Enhancing Reliability of Computerized Numerical Control (CNC) Turning Machine Through Risk Assessment and Analysis

[Virtual Presenter] Good afternoon everyone! Today I'm here to present the solutions to a common issue faced by manufacturing industries Enhancing Reliability of Computerized Numerical Control (C-N-C--) Turning Machine Through Risk Assessment and Analysis. This presentation will cover the research conducted by Ashma Thapa's company which has developed an effective approach on how to minimize machine downtime production loss and maintenance costs. I will take you through the analysis done and provide further insights on how risk assessment and analysis can be used to improve CNC Turning Machine Reliability..

[Audio] Risk assessment is the process of identifying possible risks and assessing their potential effects on a particular situation. When applied to C-N-C turning machines it can help identify potential problems and calculate the resulting losses in production maintenance costs and downtime. By employing root cause analysis and risk assessment it is possible to recognize issues that lead to frequent breakdowns determine production losses and recognize maintenance problems. These steps can help reduce downtime production losses and maintenance costs in the manufacturing sector..

[Audio] C-N-C turning machines are an integral part of many industrial production processes as they provide a useful tool for automating precision machining. However there are numerous challenges for reliability when using C-N-C turning machines that need to be taken into consideration. Common reliability issues include mechanical wear and tear electrical failures material compatibility and environmental factors. To ensure optimal reliability Fault Tree Analysis (F-T-A--) and Failure Mode Effect Analysis (F-M-E-A-) can be applied to analyse and mitigate the risks associated with C-N-C turning machines. These two techniques can be combined to create an effective strategy for ensuring reliable operation of our C-N-C turning machines..

[Audio] CNC Turning Machines have been gaining more and more relevance in today's manufacturing environment due to their high production capacity flexibility and accuracy. Since reliability is a key factor that affects profitability it is essential to understand the concept of Reliability Maintainability and Availability (R-A-M--). This is why research is being conducted on ways to improve the reliability of these machines. First introduced by Alfred Herbert Limited in the 1970s the impact of CNC Turning Machines in the manufacturing industry has seen a tremendous increase over the years thus making it necessary to understand the importance of R-A-M when developing and deploying such machines..

[Audio] We aim to enhance the reliability of C-N-C turning machines by identifying common failure modes evaluating the effectiveness of fault tree analysis (F-T-A--) and failure mode and effects analysis (F-M-E-A-) and prioritizing subsystems based on risk assessment. Additionally we plan to provide implementable recommendations for optimization that can contribute to the industry knowledge..

[Audio] Our methodological approach to enhancing reliability of C-N-C turning machines in Indian manufacturing industries involves collecting and examining failure data from 50 C-N-C turning machines. To gain further insight into the issue we will conduct a robust literature review on reliability analysis fault tree analysis (F-T-A--) and failure modes and effects analysis (F-M-E-A-). Furthermore a risk assessment methodology will be implemented to analyze and interpret the data and software will be used to classify the subsystems..

[Audio] To improve the reliability of the CNC Turning Machine we have identified 14 different subsystem classes based on the machine's components. These subsystem classes can then be used to perform risk assessment and analysis for optimal machine performance..

[Audio] Our methodological approach for enhancing the reliability of a computerized numerical control (C-N-C--) turning machine involves employing fault tree analysis (F-T-A--) a technique used to identify the root cause of errors within a complex system. The process involves creating a diagram that details the failure events and their underlying causes allowing us to identify the most likely factors contributing to the error and take the necessary steps to prevent it from reoccurring..

[Audio] The Failure Modes and Effects Analysis (F-M-E-A-) Risk Priority Number (R-P-N--) is a tool used to identify and prioritize potential failure of a system. It takes into account the severity level the occurrence rate and the detection rate to calculate the R-P-N value. This can then be used to assess and analyze potential risks in a C-N-C turning machine. A Fishbone Diagram then can be used to visualize the causes and effects of the various potential failures..

[Audio] To improve the reliability of our CNC Turning Machine we have taken a methodological approach of Risk Assessment and Analysis. We have developed a Risk Matrix based on the R-P-N scores obtained from the F-M-E-A and we have determined that there are certain critical subsystems which have higher risk levels. To mitigate these risks and ensure the highest reliability of our CNC Turning Machine we are taking the necessary steps to address and reduce the risk levels for these critical subsystems..

[Audio] I outlined the methodological approach to enhance the reliability of computerized numerical control (C-N-C--) turning machines through risk assessment and analysis in my presentation. For this I utilized Relyence Software for Fault Tree Analysis SmartDraw for Fishbone diagrams and MS Excel for risk matrix calculations. By comparing the results from the Fault Tree Analysis and Fault Mode and Effect Analysis I examined the Fishbone Diagram for common failure modes. Furthermore I identified critical failure modes and their root causes that need to be investigated further..

[Audio] We used a Failure Mode and Effects Analysis (F-M-E-A-) and a Risk Matrix to assess the reliability of the C-N-C turning machine. Increasing testing and monitoring reducing maintenance time and streamlining production processes can significantly reduce the risk of failure. The cost of risk mitigation is minor compared to the cost of replacing a faulty device or dealing with lost production..

Findings and implication. Fishbone Diagram Analysis:.

[Audio] Our comparison of Fault Tree Analysis and Failure Mode and Effect Analysis showed that F-M-E-A is more suitable for assessing the current state of a CNC Turning Machine. F-M-E-A offers a superior way to assess conditions allowing us to prioritize maintenance efforts to ensure reliability and better results. This comprehensive assessment provides us with the information to make the best decisions for improving the reliability of the machine enabling us to achieve better outcomes. F-M-E-A is a valuable asset when it comes to keeping the CNC Turning Machine running reliably..

[Audio] Risk assessment and analysis are effective ways to improve the reliability of a Computerized Numerical Control (C-N-C--) Turning Machine. Factors such as data quality and availability the scope and complexity of the analysis interpretation of issues and generalizability concerns need to be taken into account. It is also essential to identify any research limitations..

[Audio] Opportunities for improving the reliability of CNC Turning Machines are plentiful. Exploration of advanced fault analysis integration of internet of things and big data and taking into account human factors can assist in determining how CNC Turning Machines can be improved. To lower the risk of failure and maintain sustainability cross-industry comparisons and environmental impacts of CNC Turning Machines need to be taken into consideration. Moreover even more advancements can be achieved through collaborative industry partnerships..

[Audio] Computerized Numerical Control (C-N-C--) turning machines are an important element of industrial production. Risk assessment and analysis can help improve their reliability. Fault Tree Analysis and Failure Mode and Effect Analysis are two methods for discovering critical failure modes and sources. Electrical electronic and X-Z axis systems are the most significant components here. Risk assessment matrices can help prioritize maintenance initiatives and Fishbone diagrams can help identify common root causes. Further study should be done on advanced fault analysis in the long term. In summary fault analysis and risk assessment are incredibly important..

[Audio] Have discussed the components and process of risk assessment and how it can help monitor the safety and reliability of CNC Turning Machines this presentation has focused on understanding the importance of risk assessment and analysis for enhancing the reliability of a Computerized Numerical Control (C-N-C--) Turning Machine. If you have any further queries please do not hesitate to reach out at [email protected]. I hope this presentation has been helpful in providing you with valuable insights and information. Thank you for your time and attention..