CERES :: Browsing by Author "Greenough, Richard"

Browsing by Author "Greenough, Richard"

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Open Access
Conceptual design of a support documentation system to assist troubleshooting in manufacturing
(2005-04) Juliao, Jorge; Greenough, Richard
This research explores the conceptual design of a Support Documentation System (SDS), to assist manufacturing maintenance personnel during troubleshooting. Manufacturing systems maintenance is a crucial element of any organisation’s operating strategy. One of its main goals is to reduce downtime, both by avoiding the occurrence of failures and by effective reaction to breakdowns. Currently, most downtime reduction studies focus on the prevention of failures. Although these studies have made a significant contribution toward downtime reduction, it is impossible to prevent all failures. As such, troubleshooting will always be necessary for maintenance personnel to provide an effective contribution to their organisation. This research proposes a Support Documentation System that will improve maintenance through documentation management. It is argued that troubleshooting time will be reduced since such a system could provide maintenance personnel with enhanced access to support documentation, particularly to failure records. Until this research, little direct empirical evidence had been collected about the feasibility of such a system, and about the performance of current systems regarding troubleshooting support. There had also been no evidence concerning maintenance personnel requirements for improved support documentation. The objectives of this research are to assess the feasibility of the SDS, to determine why current systems do not effectively support troubleshooting, and to identify key features for the development of the SDS. To fulfil the objectives of this research, exploratory investigations were conducted. Questionnaire and interview surveys of maintenance practitioners, equipment vendors, and CMMS developers were performed to determine the status of failure records management and the reasons for the failure of current systems. A case study strategy was employed within three companies to identify requirements for the development of the SDS. The findings of this research are that the development of an SDS is feasible, and that current systems do not effectively support troubleshooting. The research identifies a set of design features for the SDS. It presents the end-user requirements, a ranking of most relevant troubleshooting data to be included in the failure records, and a list of record attributes that are to be used to better identify and classify records. The latter attributes constitute the means to manage failure records in a systematic way.
Open Access
Conceptual simulation design
(Cranfield University, 2007-09) Ochwa, Michael O,; Greenough, Richard
The work presented in this thesis considers the issues related to the design and implementation of the rotor blade production facility at Rolls-Royce. The volume production of this component will be significantly higher than Rolls Royce has ever delivered on similar projects. As a result, a future factory consisting of process lines and manufacturing cells will be built. The issue considered includes the evaluation of various factory designs and layout techniques that will improve production flow, optimal capacity utilization, and minimum work-in- process and lead-times. The subject of manufacturing cells verses machine utilization was also considered. This factory design and selection analysis was supported by extensive research comprising literature review and simulation study of various manufacturing layouts including cellular, job-shop type functional layout and hybrid configurations. Therefore, this study provides a basis to properly carry out analysis of the current Rolls-Royce production facilities and subsequently the preliminary conceptual simulation design of the future factory to manufacture L-Generic-blisk and F-Generic-blisk drive engine compressor Generic-blisk. A number of cell and flow-line design concepts were analysed with a succession of flexible Witness models (configured and driven by Microsoft Excel) and used to analyse the flow and productivity, to support a sustained growth in production volumes and maturation of process.
