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PRINCIPLES OF PRODUCTION AND INDUSTRIAL SAFETY ENGINEERING

CODE 90455
ACADEMIC YEAR 2022/2023
CREDITS
  • 6 cfu during the 2nd year of 9269 INGEGNERIA MECCANICA - PROGETTAZIONE E PRODUZIONE(LM-33) - GENOVA
  • 5 cfu during the 1st year of 10377 SAFETY ENGINEERING FOR TRANSPORT, LOGISTICS AND PRODUCTION(LM-26) - GENOVA
  • SCIENTIFIC DISCIPLINARY SECTOR ING-IND/17
    LANGUAGE English
    TEACHING LOCATION
  • GENOVA
  • SEMESTER 1° Semester
    MODULES This unit is a module of:
    TEACHING MATERIALS AULAWEB

    AIMS AND CONTENT

    LEARNING OUTCOMES

    The course is aimed at studying various aspects of safety and security in industrial applications including: chemical plants, oil & gas, dangerous goods handling etc. Starting form reliability analysis, through Bayesian statistics, reliability modelling and simulation, failure analysis the course will guide the identification of possible risk factors and will presents the most promising methodological approaches. Two practical assignment will be given focusing on industrial incidents involving chemical spills and complex plants failures.

    AIMS AND LEARNING OUTCOMES

    The course addresses structurally the problem of the safety of industrial settlements and industrial plants in general, the introduction provides a basic framework and the connection with the notions learned in the Degree course with the possible completion of the existing "gap" . Part I addresses the structural patterns of cuts and collapses of industrial constructions, structures and carpentry as events often at the root of accidents. Through the analysis of theories and models, the student learns the "safe" design principles in the various scenarios considered. Part II addresses the consequences that industrial accidents can have on the environment and on people by emphasizing causal links and the interconnection between the structural, operational and human aspects of the incident phenomenon. The course is purely applicative with reference to industrial sectors considered to be "high risk" (chemical, nuclear, oil & gas, etc.).

    TEACHING METHODS

    Theoretical lectures with support of slides and in-classroom exercises, assigments and seminars.

    SYLLABUS/CONTENT

    Production Principles & Operations
    Forecasting, Planning and Scheduling

     

    • Forecasting
    • Planning
    • Scheduling
    • MRP & ERP

    Statistical Process Control (SPC)

     

     

    • What is Statistical Process Control
    • Variability
    • Control Charts
    • Process Capability Cp
    • Measuring Instruments
    • Repeatability & Reproducibility

    Six Sigma

     

     

    • What is Six Sigma?
    • Phases of Six Sigma
    • Define
    • Measure
    • Evaluate / Analyze
    • Improve
    • Control
    • Design for Six Sigma
    • Green Belts & Black Belts

    Job Design, Work Measurement and Labor Standards

     

     

    • Job Design
    • Job specialization
    • Job expansion
    • Psychological components
    • Self-directed teams
    • Motivation and incentive systems
    • Ergonomics and work methods
    • Work Measurement
    • Time Studies
    • Work Sampling
    • Labor Standards

    Mistake Proofing and Poka Yoke

     

     

    • What is Mistake Proofing?
    • Everyday Examples
    • Effectiveness & ROI
    • Error Proofing and SPC
    • Inspection Techniques
    • Types of Poka YokesSafety Principles
      Fire Hazards
    • Fires and fire hazard, Systems for fire-fighting, Classification of Fires, The trigger sources, The products of combustion, Extinguishing agents, Main effects of the fire on man, Fire prevention, Analysis of the most common causes of fire, The fire protection, Reference standard, Procedures in case of fire
    • Mechanical Hazards
    • Mechanical hazard, Movement mechanical hazards, Machinery, Equipment  for lifting,  hauling and storage, Elements of a machine, Equipment for lifting materials, Lifters
    • Ergonomics
    • Noise, Ligthing, Ergonomics-Quality of working environment Airborne chemical pollution, Severe thermal environments
    • Reliability Analysis through TARAS Software:
    • Introduction
    • The TARAS software
    • Construction of plant operational tree
    • TARAS functions and windows
    • Description of the test case plant

     

     

     

     

