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Article
Publication date: 31 July 2023

Dinesh Kumar Kushwaha, Dilbagh Panchal and Anish Sachdeva

To meet energy demand and tackle the challenges posed by global warming, Bagasse-based Cogeneration Power Generation (BCPG) plant in sugar mills have tremendous potential due to…

Abstract

Purpose

To meet energy demand and tackle the challenges posed by global warming, Bagasse-based Cogeneration Power Generation (BCPG) plant in sugar mills have tremendous potential due to large-scale supply of renewable fuel called bagasse. To meet this goal, an integrated framework has been proposed for analyzing performance issues of BCPG.

Design/methodology/approach

Intuitionistic Fuzzy Lambda-Tau (IFLT) approach was implemented to compute various reliability parameters. Intuitionistic Fuzzy Failure Mode and Effect Analysis (IF-FMEA) approach has been implemented for studying risk issues results in decrease in plant's availability. Moreover, IF- Technique for Order Performance by Similarity to Ideal Solution (IF-TOPSIS) is implemented to verify accuracy of IF-FMEA approach.

Findings

For membership and non-membership functions, availability decreases to 0.0006% and 0.0020% respectively for spread ±15% to ±30%, and further decreases to 0.0127% and 0.0221% for spread ±30% to ±45%. Under risk assessment failure causes namely Storage tank (ST3), Valve (VL6), Transfer pump (TF8), Deaerator tank (DT11), High pressure heater and economiser (HP15), Boiler drum and super heater (BS22), Forced draft and Secondary air fan (FS25), Air preheater (AH29) and Furnace (FR31) with Intuitionistic Fuzzy Hybrid Weighted Euclidean Distance (IFHWED) based output scores – 0.8988, 0.9752, 0.9400, 0.8988, 0.9267, 1.1131, 1.0039, 0.8185, 1.0604 were identified as the most critical failure causes.

Research limitations/implications

Reliability and risk analysis results derived from IFLT and IF-FMEA approaches respectively, to address the performance issues of BCPG is based on the quantitative and qualitative data collected from the industrial experts and maintenance log book. Moreover, to take care of hesitation in expert's knowledge, IF theory-based concept is incorporated so as to achieve more accuracy in analysis results. Reliability and risk analysis results together will be helpful in analyzing the performance characteristics and diagnosis of critical failure causes, which will minimize frequent failure in BCPG.

Practical implications

The framework will help plant managers to frame optimal maintenance policy in order to enhance the operational aspects of the considered unit. Moreover, the accurate and early detection of failure causes will also help managers to take prudent decision for smooth operation of plant.

Social implications

The results obtained ensure continuous operation of plant by utilizing the bagasse as fuel in boiler and also mitigate the wastages of fuel. If this bagasse (green fuel) is not properly utilized, there remains a dependency on coal-based power plants to meet the power demand. The results obtained are useful for decreasing dependency on coal, and promoting bagasse as the green, and alternative fuel, the emission by burning of these fuels are not harmful for environment and thereby contribute in preventing the environment from harmful effect of GHGs gases.

Originality/value

IFLT approach has been implemented to develop reliability modeling equations of the BCPG unit, and furthermore to compute various reliability parameters for both membership and non-membership function. The ranking results of IF-FMEA are compared to IF-TOPSIS approach. Sensitivity analysis is done to check stability of proposed framework.

Details

International Journal of Quality & Reliability Management, vol. 41 no. 2
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 13 February 2024

Dinesh Kumar Kushwaha, Dilbagh Panchal and Anish Kumar Sachdeva

An integrated intuitionistic fuzzy (IF) modelling-based framework for examining the performance analysis of a packaging unit (PU) in three different stages has been proposed.

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Abstract

Purpose

An integrated intuitionistic fuzzy (IF) modelling-based framework for examining the performance analysis of a packaging unit (PU) in three different stages has been proposed.

Design/methodology/approach

For the series and parallel configuration of PU, a mathematical model based on the intuitionistic fuzzy Lambda–Tau (IFLT) approach was developed in order to calculate various reliability parameters at various spreads. For determining membership and non-membership function-based reliability parameters for the top event, AND/OR gate transitions expression was employed.