Open Access
The contribution of lean thinking to the maintenance of manufacturing systems
(Cranfield University, 2003) Davies, Christopher; Greenough, Richard
Despite many significant contributions and advances of lean thinking recorded in articles, books, and industrial case studies, its impact upon the maintenance function has not been fully investigated. From a maintenance perspective, excluding TPM, little or no insight into the use of lean thinking concepts in maintenance can be found in the literature, despite prominent contributors advocating greater management and business integration. An objective of the research described in this thesis was to satisfy the need for industry to understand the contribution of lean thinking to the maintenance of manufacturing systems. A research hypothesis (lean thinking improves the effectiveness of the maintenance function) was therefore devised that aimed to bridge this gap in knowledge in which the researcher developed two new tools alongside existing methodologies for further investigation. The first novel research tool, a lean concept reference framework, was used to comprehensibly represent fe--antfiffikifig concepts possible within a company, and maintenance in particular. Ihe sec n oyýý _411 measure of maintenance performance comprised a number of indicators that sign ough ify c maintenance activity. This was used to reflect the impact of lean concept use by maintenance through change in activity performance. The research investigates the current views of lean thinking and maintenance within the UK, and particularly in the automotive industry. It exposes the diversity of maintenance as a function within this industry, and highlights the scope of lean concept use and understanding. As an outcome of the research, it was found that each company investigated had different reasons for adopting and using lean concepts within their maintenance function. Similarly, each company differed in the management and use of their performance data. Nonetheless, all those investigated accepted the role of lean concept use within maintenance, and considered certain elements useful. These elements were used as an aggregation of tools to assist maintenance in their activities rather than using them to develop an alternative maintenance strategy. However, perception of lean concept use, and the perceived benefits gained differed according to different viewpoints. Although it was generally accepted that lean use bought about or improved overall skills, and helped provide the basis of a more robust and standardised maintenance department, concern was expressed concerning the difficulty in translating essentially lean manufacturing techniques to suit maintenance.
Open Access
A development methodology for industrial hypermedia task support systems
(2003-04) Tjahjono, Benny Eko; Greenough, Richard
Workers in today’s manufacturing environments have to cope with a greater variety of complex and rapidly changing tasks than ever before. To ensure consistent high quality of products and manufacturing processes, workers require constantly available source of information that serves as a task support and an aide-memoire for settings and task procedures. Hypermedia technology has been proven suitable for this purpose. However, developing industrial hypermedia task support systems (TSS) is different to developing conventional, non-industrial hypermedia applications. This research, therefore, aims to formulate the development methodology that can be used as a guidance to develop industrial hypermedia task support systems. The development methodology, incorporating formal design methods and design heuristics, has been used to develop a number of industrial hypermedia TSS. Both the hypermedia TSS and the methodology have been evaluated through a series of case studies. The thesis confirms that the success of the hypermedia task support systems is not only dependent on the usability of the system, but also on the quality of the content. Difficult and time consuming updating processes will cause poor accuracy and currency of the content, resulting in the users not being able to get the benefits from using it. The collaborative authoring environment that exists within the development methodology enables the content of the hypermedia task support system to be easily created and maintained, so as to ensure its usability. Compared to existing methodologies, the proposed methodology is more comprehensive and more suitable for developing industrial hypermedia systems. In addition to the formal approach typically found in ‘off-the-shelf methodologies, the methodology formulated in this research incorporates design heuristics that aim to improve an application’s coherence and to reduce users’ cognitive overhead, two important requirements for designing the user interface of industrial hypermedia systems.
Open Access
Development of a relationship management framework and related performance matrics for outsourced aircraft maintenance
(Cranfield University, 2008-08) Sakburanapech, Araya; Greenough, Richard
Driven by an intensely competitive world, the use of outsourcing is extensive and growing especially in the service business area. Outsourcing provides companies with benefits such as cost reduction and performance enhancement. Despite these advantages, companies need to be aware that successful outsourcing requires an appropriate long term strategy in managing the relationships with their providers. In turn, the providers have to develop collaborative relationships with their customers in order to improve customer satisfaction. Although relationship management of relevance to outsourcing is recognised as an important concept, it has not received attention from both practitioners and researchers, especially with regard to aircraft maintenance outsourcing which is considered to be critical outsourcing associated with high financial and strategic risks. Therefore, the aim of this research study is “to improve aircraft maintenance outsourcing through relationship management”. This research has been divided into three stages to achieve the research aim. The first stage related to an exploration of the key factors for the management of outsourcing relationship, starting with a review of the relevant literature. A multiple case study was then selected to investigate today’s practices of the management of the IT outsourcing relationship, which has similar characteristics to aircraft maintenance outsourcing. A questionnaire survey was also conducted to explore key factors of relationship management for aircraft maintenance outsourcing. With these three sources of evidence, a conclusive finding is that relationship management of relevance to outsourcing comprises six key factors which are clearly defined requirements, agreement, delivery governance, service delivery, performance evaluation and inter-organisational coordination. The second stage focused on exploring how the relationship between an aircraft maintenance provider and an aircraft maintenance customer is managed. The three cases study relationships featuring the four case companies were selected to carry out an in-depth investigation of relationship management for aircraft maintenance outsourcing. The researcher used interview, observation and documentation to collect data from these four case companies. The findings showed that the six key factors identified in the first stage influence the establishment and development of the relationship between the aircraft maintenance provider and customer. Moreover, external factors also have an impact on the way that both parties manage their relationship. The third stage was to develop a proposed approach to performance measurement which is viewed as a key factor of the management of the relationship between an aircraft maintenance provider and an aircraft maintenance customer. The researcher conducted an action research in cooperation with the main subject of this research. The study discovered that the gap model is applicable for performance measurement in aircraft maintenance outsourcing. The improved version of performance measurement model includes new performance metrics that are essential for monitoring the gaps between the provider and customer.
