Isaac Animah, Mahmood Shafiee, Nigel Simms, John Ahmet Erkoyuncu and Jhareswar Maiti
A substantial number of production assets in the offshore oil and gas industry are facing operation beyond their anticipated design life, thus necessitating a service life…
Abstract
Purpose
A substantial number of production assets in the offshore oil and gas industry are facing operation beyond their anticipated design life, thus necessitating a service life extension program in the future. Selection of the most suitable strategy among a wide range of potential options to extend the lifetime of equipment (e.g. re-using, reconditioning, remanufacturing, refurbishing and adding on safety/process control measures) remains a challenging task that involves several technical, economic and organizational complexities. In order to tackle this challenge, it is crucial to develop analytical tools and methods capable of evaluating and prioritizing end-of-life strategies with respect to their associated costs and quantifiable benefits. The paper aims to discuss these issues.
Design/methodology/approach
This paper presents a life-cycle cost-benefit analysis approach to identify the most suitable life extension strategy for ageing offshore assets by taking into account all the capital, installation, operational, maintenance and risk expenditures during the extended phase of operation. The potential of the proposed methodology is demonstrated through a case study involving a three-phase separator vessel which was constructed in the mid-1970s.
Findings
The results from the application case indicate that the capital expenditure (CapEx) accounts for the largest portion of life cycle cost for the replacement strategy, while risk expenditure (RiskEx) is the major contributor to costs associated with life extension. A sensitivity analysis is also conducted to identify factors having the greatest impact on the optimum life extension solution, including oil price, production rate and money interest rate.
Practical implications
In the past, the decisions about life extension or replacement of in-service equipment were often made in a qualitative way based on experience and judgment of engineers and inspectors. This study presents a “quantitative” framework to evaluate and compare the costs, benefits and risks associated with life extension strategies and subsequently to select the best strategy based on benefit/cost ratios.
Originality/value
To the best of authors’ knowledge, no studies before have applied life cycle assessment and cost-benefit analysis methods to prioritize the potential life extension strategies in the oil and gas industry sector. The proposed approach not only assists decision makers in selecting the most suitable life extension strategy but also helps duty holders reduce the costs corresponding to life extension execution.
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Chanchal Ghosh, J. Maiti, Mahmood Shafiee and K.G. Kumaraswamy
The modern helicopters are designed with maximum serviceability and long life expectancy to ensure minimum life cycle cost. The purpose of this paper is to present a framework to…
Abstract
Purpose
The modern helicopters are designed with maximum serviceability and long life expectancy to ensure minimum life cycle cost. The purpose of this paper is to present a framework to incorporate the customer requirements on reliability and maintainability (R&M) parameters into the design and development phase of a contemporary helicopter, and to discuss the way to capture operational data to establish and improve the R&M parameters to reduce life cycle cost.
Design/methodology/approach
From the analysis, it is established that the reliability and maintainability cost is the major contributor to the life cost. The significant reliability and maintainability parameters which influence R&M cost are identified from analysis. The operational and design data of a contemporary helicopter are collected, compiled and analyzed to establish and improve the reliability and maintainability parameters.
Findings
The process depicted in the paper is followed for a contemporary helicopter and substantial amount of life cycle cost reduction is observed with improvement of R&M parameters.
Practical implications
The benefits of this methodology not only reduce life cycle cost but also improve the availability/serviceability through less failure and less time for scheduled maintenance. The methodologies also provide the reliability trends indicating potential area for design improvement.
Originality/value
The proposed approach assists asset managers to reduce the life cycle costs through improvement of R&M parameters.
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Pankaj Kumar and J. Maiti
The purpose of this paper is to evaluate the technical efficiency and productivity changes in the integrated steel plants in India over a period of five years.
Abstract
Purpose
The purpose of this paper is to evaluate the technical efficiency and productivity changes in the integrated steel plants in India over a period of five years.
Design/methodology/approach
Since this evaluation of integrated steel plants needs consideration of multiple input and output factors, data envelopment analysis (DEA) has been employed including bootstrapping (to account for statistical noise) to evaluate the relative efficiency of the steel manufacturing units. The efficiency and Malmquist productivity indices of a sample of ten integrated steel plants producing around 55 percent of the industry’s output were determined for the period 2008-2013. The results of these changes were further categorized according to the management control, route followed to produce crude steel, size and age of these steel plants, for gaining insights.
Findings
The study finds that private sector steel plants with larger capacity and which have adopted the latest and most modern technologies are more efficient and productive over the study period.
Practical implications
Public sector steel plants should therefore be provided with more autonomy and delegation of power and should be agiler in responding to market requirements as well as increasing their installed capacities to be competitive in technical efficiency and productivity as well as profitability in the long term to ensure sustainable achievements.
Originality/value
Productivity changes over time, both with respect to technological and efficiency changes, for the Indian integrated steel plants producing comparable products using DEA.