Findings

For 15%–30% spread, unit’s availability for the membership function falls by 0.006442%, and it falls even more by 0.014907% with an increase in spread from 30% to 45%. In contrast, for 15%–30% spread, the availability of non-membership function-based systems reduces by 0.007491% and further diminishes. Risk analysis has presented applying an emerging approach called intuitionistic fuzzy failure mode and effect analysis (IFFMEA). For each of the stated failure causes, the output values of the intuitionistic fuzzy hybrid weighted Euclidean distance (IFHWED)-based IFFMEA have been tabulated. Failure causes like HP1, MT6, FB9, EL16, DR23, GR27, categorized under subsystems, namely hopper, motor, fluidized bed dryer, distributor, grader and bin, respectively, with corresponding IFFMEA output scores 1.0975, 1.0190, 0.8543, 1.0228, 0.9026, 1.0021, were the most critical one to contribute in the system’s failure.

Research limitations/implications

The limitation of the proposed framework lies in the fact that the results obtained for both reliability and risk aspects mainly depend on the correctness of raw data provided by the experts. Also, an approximate model of PU is obtained from plant experts to carry performance analysis, and hence more attention is required in constructing the model. Under IFLT, reliability parameters of PU have been calculated at various spreads to study and analyse the failure behaviour of the unit for both membership and non-membership function in the IFS of [0.6,0.8]. For both membership- and non-membership-based results, availability of the considered system shows decreasing trend. To improve the performance of the considered system, risk assessment was carried using IFFMEA technique, ranking all the critical failure causes against IFHWED score value, on which more attention should be paid so as to avoid sudden failure of unit.

Social implications

The livelihood of millions of farmers and workers depends on sugar industries. So perpetual running of these industries is very important from this viewpoint. On the basis of findings of reliability parameters, the maintenance manager could frame a correct maintenance policy for long-run availability of the sugar mills. This long-run availability will generate revenue, which, in turn, will ensure the livelihood of the farmers.

Originality/value

Mathematical modelling of the considered unit has been done applying basic expressions of AND/OR gate. IFTOPSIS approach has been implemented for ranking result comparison obtained under IFFMEA approach. Eventually, sensitivity analysis was also presented to demonstrate the stability of ranking of failure causes of PU.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 8 January 2024

Fatemeh Sajjadian, Mirahmad Amirshahi, Neda Abdolvand, Bahman Hajipour and Shib Sankar Sana

This study aims to endeavor to shed light on the underlying causal mechanisms behind the failure of startups by examining the failure process in such organizations. To achieve…

Abstract

Purpose

This study aims to endeavor to shed light on the underlying causal mechanisms behind the failure of startups by examining the failure process in such organizations. To achieve this goal, the study conducted a comprehensive review of the literature on the definition of failure and its various dimensions, resulting in the compilation of a comprehensive list of causes of startup failure. Subsequently, the failure process was analyzed using a behavioral strategy approach that encompasses rationality, plasticity and shaping, as well as the growth approach of startups based on dialectic, teleology and evolution theories.

Design/methodology/approach

The proposed research methodology was a case study using process tracing, with the sample being a failed platform in the ride-hailing technology sector. The causal mechanism was further explicated through the combined application of the behavioral strategy approach and interpretive structural modeling analysis.

Findings

The findings of the study suggest that the failure of startups is a result of interlinked causes and effects, and growth in these organizations is driven by dialectic, teleology and evolution theories.

Originality/value

The outcomes of the research can assist startups in formulating an effective strategy to deliver the right value proposition to the market, thereby reducing the chances of failure.

Details

Journal of Modelling in Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1746-5664

Keywords

Article
Publication date: 27 March 2024

Temesgen Agazhie and Shalemu Sharew Hailemariam

This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.

Abstract

Purpose

This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.

Design/methodology/approach

We employed fuzzy techniques for order preference by similarity to the ideal solution (FTOPSIS), fuzzy analytical hierarchy process (FAHP), and failure mode effect analysis (FMEA) to determine the causes of defects. To determine the current defect cause identification procedures, time studies, checklists, and process flow charts were employed. The study focuses on the sewing department of a clothing industry in Addis Ababa, Ethiopia.