Open Access
The development of successful industrial hypermedia applications
(Cranfield University, 2000-03) Fakun, D.; Greenough, Richard
The changing manufacturing environment is putting pressure on shop floor operators. To help them cope with the pressures and support them in their tasks an industrial hypermedia application, a computerised information system (IS), has been proposed. However, resistance to IS by target users is a widespread problem. Therefore, companies need guidance on how to augment user acceptance, hence success, of these applications. A literature review on industrial hypermedia applications revealed that five research issues needed to be investigated. Among those issues were the lack of recommendations to hypermedia application developers and managers of manufacturing companies intending to invest in industrial hypermedia applications. This research makes a major contribution by providing a set of recommendations that when adopted may produce successful applications benefiting both the operators and the manufacturing company. This research started by reviewing management of information systems (MIS), human computer interaction (HCI) and hypermedia disciplines to deduce a set of hypothesised factors or constructs that might influence success, measured through intention to use and subjective use. The factors, individual, organisational, task and system, were employed to develop two predictive and explanatory theoretical models, a pre-implementation and a post-implementation model. Empirical data for the constructs in the models were collected in the work place and statistically analysed. Based on the analysis, the ecologically valid findings suggest that shop floor operators can use industrial hypermedia applications and are rational when deciding whether or not to use the applications. The factor having a significant positive influence on user acceptance was an attribute of the application, namely perceived usefulness. The latter is influenced by other factors that can be controlled by developers and facilitated or mitigated by managers. With the proposed recommendations developers and managers may make informed decisions and meet the challenge of developing applications that are successful. Page i Abstract Abstract The changing manufacturing environment is putting pressure on shop floor operators. To help them cope with the pressures and support them in their tasks an industrial hypermedia application, a computerised information system (IS), has been proposed. However, resistance to IS by target users is a widespread problem. Therefore, companies need guidance on how to augment user acceptance, hence success, of these applications. A literature review on industrial hypermedia applications revealed that five research issues needed to be investigated. Among those issues were the lack of recommendations to hypermedia application developers and managers of manufacturing companies intending to invest in industrial hypermedia applications. This research makes a major contribution by providing a set of recommendations that when adopted may produce successful applications benefiting both the operators and the manufacturing company. This research started by reviewing management of information systems (MIS), human computer interaction (HeI) and hypermedia disciplines to deduce a set of hypothesised factors or constructs that might influence success, measured through intention to use and subjective use. The factors, individual, organisational, task and system, were employed to develop two predictive and explanatory theoretical models, a pre-implementation and a post-implementation model. Empirical data for the constructs in the models were collected in the work place and statistically analysed. Based on the analysis, the ecologically valid findings suggest that shop floor operators can use industrial hypermedia applications and are rational when deciding whether or not to use the applications. The factor having a significant positive influence on user acceptance was an attribute of the application, namely perceived usefulness. The latter is influenced by other factors that can be controlled by developers and facilitated or mitigated by managers. With the proposed recommendations developers and managers may make informed decisions and meet the challenge of developing applications that are successful.
