Development of hybrid problem solving method for subsea industry
This research is about the development of hybrid problem solving method to identify failures mainly applied in the subsea environment. A3 analysis with support from fishbone diagram and 5 whys analysis techniques were introduced to identify the actual cause of failures. The integration between...
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| Autor Principal: | |
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| Formato: | Thesis |
| Idioma: | English |
| Publicado: |
2018
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| Subjects: | |
| Acceso en liña: | http://psasir.upm.edu.my/id/eprint/71383/1/FK%202018%2084%20IR.pdf |
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| Summary: | This research is about the development of hybrid problem solving method to
identify failures mainly applied in the subsea environment. A3 analysis with
support from fishbone diagram and 5 whys analysis techniques were
introduced to identify the actual cause of failures. The integration between
these two techniques known as a hybrid problem solving method was then
applied to identify the actual cause of failures. Upon identification of the actual
cause of failure, improvement actions were taken to eliminate the actual cause.
In this research, few comparisons in terms of different problem solving
methodology applied for different industries namely aerospace, automotive,
semi-conductor, chemical and oil and gas industry were reviewed and
evaluated to understand the differences for closing the gaps with this new
methodology. The proposed hybrid problem solving methodology was
validated using a case study. The case study was focusing into the
identification of the actual cause of failure related to the Inconel 718 fasteners
that were used for Methanol Injection Tree Valve (MITV). Proposal on the lab
analysis on fresh and failure fasteners was performed upon reviewing the
outcome from the hybrid methodology to ensure the effectiveness of the
analysis technique. Few analysis activities were performed consisting of
mechanical property evaluation, chemical composition and microstructure
review for validating the results. It was identified that the hardness value for
Inconel 718 that was applied for this application was 18% higher than the
maximum value of 40HRC as stated in MS-607 requirement of material Inconel
718 and API standard 6A718-2009. The data was then compared to
understand the characteristics of the failure. One of the steps in the A3
technique is future state and target that requires a mitigation action to eliminate
the cause of failure. This was performed by conducting a new material analysis
e.g. L7M fasteners for future reference. There is no similar re-occurrence
recorded upon implementing the mitigation actions of this problem solving
methodology since 2012. This achievement can be concluded as a success of identifying the real cause of failure using hybrid root cause analysis technique.
Standard template for subsea's problem solving method was established upon
completing the analysis for future use to increase efficiency and reduce cost
of failures for each issue in the future. |
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