Findings

These techniques outperform conventional techniques and offer a better solution for challenging decision-making situations. Each lean waste’s FMEA criteria, such as severity, occurrence, and detectability, were examined. A pairwise comparison revealed that defect has a larger effect than other lean wastes. Defects were mostly caused by inadequate operator training. To minimize lean waste, prioritizing their causes is crucial.

Research limitations/implications

The research focuses on a case company and the result could not be generalized for the whole industry.

Practical implications

The study used quantitative approaches to quantify and prioritize the causes of lean waste in the garment industry and provides insight for industrialists to focus on the waste causes to improve their quality performance.

Originality/value

The methodology of integrating FMEA with FAHP and FTOPSIS was the new contribution to have a better solution to decision variables by considering the severity, occurrence, and detectability of the causes of wastes. The data collection approach was based on experts’ focus group discussion to rate the main causes of defects which could provide optimal values of defect cause prioritization.

Details

International Journal of Quality & Reliability Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 27 November 2023

Davood Javanmardi and Mohammad Ali Rezvani

Bearings are critical components used to support loads and facilitate motion for rotating and sliding parts of the machinery. Bearing malfunctions can cause catastrophic failures…

Abstract

Purpose

Bearings are critical components used to support loads and facilitate motion for rotating and sliding parts of the machinery. Bearing malfunctions can cause catastrophic failures. Hence, failure analysis and endeavors to improve bearing performance are essential discussions for worldwide designers, manufacturers and end users of vital machinery. This study aims to investigate a type of roller bearing from the railway industry with premature failures. The task arises because locomotives’ maintenance and service life quality are vital to railway operations while providing transportation services for the nation. To assist in maintaining the designated locomotives, the present study scrutinizes the causes of failure of heavy-duty roller bearings from locomotive bogie axleboxes.

Design/methodology/approach

It is intended to inspect this bearing service life and statistically scrutinize its design parameters to reveal the failures’ shortcomings and origins. The significant measures include examinations of their failures’ primary and vital factors by comparing them with a real-life service history of 16 roller bearings of the same type. The bearings come from the axleboxes of a locomotive bogie with an axle load of 20 tons. The bearing loads are estimated using the EN13104 standard document and confirmed by the finite element method using ABAQUS engineering software. To validate the finite element modeling results, the bearings’ stress analysis is performed using the Hertzian contact theory that demonstrated perfect conformity. The said methods are also used to search for the areas susceptible to failures in these bearings. With the inclusion and exploitation of the bearing maintenance conditions and the logbook recordings of the locomotives for the past seven years, the critical cause for this type of bearing’s failures is surveyed and discussed.

Findings

With the inclusion and exploitation of the bearing maintenance conditions and the logbook recordings of the locomotives for the past seven years, the critical cause for this type of bearing’s failures is surveyed and discussed. As a crucial result, it is found that deprived maintenance and inadequate lubrication are the root causes of the loss of the selected bearings.

Originality/value

For the designated locomotives, the origins of the heavy-duty roller bearing failures and its design shortcomings are revealed by examining and comparing them with a real-life service history of many of the same types of bearings. The novelty of the research is in using the combination of the methods mentioned above and its decent outcome.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 4 September 2023

Xuanzhi Li, Suduo Xue, Xiongyan Li, Guanchen Liu and Renjie Liu

Instantaneous unloading with equal force is usually used to simulate the sudden failure of cables. This simulation method with equivalent force requires obtaining the magnitude…

Abstract

Purpose

Instantaneous unloading with equal force is usually used to simulate the sudden failure of cables. This simulation method with equivalent force requires obtaining the magnitude and direction of the force for the failed cable in the normal state. It is difficult, however, to determine the magnitude or direction of the equivalent force when the shape of the cable is complex (space curve). This model of equivalent force may be difficult to establish. Thus, a numerical simulation method, the instantaneous temperature rise method, was proposed to address the dynamic response caused by failures of the cables with complex structural form.

Design/methodology/approach

This method can instantly reduce the cable force to zero through the instantaneous temperature rise process of the cable. Combined with theoretical formula and finite element model, the numerical calculation principle and two key parameters (temperature rise value and temperature rise time) of this method were detailed. The validity of this approach was verified by comparing it with equivalent force models. Two cable-net case with saddle curved surfaces were presented. Their static failure behaviors were compared with the dynamic failure behaviors calculated by this method.