Open Access
ERP system upgrade: an analysis of the costs, benefits and requirements
(2002-09) Shaw, C.; Greenough, Richard
This project looks at the feasibility of the high performance vehicle manufacturer, Ray Mallock Limited (RML), upgrading their current version of their Frontstep produced Enterprise Resource Planning (ERP) system from version 4 to the latest version 6. The project outlines a cost benefit analysis of the upgrade so RML can see the value of the new features of the system and weigh these up with the costs that would be incurred. The project then goes on to look at the risks that RML would face if they chose to upgrade or not to upgrade the ERP system and the timescales of the upgrade process. Finally, some suggestions are made to ensure that RML can take full advantage of their current system while being in a position to upgrade effectively in the future. After considerable analysis, this report suggests that an upgrade at this point in time for RML is not a viable option due to the high cost and high risk of the project. In addition, this project suggests that that an ERP system needs management and development on an ongoing basis to ensure that a company is in a strong position to take advantage of new versions without having to incur high risks and even higher costs. The ongoing costs of an ERP system are significant and often misjudged by many companies during the implementation phase, especially if they want to stay on the support contracts as they become tied to an upgrade path dictated by the supplier. Companies must also ensure that they are in a position to take advantage of the upgrades and do not lose skills within the business to manage a change of this nature and they have the business and IT infrastructure in place to support the upgrade.
Open Access
An Evaluation of hypermedia information systems support for CNC machinists
(Cranfield University, 2003-10) Butcher, Timothy Jon; Greenough, Richard
As information technology (IT) capabilities increase, manufacturing businesses are realigning their information systems infrastructure to remain competitive. This has resulted in substantial increases in IT use in technical areas of the business. Nevertheless, conventional paper-based information systems are still common at the shopfloor. Hence, manufacturers need to understand whether there is any benefit in extending IT functionality to the shopfloor. The focus of this research is the support of the CNC machinist, who has a specific set of craft skills and knowledge that are a core business capability in the metal cutting industry. By evaluating the impact of hypermedia information systems upon the independent decision-making and communication capabilities of CNC machinists, this research aims to provide an understanding of the shopfloor performance benefits of replacing existing paper-based systems with this relatively new technology. This research finds that in CNC machining environments where there are limited divisions of labour, hypermedia-based manufacturing instructions support CNC machinist independent decision-making and cross-boundary communications as effective as paper-based manufacturing instructions. CNC machinists also demonstrate an acceptance of the new technology. Hence, the sponsor and the research community can pursue continued research to develop the technical and social systems to achieve predicted business benefits.
Open Access
Machined part cost estimating in SMEs: a feature-driven case-based approach
(Cranfield University, 2010-03) Dimmock, S. I.; Greenough, Richard; Tjahjono, Benny; Clark, G.; Hadley, S. J.
This thesis describes the application of a novel decision support process for machined part estimating in small and medium-sized engineering companies. Many SMEs tend to adopt manual estimating techniques, however this dependence on human expertise represents a risk to such organizations. Better information management in estimating can improve process performance and contribute to increased competitiveness. The research which is the subject of this thesis investigated whether a systems approach to machined part estimating would extend the capacity of an SME to manage knowledge more effectively. The research explored the workplace learning context, the provision of learning opportunities and the management of organizational knowledge; before determining that an intelligent information system offered the most beneficial solution to the situation-of-interest. The case study company produce low-volume, make-to-order, medium and large sized machined steel forgings; utilising conventional machine tool equipment. The application of the decision support system enabled novice estimators to produce viable cost estimates; reducing the risk from reliance on human expertise inherent in manual estimating. The hybrid feature-based costing / case-based reasoning estimating technique, which is the core of the novel METALmpe cost model, proved exceptionally well suited to the SME environment. Estimates produced using METALmpe were consistently more accurate than those of the human expert; with a level of accuracy that exceeds the initial research aim, i.e. a tolerance of -5% / +10%. Significantly, implementation of METALmpe (hardware, software and support for 5 users), can be provided at a cost which is within the typical information technology budget of many SMEs. With demands on organizations to process and disseminate ever increasing volumes of information, METALmpe can improve an SME’s information management capabilities and contribute to competitive advantage through strengthening strategic assets and core competencies.