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Pankaj Kumar, J. Maiti and Angappa Gunasekaran
Within the operations management literature, quality management (QM) has been one of the most popular research areas over the last few decades. The impact of QM systems on firm…
Abstract
Purpose
Within the operations management literature, quality management (QM) has been one of the most popular research areas over the last few decades. The impact of QM systems on firm performance has been the subject of constant interest and challenge among researchers. Last such review was done in 2002 based on QM-related articles published between 1994 and 1999 and these were primarily on Total Quality Management (TQM). In the last 18 years, a large number of empirical studies have been attempted to investigate QM system-performance relationships in different contexts, covering not only TQM but also other QM systems such as ISO 9001, Total Productive Maintenance (TPM), Lean Manufacturing, Theory of Constraints (TOC), and Six Sigma Continuous Improvement projects. The paper aims to discuss these issues.
Design/methodology/approach
Based on an extensive review of 263 papers published in 17 reputed journals during the period 2000 to 2017, this paper shows the reflections of QM systems with respect to study of different QM systems, type of research designs being used, performance categories and metrics being used, and application of tools/techniques.
Findings
The literature review has revealed several gaps in research in the area of QM and calls for research on: empirical longitudinal case studies; implementation of multiple QM systems; identification of leading indicators of firm’s performance; standardization of performance measures; safety, environment and health-related performance measures; the differences in the QM systems on firm’s performance for manufacturing vs service organizations; application of QM systems in developing countries including Asian countries; and impact of ISO 9001 QM system on firm’s performance.
Originality/value
The literature reviews in the past had considered only the TQM-related articles published in reputed journals and did not cover other QM systems such as TPM, TOC, Toyota Production System, Six Sigma, ISO 9001 QMS, etc., which have also been widely used in many organizations, more so in the last 15 years.
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Sandipan Karmakar and Jhareswar Maiti
The purpose of this paper is to present a state‐of‐the‐art review of dimensional tolerance synthesis and to demonstrate the evolution of tolerance synthesis from product to…
Abstract
Purpose
The purpose of this paper is to present a state‐of‐the‐art review of dimensional tolerance synthesis and to demonstrate the evolution of tolerance synthesis from product to process‐oriented strategy, as well as to compare the same for single stage and multistage manufacturing systems (MMS). The main focus is in delineating the different approaches, methods and techniques used with critical appraisal of their uses, applicability and limitations, based on which future research directions and a generic methodology are proposed.
Design/methodology/approach
Starting with issues in tolerancing research, the review demonstrates the critical aspects of product and process‐oriented tolerance synthesis. The aspects considered are: construction of tolerance design functions; construction of optimization functions; and use of optimization methods. In describing the issues of process‐oriented tolerance synthesis, a comparative study of single and multistage manufacturing has been provided.
Findings
This study critically reviews: the relationship between the tolerance variables and the variations created through manufacturing operations; objective functions for tolerance synthesis; and suitable optimization methods based upon the nature of the tolerance variables and the design functions created.
Research limitations/implications
This study is limited to dimensional tolerance synthesis problems and evolution of process‐oriented tolerance synthesis to counteract dimensional variation problems in assembly manufacturing.
Originality/value
The paper provides a comprehensive and step‐by‐step approach of review of dimensional tolerance synthesis.
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Anupam Das, J. Maiti and R.N. Banerjee
Monitoring of a process leading to the detection of faults and determination of the root causes are essential for the production of consistent good quality end products with…
Abstract
Purpose
Monitoring of a process leading to the detection of faults and determination of the root causes are essential for the production of consistent good quality end products with improved yield. The history of process monitoring fault detection (PMFD) strategies can be traced back to 1930s. Thereafter various tools, techniques and approaches were developed along with their application in diversified fields. The purpose of this paper is to make a review to categorize, describe and compare the various PMFD strategies.
Design/methodology/approach
Taxonomy was developed to categorize PMFD strategies. The basis for the categorization was the type of techniques being employed for devising the PMFD strategies. Further, PMFD strategies were discussed in detail along with emphasis on the areas of applications. Comparative evaluations of the PMFD strategies based on some commonly identified issues were also carried out. A general framework common to all the PMFD has been presented. And lastly a discussion into future scope of research was carried out.
Findings
The techniques employed for PMFD are primarily of three types, namely data driven techniques such as statistical model based and artificial intelligent based techniques, priori knowledge based techniques, and hybrid models, with a huge dominance of the first type. The factors that should be considered in developing a PMFD strategy are ease in development, diagnostic ability, fault detection speed, robustness to noise, generalization capability, and handling of nonlinearity. The review reveals that there is no single strategy that can address all aspects related to process monitoring and fault detection efficiently and there is a need to mesh the different techniques from various PMFD strategies to devise a more efficient PMFD strategy.
Research limitations/implications
The review documents the existing strategies for PMFD with an emphasis on finding out the nature of the strategies, data requirements, model building steps, applicability and scope for amalgamation. The review helps future researchers and practitioners to choose appropriate techniques for PMFD studies for a given situation. Further, future researchers will get a comprehensive but precise report on PMFD strategies available in the literature to date.
Originality/value
The review starts with identifying key indicators of PMFD for review and taxonomy was proposed. An analysis was conducted to identify the pattern of published articles on PMFD followed by evolution of PMFD strategies. Finally, a general framework is given for PMFD strategies for future researchers and practitioners.