Findings

This simulation method can effectively address the structural dynamic response caused by cable failure and may be applied to all cable structures.

Originality/value

An instantaneous temperature rise method (ITRM) is proposed and verified. Its calculation theory is detailed. Two key parameters, temperature rise value and temperature rise time, of this method are discussed and the corresponding reference values are recommended.

Details

Engineering Computations, vol. 40 no. 9/10
Type: Research Article
ISSN: 0264-4401

Keywords

Article
Publication date: 7 December 2022

Qing-Wen Zhang, Pin-Chao Liao, Mingxuan Liang and Albert P.C. Chan

Quality failures in grid infrastructure construction would cause large-scale collapses in power supply and additional expenditures by reworks and repairs. Learning from quality…

Abstract

Purpose

Quality failures in grid infrastructure construction would cause large-scale collapses in power supply and additional expenditures by reworks and repairs. Learning from quality failures (LFQF) extracts experience from previous quality events and converts them into preventive measures to reduce or eliminate future construction quality issues. This study aims to investigate the influence factors of LFQF in the construction of grid infrastructure.

Design/methodology/approach

The related factors of LFQF, including quality management (QM) practices, quality rectification, and individual learning, were identified by reviewing literature about organizational learning and extracting experience from previous failures. A questionnaire survey was distributed to the grid companies in North, Northeast, Northwest, East, Central, and Southwest China. 381 valid responses collected and analyzed using structural equation modeling (SEM) to test the influence of these factors on LFQF.

Findings

The SEM results support that QM practices positively affect individual learning and LFQF. Quality rectification indirectly impacts LFQF via individual learning, while the results did not support the direct link between quality rectification and LFQF.

Practical implications

The findings strengthen practical insights into extracting experience from poor-quality issues and continuous improvement. The contributory factors of LFQF found in this study benefit the practitioners by taking effective measures to enhance organizational learning capability and improve the long-term construction quality performance in the grid infrastructure industry.

Originality/value

Existing research about the application of LFQF still stays at the explorative and conceptual stage. This study investigates the related factors of LFQF, including QM practices, quality rectification, and individual learning, extending the model development of learning from failures (LFF) in construction QM.

Details

Engineering, Construction and Architectural Management, vol. 31 no. 4
Type: Research Article
ISSN: 0969-9988

Keywords

Article
Publication date: 14 November 2023

Jessica Vredenburg, Sommer Kapitan and Sharon Jang

This paper aims to formally conceptualize service mega-disruptions as any far-reaching and unforeseen general environmental stressor or threat that impacts a service…

Abstract

Purpose

This paper aims to formally conceptualize service mega-disruptions as any far-reaching and unforeseen general environmental stressor or threat that impacts a service organization’s ability to provide a desired level of service. The authors differentiate sudden large-scale general environmental threats from traditional service failures in scope and scale of impact via number of customers and sectors affected and duration and speed of the disruption.

Design/methodology/approach

This paper draws from service recovery theory to build a conceptual model of service mega-disruptions. The resulting conceptual model maps service failure recovery strategies against a service mega-disruption recovery approach to examine consumer response to changes in service value. This work further articulates additional research needs including conceptualization, measurement and methods as traditional drivers of service recovery and the value of the service experience change in response to service mega-disruptions.

Findings

This work proposes a research agenda to investigate whether service mega-disruptions can bypass the need for service recovery due to a consumer self-moderating process. As past research shows, the less control a service provider has over a failure, the more customers attribute fault to the situation and transfer blame away from an organization. This paper suggests that this self-moderating process disrupts the need for service providers to court forgiveness for a failure with perceptions of similarity and controllability providing an alternate pathway to customer forgiveness. Similarly, it is suggested that service mega-disruptions play a role in transforming service ecosystems into tighter, more contractual systems with less agency for service providers and poorer ability to adjust to market conditions. The duration and longevity of effects on service providers’ control, agency and ability to adjust following a service mega-disruption must be researched further.

Originality/value

This paper builds theory to develop a conceptual model of service mega-disruptions and their role in customer engagement and reshaping the service ecosystem. This paper culminates in the proposition of a research agenda that aims to build research capacity among services marketing scholars as service providers’ coordination and market conditions are challenged by service mega-disruptions.

