Serge Lambert

A reliability based maintenance policy: a case study

Reliability centered maintenance (RCM) incorporates sound guidance for managers who wish to attain high standards of maintenance at their operating plants. Since the amount and type of maintenance which is applied depend strongly on the machine or components age (DFR, CFR or IFR), on its replacement cost as well as on the cost and safety consequences of system failure, a careful analysis of the system components based on their reliability data should be done in order to optimize the maintenance program. This paper describes the methodology which was used at an aluminum plant in order to select critical machines and to develop an optimal maintenance policy based on reliability data of each machine, safety consequences of system failure, lead time and repair time, and components criticality.

Mixed production, flexibility and SME

In this study, a step by step management approach is developed in order to help SME (Small Manufacturing Enterprise) to reach basic, system, and aggregate flexibility and agility, despite their lack of resources. This research is justified by the fact that some large factories are lowering their fixed cost by moving processing machine towards specialized SME, and creating intelligent network of factories based on innovation, agility and JIT philosophy.

Adaptation of JIT phylosophy and Kanban technique to a small-sized manufacturing firm; a project management approach

Abstract In this study, a project management approach is used, in order to implement some elements of the Just-In-time philosophy to a small-sized manufacturing firm. The objective of this applied research was to overcome some of the problems that most of small firms are facing when implementing JIT, such problems are: lack of materials and human resources, high employees turnover, lack of influence over suppliers, etc. In order to overcome those obstacles, a project management approach was used. As a result of this project, productivity and quality went up, and lead time went down from six to less then two months.

Experimental analysis of 31 risk estimation tools applied to safety of machinery.

Abstract This article studies differences in the results of using different risk estimation tools in the same hazardous situations involving dangerous machinery. We investigated how (a) types of risk estimation parameters and methods of constructing tools, (b) the number of levels of each parameter, and (c) the number of risk levels influence the results. Consequently, 31 risk estimation tools were compared by using them to estimate risk levels associated with 20 hazardous situations. Risk estimation appears to be tool-dependent, as different tools give different results with identical hazardous situations. The scope of the tool, its use, and construction could explain these differences. This article also proposes a series of rules for constructing tools to alleviate many problems associated with the variability of risk estimations.

Manufacturing flexibility: SMT factors study

Electronics manufacturers are facing evolutionary and highly dynamic environment. Flexibility is becoming a must in their manufacturing processes especially those using surface mount technology (SMT). This study consists of assessing and predicting the effects of different strategies of products family formation based on different group technology policies (GSU and SDS); other operational variables are the flexibility and the performance of a SMT assembly line and reduction of setup time. Simulation and experimental design are used in order to predict the line performance.

Comparison study of scheduling rules and set-up policies for a SMT production line

This paper examines the effects of some independent variables on the performance of an electronic manufacturing Surface Mount Technology (SMT) production line operating in a highly dynamic environment. Variables considered are: scheduling rules and set-up policies. Experimental design, ANOVA and simulation techniques (Awesim, C) are used in order to predict the performance of a SMT line on the work-in-process, the throughput time and set-up time.

COMBINING REVERSE LOGISTICS TRANSPORT OF HAZARDOUS MATERIAL RETURNS WITH DISTRIBUTION

Abstract This paper deals with the transportation of hazardous waste returns when combining them with the existing distribution network. A mathematical model and a solution method to this industrial case study are proposed. Two scenarios are studied in order to assess the impact of adding hazardous waste returns to existing distribution routes. The results show that in order to accommodate returns, many of the existing routes will need to have more than 2 hours of unused time. The capacity of the trucks is a negligible factor. It is proposed to do a new combined study to consider the particular needs of both problems.