Open Access
Modelling the impact of reduced variability of machine tool downtime
(Cranfield University, 2008-09) Pearce, Nicholas Farquharson; Greenough, Richard
A model is presented, which allows a machine tool in a service arrangement to be simulated. The impact of machine tool downtime and the sensitivity of machine performance to the services provided may be modelled and optimised. SHOAM, developed by the Boeing Company, is used to make the model and modified to make it applicable for use with a machine tool. SHOAM is a tool which uses discrete event simulation to analyse the performance of an aircraft in a realistic operational setting, allowing the benefits of using health management technologies, which use vehicle condition based information to predict failures and plan the support services, to be assessed. Machine tool industry members are interviewed to gather information on typical operational scenarios involving advanced machine tools and the approaches to the services provided to maintain them. These reveal the highly user-driven nature of the machine tool service industry, with users specifying the services they desire, the costs of which are then added to machine sales for a premium. Machine maintenance is often neglected by users who value short-term productivity gains over longer-term performance and manufacturers are therefore unable to guarantee performance based contracts. This neglect and the variability in machine tool environments are found to impede the development of machine reliability. The information from the interviews, in concert with a literature review of equipment service management is used to develop the behavioural requirements. A new model is then created using elements from SHOAM. Fundamental changes are made to the way SHOAM models operational scenarios and the response to condition-based information to represent the current behaviour in the machine tool industry. Typical machine tool services are included, which allows the costs and benefits of using health management technologies to be compareto existing machine services. These technologies are found to increase machine tool operational reliability and make a significant contribution to reducing lifecycle costs.
Open Access
On the effectiveness and efficiency of discrete-event simulation for designing manufacturing systems
(Cranfield University, 2000-06) Potter, J.; Greenough, Richard; McMaster, R.; Sweeney, M.; Stone, K.
This thesis investigates the effectiveness (doing the right thing) and efficiency (doing the thing right) of computer-based discrete-event simulation for designing manufacturing systems. This investigation looked at the use of this technology in the manufacture of discrete components in aerospace, automotive and consumer electrical (white goods) industries and for material handling (warehousing). Continuous and quasi-continuous manufacture have not been investigated and hence, the conclusions of this thesis cannot be generalised to cover these areas. Working hypotheses were developed and tested which looked at how discrete-event simulation influences the understanding of, confidence in and credibility of a system's design. Testing these working hypotheses lead to conclusions about how discrete-event simulation affects the quality of decision making and the lead-time to develop, commission and ramp-up a manufacturing facility. The following five factors were identified as influencing the efficiency of delivery of discrete-event simulation: l. Management of the simulation study and its intended benefits. 2. Management of customers' expectations. 3. Use of geometric animation. 4. Validation and establishing credibility. 5. How simulation's effectiveness varies over the life of a manufacturing system development project. A qualitative research methodology was employed to test these working hypotheses and to explore these efficiency factors. Twenty-three research subjects, in twelve companies, were drawn from the following three groups: ° Modellers (who provide the modelling service). ° Team members (who are closely involved with supporting the execution of a simulation study). Senior decision makers (who are not closely involved with the execution of the study, but who review its findings). A good practice model was developed for the efficient acquisition and application of the technology. This model consists of the following six elements: 1. Establishing and maintaining a DES modelling capability in the organisation. 2. Knowing whether to use DES modelling for this manufacturing system and when. 3. Defining the study's objectives and their means of measurement. 4. Specify responsibilities for supporting the study and implementing its findings. 5. There is no improvement in the effectiveness of DES modelling in using 2D rather than 3D geometric animation. 6. 3D geometric animation can increase the efficiency of a study, if used appropriately. Conclusions were made about the effectiveness of discrete-event simulation, how the above mentioned factors influence its efficiency of delivery and how to implement the good practice model.