    RECOMMENDED READING/BIBLIOGRAPHY

    Reference textbooks

    • Beer, Johnston & Dewolf, Mechanics Of Materials 
      McGraw-Hill series in mechanical engineering, Tata McGraw-Hill Education, 2004, ISBN: 978-0-07-0535107

    • Riccardo Baldacci, Scienza delle Costruzioni, Vol II, Fondamenti di Meccanica delle Strutture (I-III, V-VI, IX), Edizioni UTET Torino, ISBN 88-02-04634-4, 1997
     
    • Leone Corradi Dell'Acqua, Meccanica delle strutture 2/ed, Vol III, Mc Graw Hill, ISBN: 978-88386-72309
     
    • Donald Ermak, SLAB User Manual, Lawrence Livermore National Laboratory, USA, 1990 (Public Domain)
     
    • DoD, Applied R&M manual for defense systems, USA,
     
    • Patrick O'Connor, Practical reliability engineering, John Wiley & Sons Fifth Edition., UK, 2012.
     
    • Riccardo Baldacci, Scienza delle Costruzioni, Vol I, Fondamenti di Meccanica dei Solidi (I-IV, VIII), Edizioni UTET Torino, ISBN 88-02-03853-8, 1997
       

     

    Deepening textbooks

    • Armando Monte, Elementi di Impianti Industriali Volume 1, Edizioni Libreria Cortina, Torino.
     
    • James Zapert, Richard Londergan, Harold Thistle Evaluation of dense gas simulation models, EPA, USA, 1991
     
    • Roberto Revetria,  Roberto Mosca  “Distributed Simulation in Industry” chapter 2 from Dr. Evon M. Abu- Taieh, “Simulation and Modeling: Current Technologies and Application” ISBN 978-159904198-8 Idea Group, Inc., Hershey, PA 17033, USA, 2007.
     
    • Maurizio Catino, Da Chernobyl a Linate: incidenti tecnologici o errori organizzativi?, Bruno Mondadori Editore, Italia, 2006.

    TEACHERS AND EXAM BOARD

    Exam Board

    ROBERTO REVETRIA (President)

    ELVEZIA MARIA CEPOLINA

    LORENZO DAMIANI

    ANASTASIIA ROZHOK

    FLAVIO TONELLI (President Substitute)

    LESSONS

    Class schedule

    All class schedules are posted on the EasyAcademy portal.

    EXAMS

    EXAM DESCRIPTION

    EXAM DESCRIPTION
    Students with learning disorders ("Disturbi Specifici di Apprendimento", DSA) will be allowed to use specific modalities and supports that will be determined on a case-by-case basis in agreement with the delegate of the Engineering courses in the Committee for the Inclusion of Students with Disabilities.
    The exam is composed of three main parts:

    • 20 multiple choice quiz for a total of 25 points over 30
    • assignments for a total of 7 points over 30
    • oral examination for a total of 32 points over 30

    Final grade is the average of (quiz + assignments) and oral examination.
    Oral examination is based on a presentation made on a course topic chosen by the student and 3 open questions by the teacher.
    The exercises (assignments) must be delivered to the address: assignments.revetria@dime.unige.it by the day of the exam. Late exercises are not accepted. The exercises done in groups must report on all in the name of the group members. Similar exercises that do not correctly name the group members will be waived.
    For every wrong question given at quiz time a -0.5 points are subtract.

    ASSESSMENT METHODS

    Evaluation of the level of understanding of the theoretical concepts, evaluation of the practical design and calculation skills, evaluation of the comunication competences in a session of a real life project presentation.

    Exam schedule

    Date Time Location Type Notes
    20/12/2022 09:00 GENOVA Scritto + Orale
    18/01/2023 09:00 GENOVA Scritto + Orale
    01/02/2023 09:00 GENOVA Scritto + Orale
    29/05/2023 09:00 GENOVA Scritto + Orale
    27/06/2023 09:00 GENOVA Scritto + Orale
    13/07/2023 09:00 GENOVA Scritto + Orale
    15/09/2023 09:00 GENOVA Scritto + Orale

    FURTHER INFORMATION

    Exercises, software use and seminars are offered during the lectures period.