Details

Journal of Services Marketing, vol. 38 no. 1
Type: Research Article
ISSN: 0887-6045

Keywords

Article
Publication date: 23 October 2023

Mariam Bader, Jiju Antony, Raja Jayaraman, Vikas Swarnakar, Ravindra S. Goonetilleke, Maher Maalouf, Jose Arturo Garza-Reyes and Kevin Linderman

The purpose of this study is to examine the critical failure factors (CFFs) linked to various types of process improvement (PI) projects such as Kaizen, Lean, Six Sigma, Lean Six…

Abstract

Purpose

The purpose of this study is to examine the critical failure factors (CFFs) linked to various types of process improvement (PI) projects such as Kaizen, Lean, Six Sigma, Lean Six Sigma and Agile. Proposing a mitigation framework accordingly is also an aim of this study.

Design/methodology/approach

This research undertakes a systematic literature review of 49 papers that were relevant to the scope of the study and that were published in four prominent databases, including Google Scholar, Scopus, Web of Science and EBSCO.

Findings

Further analysis identifies 39 factors that contribute to the failure of PI projects. Among these factors, significant emphasis is placed on issues such as “resistance to cultural change,” “insufficient support from top management,” “inadequate training and education,” “poor communication” and “lack of resources,” as primary causes of PI project failures. To address and overcome the PI project failures, the authors propose a framework for failure mitigation based on change management models. The authors present future research directions that aim to enhance both the theoretical understanding and practical aspects of PI project failures.

Practical implications

Through this study, researchers and project managers can benefit from well-structured guidelines and invaluable insights that will help them identify and address potential failures, leading to successful implementation and sustainable improvements within organizations.

Originality/value

To the best of the author’s knowledge, this paper is the first study of its kind to examine the CFFs of five PI methodologies and introduces a novel approach derived from change management theory as a solution to minimize the risk associated with PI failure.

Details

International Journal of Lean Six Sigma, vol. 15 no. 3
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 14 September 2022

Bingsheng Liu, Juankun Li, Dan Wang, Henry Liu, Guangdong Wu and Jingfeng Yuan

This study aims to develop a collaborative governance framework (CGF) to systematically investigate the impeding factors (IFs) in terms of the operational sustainability of PPPs…

Abstract

Purpose

This study aims to develop a collaborative governance framework (CGF) to systematically investigate the impeding factors (IFs) in terms of the operational sustainability of PPPs. It examines the transmission pattern (i.e. the way in which network members react to each other) of the IFs network.

Design/methodology/approach

Literature review and interview were adopted to identify the IFs. Then, with the data collected from the interview in China, the social network analysis and interpretive structure model were synergised to examine the chain reaction, driving and dependent powers, and hierarchical structure of the identified IFs.

Findings

The results reveal that the cognition, institutional, financial and participation aspects are key barriers confronted by PPP sustainability, and the government plays a leading role in controlling factors causing sustainability-related problems in PPPs. Weak government leadership and institutional environment were identified as the most fundamental reasons triggering a chain of IFs, while project governance and management activities act as bridge nodes that play an intermediary role in the IFs network.

Research limitations/implications

This research contributes to the literature on PPP governance by (1) bridging the literature gap through the development of CGF for explaining the governance of PPP sustainability with a holistic view that considers both macro environment and operational project processes; and (2) identifying the transmission pattern of IFs network which uncovers the underlying dynamics causing the unsustainable operation of PPPs.

Practical implications

This research provides practitioners with a list of key checkpoints for preventing failure escalation, enables decision-makers to prioritise obstacle-mitigation efforts and develop a feasible process to control PPP operation, and offers management countermeasures to remove the key barriers impeding PPP sustainability.

Originality/value

This study is novel for adopting network-oriented techniques to quantify the relative importance of the IFs and examine the transmission pattern of the IFs system. Therefore, it visualises the complex underlying dynamics causing unsustainable PPP operation, identifies root and direct causes of PPP failures, and provides decision-makers with insights into sustaining PPP sustainability from a network-oriented perspective.

Details

Engineering, Construction and Architectural Management, vol. 31 no. 1
Type: Research Article
ISSN: 0969-9988

Keywords

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