RELIABILITY ANALYSIS OF A CIRCULAR KNITTING MACHINE

Year 2023, , 291 - 308, 31.03.2023

Sümeyra Gülbahar , Selda Kapan Ulusoy , Mithat Zeydan

https://doi.org/10.30783/nevsosbilen.1196320

Abstract

One of the main factors affecting the quality of the product in production systems is the quality of the manufacturing process that produces the product. Failure of production equipment can increase the rate of faulty products and reduce the production time due to the time spent in repair. In order to minimize the failures, the reliability of the machines should be modeled and the machine maintenance plan should be determined in line with the predictions obtained from the model. The aim of this study is to model the mechanical failures that may occur during fabric production in a circular knitting machine in a company in the bedding fabric sector in Turkey by using counting processes. In the study, firstly, the production and failure records of the past days were examined and the mechanical failures in production were determined and arranged. As a result of trend analyzes using graphical methods and hypothesis tests, it has been determined that the appropriate model for the failure behavior of the machine is the Nonhomogeneous Poisson Process (HOPS). The failure density function of HOPS is expressed by the Power Law model. The adequacy of the model was demonstrated by the goodness-of-fit test based on R2. Reliability measures estimated from the model revealed that the machine was failing more and more frequently. This showed the necessity of overhauling the machine in order to minimize production time loss and quality loss. This study example demonstrates the importance of reliability analysis in maintenance planning.

Keywords

Reliability, Nonhomogeneous Poisson Process, Power Law Model, Stoppage Estimation, Stochastic Processes

BİR YUVARLAK ÖRME MAKİNESİNİN GÜVENİLİRLİK ANALİZİ

Abstract

Üretim sistemlerinde ürünün kalitesini etkileyen ana faktörlerden biri ürünü üreten imalat sürecinin kalitesidir. Üretim ekipmanlarının arızalanması hatalı ürün oranını artırabilmekte ve tamirde geçen süre nedeni ile üretim süresini azaltmaktadır. Arızaları en aza indirmek için makinelerin güvenilirliğinin modellenerek, modelden elde edilen tahminler doğrultusunda makine bakım planının belirlenmesi gerekmektedir. Bu çalışmada, Türkiye’de yatak kumaşı sektöründe faaliyet gösteren bir firmada, yuvarlak örme makinesinde kumaş üretimi esnasında meydana gelebilecek mekanik arızalar sayma süreçleri kullanılarak modellenmiştir. Çalışmada öncelikle geçmiş günlere ait üretim ve arıza kayıtları incelenerek üretimde gerçekleşen mekanik arızalar tespit edilmiş ve düzenlenmiştir. Grafiksel yöntemler ve hipotez testleri kullanılarak yapılan trend analizleri sonucunda makinenin arızalanma davranışı için uygun modelin Homojen Olmayan Poisson Süreci (HOPS) olduğu belirlenmiştir. HOPS’un arıza yoğunluk fonksiyonu Kuvvet Yasası modeli ile ifade edilmiştir. Modelin yeterliliği R2’ye dayalı uyum iyiliği testi ile gösterilmiştir. Modelden tahmin edilen güvenilirlik ölçütleri makinenin gittikçe daha sık arızalandığını ortaya çıkarmıştır. Bu durum üretim zamanı kaybı ve kalite kaybını en aza indirmek için makineye revizyon yapılması gerekliliğini göstermiştir. Bu çalışma örneğinde bakım planlanmasında güvenilirlik analizinin önemi görülmüştür.

Keywords

Güvenilirlik, Homojen Olmayan Poisson Süreci, Kuvvet Yasası Modeli, Duruş Tahmini, Stokastik Süreçler

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