Open Access
Organisation of in-process inspection and control of the lamination process in carbon fibre composites manufacturing
(Cranfield University, 2006-09) Kujinga, Aram; Greenough, Richard
The lamination process is the core in the manufacture of carbon fibre composites. This thesis is a detailed study of the manner in which in-process inspection can be organised so that process flaws that subsequently result in defects can be eliminated or minimised. The quality management system and the inspection methods in force at Lola are thus subjected to intensive scrutiny so as to identify opportunities for improvement. A review of relevant literature on quality management, continuous improvement, mistake-proofing and zero defect initiatives helped map out a methodology for the research. The literature has also looked at the human issues that influence quality and inspection methods. The approach to the study has been to establish quality performance in the past and at present, establish quality attitudes and evaluate inspection methods. Visual inspection is the widely used method of inspection within the industry and instrument aided methods are still an area for research. Ways in which defects may be prevented from occurring and analysing the defects when they occur so as to get to the root causes have been suggested. This study has highlighted the need to adhere to standard operating procedures which account for errors that are avoidable. Motivation and inspiration can only be cultivated into workers through recognition and rewards. Employee engagement is very crucial and workers need to be supported with focussed training and appropriate working aids. Recommendations have been made on involving workers right from the design stage through the manufacturing process right to the customer. Customer requirements will need to be executed with certainty and all necessary information deemed useful will must be input at the design stage. In-process inspection must take a holistic approach i.e. both horizontal and vertical inspection. A point worth noting is that visual inspection accounts for at least 80% of inspections carried out in the manufacture of carbon fibre composites.
Open Access
A practical decision support tool for the design of automated manufacturing systems: incorporating human factors alongside other considerations in the design
(2005-09) Al-Mannai, Bader Darwish; Greenough, Richard; Kay, John M.
The way in which a manufacturing system is designed is a crucial determinant of its ability to meet the current competitive challenges. The existing literature and research findings draw attention to the importance of addressing human factors in the design of the manufacturing systems to face these challenges. However, the evidence gathered from the literature clearly illustrates that organisations are not fully incorporating human factors (macro- and micro-ergonomics) in the design of manufacturing systems. In addition, the current system design practices tend to relegate ergonomics evaluation to post-design, leaving ergonomists little opportunity to make significant and important changes. This thesis details a study which investigates the role of human factors in manufacturing systems design and how it can be integrated into automated manufacturing decision-making. Focus is given to the area of manufacturing automation selection within workstation and cell design. The aim of this research is to support manufacturing systems designers to better incorporate human factors in manufacturing systems design. A research programme has been designed to fulfil this aim. It consisted of three phases: industrial survey, decision support tool formulation, and practical evaluation. The first phase involved conducting interviews with leading manufacturing organisations in the United Kingdom to determine the work practice in industry and the need for' improvements. The second phase comprised the design and development of the decision support tool in a workbook and software application. The final phase was the evaluation of the tool in collaboration with industry. Overall the outcome of this research was a novel structured approach that deploys both the Quality Function Deployment and Failure Mode and Effect Analysis methods to incorporate human factors alongside technical, organisational, and economical factors in the decision-making process of manufacturing systems design, thereby allowing the consideration of human factors at the feasibility study stage.
Open Access
The use of computerised maintenance management systems to support team-based maintenance
(Cranfield University, 1998-09) Boznos, D.; Greenough, Richard
With increasing competitive pressures in a global economy, manufacturing organisations are constantly looking for new methods to maximise efficiency and effectiveness, and hence profitability. Philosophies like Total Productive Maintenance (TPM), and Reliability-Centred Maintenance (RCM) have been employed to help companies achieve this aim, by focusing on the maintenance function and activities. As a result, in many such organisations, the manufacturing and production environments have changed dramatically. The modern maintenance model now revolves around empowered teams. This maintenance environment is also characterised by fewer engineers or craftspeople being required to be more productive. ln addition, more data, information, and knowledge are essential for attaining full technical and operational understanding of the plant, equipment and processes. Information technology is being called upon to assist in achieving a broad range of objectives in contemporary maintenance management. Computerised maintenance management systems (CMMS) in particular, are nowadays expected to facilitate teamwork, and support maintenance programmes based on the contemporary philosophies of TPM and RCM. This thesis investigates the design, as well as the use and application of CMMS in manufacturing industry. The main outcome provides the principal aspects and necessary features of CMMS that can successfully facilitate teamwork, and support TPM or RCM programmes across the whole manufacturing sector. The research was actually based on an extensive literature survey from a plethora of available information sources, as well as a manufacturing industry survey based on postal questionnaires and actual visits to manufacturing plants.

Browsing by Author "Greenough, Richard"

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