (O&M). However, for a large fleet of turbines, adopting the RCM approach becomes difficult due to the complexities that arise as a result of the interactions between individual elements that make up the system in the product lifecycle. This paper discusses how a systems thinking approach can be used to identify the relevant aspects and possible interactions between the RCM approach and wind turbine gearboxes and also how the gaps that exist within the system can be closed so as to add value to business. The outcome of the paper is a proposal for applying a systems approach to wind turbine gearbox operation and maintenance, optimising the asset value adding contribution at minimal total cost to the operator.

Introducing OEE as a measure of lean Six Sigma capability

Purpose – The current paradigm for assessing overall equipment effectiveness (OEE) is challenged as being anachronistic to the needs of businesses that now require a more holistic indicator of plant and process effectiveness. The purpose of this paper is to introduce a new framework that expands the original OEE measure to inform business performance at multiple levels focusing on adding benchmarkable indicators of asset management effectiveness and process capability. The ability to compare internal performance against external competition and vice verse is argued as being a critical attribute of any performance measurement system.Design/methodology/approach – The research methodology taken incorporated an action research approach using a pilot study combining case study research with an action research process of planning, observing and reflecting summarized as taking an action case research design.Findings – The OEE and related literature is replete with many different enhancements to the original OEE ...

The development of a value improvement model for repetitive processes (VIM)

Purpose – The purpose of this paper is to introduce a value improvement model (VIM) for repetitive processes applicable to any business where people and/or plant provide a service to support the overall business objective. Arguing competitive advantage can be realised through different amalgams of productive and strategic resources, the VIM introduced focuses on aligning resource bundles and influencing factors creating efficacious, efficient and effective processes by applying Lean thinking and Six Sigma tools and techniques more holistically.Design/methodology/approach – The research methodology taken incorporated a case study approach complimented by the action research process of planning, observing and reflecting summarized as an action case study research design. The case study data examine the development of a management cycle of value improvement on an inter‐terminal shuttle transportation system within a busy international airport.Findings – The VIM has been proven as a useful model for understan...

Developing an asset management value improvement model (a‐VIM) approach for an airport operational engineering environment

Purpose – A previous attempt to implement the use of historical measures of asset management effectiveness – as part of a value improvement model (VIM) for repetitive processes – had not been 100 percent successful within an airport operational engineering environment. Taking into account the more holistic approach realised through applying a soft systems methodology (SSM), the purpose of this paper was to use the CATWOE (Customers, Actors, Transaction, World View, Owner and Environment) tool to gain an understanding of the root definition of the problem statement developing a conceptual model used to facilitate an improvement to the implementation process.Design/methodology/approach – The research methodology taken incorporated an action research approach combining case study research with an action research process of planning, observing and reflecting summarized as taking an action case research design.Findings – This research has developed a visual and systematic framework that enables managers to und...

The development of a lean resource mapping framework: introducing an 8th waste

Purpose – The purpose of this paper is to develop a useful framework for identifying a new lean waste classified as polarization. Complementing the extant lean conceptual framework, the authors argue there is a need to understand how resources are deployed and how these can be best aligned to maximise their value‐adding contributions. The purpose of this paper is therefore to identify a conceptual framework and a supporting practitioner approach for understanding and identifying instances of the non‐value adding polarization of resources.Design/methodology/approach – A captious and taxonomic review of the lean conceptual literature is made and the link to the resource‐based view (RBV) of the firm is acknowledged. A conceptual framework is developed and adopting an action case study approach through practitioner intervention, a lean resource mapping framework is presented.Findings – A useful mechanism is developed following a sequential processing mapping framework concluding with a “current state” lean re...

The Application of a Lean Philosophy During Manufacture of Advanced Airframe Structures in a New Product Introduction (NPI) Environment

The manufacture of primary structural wing components from high-performance composite materials is a relatively new technique. GKN Aerospace faces the challenge of manufacturing complex large-scale aero-structures by the ‘Automated Fibre Placement’ (AFP) process whilst transitioning from the ‘new product introduction environment’ to meet contractual production rates. This paper reports on the adoption of the Lean philosophy within a ‘value stream’ by capturing staff perceptions to gain an understanding of the success levels and areas of concern. The research is of particular importance since the ‘barriers of resistance’ in manufacturing environments can be high if Lean is not introduced in a fashion production staff can relate to. Therefore, the research conducted offers GKN the opportunity to focus on the specific areas to realise continuous improvement through the adoption of Lean. The research investigation consisted of a questionnaire employed to gauge staff perceptions from the end of operations at Year 1. At the end of Year 2, the questionnaire was repeated to broaden the cross-sectional study over a longitudinal time horizon. The results were subject to statistical significance testing which showed the differences in staff perceptions were evident. These differences were attributed to the overall level of Lean understanding and appreciation within the facility. The novelty of this research is manifested in how well Lean practice has been adopted in a large-scale aerospace manufacturing facility transitioning from the NPI environment to serial production. Other Lean practitioners and academics will be able to apply the approach in their work, especially those looking to incorporate a Lean philosophy in a NPI environment.

A Framework for Optimizing Product Performance Through Using Field Experience of In-Service Products to Improve the Design and Manufacture Stages of the Product Lifecycle

For many component sub-systems which make up the individual elements of a larger product system, the optimization of their performance in the system becomes more difficult through design modifications and/or manufacturing process improvements alone. The authors argue this can be improved if adequate field performance data has been fed back to the early stages of the product lifecycle. This paper presents a framework for an inclusive lifecycle approach to optimizing product performance through the effective use of field experience and knowledge to improve the design and manufacturing of sub-systems. The problem is presented alongside a taxonomic and captious review of literature of relevant subject areas, followed by a case study using wind turbine sub-system components as a basis to support the investigation. A framework is then developed through the combination of systems thinking and continuous improvement tools, applied to the conventional product lifecycle. The findings of the investigation indicate that sub-system performance can be improved through the accumulation of knowledge fed back to the design and manufacture stages of the product lifecycle using information from in-service product performance. The approach would be useful to practitioners and academics with an interest in applying an inclusive and holistic approach to product lifecycle management. This framework is particularly useful for companies that produce and/or operate systems whose sub-systems are manufactured by different suppliers.

A systems a Reliability-Centred Maintenance (RCM) of wind turbines

Abstract Wind turbines are a proven source of clean energy with wind power energy harvesting technologies supplying about 3% of global electricity consumption. However there is an increasing demand on maintenance and operational improvements since turbines have been plagued with downtime problems of major components e.g. gearboxes and generators, especially with offshore turbines which are difficult to access. Reliability Centric Maintenance (RCM) is a way of capturing the potential causes of downtime and poor performance by preventing failures and having a proactive approach to operations and maintenance (O&M). However, for a large fleet of turbines, adopting the RCM approach becomes difficult due to the complexities that arise as a result of the interactions between individual elements that make up the system in the product lifecycle. This paper discusses how a systems thinking approach can be used to identify the relevant aspects and possible interactions between the RCM approach and wind turbine gearboxes and also how the gaps that exist within the system can be closed so as to add value to business. The outcome of the paper is a proposal for applying a systems approach to wind turbine gearbox operation and maintenance, optimising the asset value adding contribution at minimal total cost to the operator.

Introducing a Value Improvement Model for Manufacturing (m-VIM)

This paper introduces a value improvement model (VIM) for repetitive processes applicable to any business where people and/or plant provide a service to support the overall business objective. Arguing competitive advantage can be realised through different amalgams of productive and strategic resources, the VIM introduced focuses on aligning resource bundles and influencing factors creating efficacious, efficient and effective processes by applying Lean thinking and Six Sigma tools and techniques more holistically. The research methodology taken incorporated a case study approach complimented by the action research process of planning, observing and reflecting summarized as an action case study research design. The case study data presented examines the possible improvements to an Extrusion manufacturing process that are achieved through the adoption of the VIM. The m-VIM is introduced as a useful tool for a visual and systematic framework that enables managers to understand, assess and improve repetitive processes within their businesses.

Procedia Computer Science

Abstract Wind turbines are a proven source of clean energy with wind power energy harvesting technologies supplying about 3% of global electricity consumption. However there is an increasing demand on maintenance and operational improvements since turbines have been plagued with downtime problems of major components e.g. gearboxes and generators, especially with offshore turbines which are difficult to access. Reliability Centric Maintenance (RCM) is a way of capturing the potential causes of downtime and poor performance by preventing failures and having a proactive approach to operations and maintenance (O&M). However, for a large fleet of turbines, adopting the RCM approach becomes difficult due to the complexities that arise as a result of the interactions between individual elements that make up the system in the product lifecycle. This paper discusses how a systems thinking approach can be used to identify the relevant aspects and possible interactions between the RCM approach and wind turbine gearboxes and also how the gaps that exist within the system can be closed so as to add value to business. The outcome of the paper is a proposal for applying a systems approach to wind turbine gearbox operation and maintenance, optimising the asset value adding contribution at minimal total cost to the operator.