An Application of Reliability Centered Maintenance Using RPN Mean and Range on Conventional Lathe Machine

2016 ◽  
Vol 23 (06) ◽  
pp. 1640010 ◽  
Author(s):  
G. Gupta ◽  
R. P. Mishra ◽  
P. Singhvi
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Mechanical Equipment ◽  
Maintenance Strategy ◽  
Risk Priority Number ◽  
Key Factors ◽  
Effect Analysis ◽  
Reliability Centered Maintenance ◽  
Lathe Machine ◽  
Selection Of

RCM provides a structured and practical approach for arriving at an acceptable maintenance strategy for each component of a given system. In this paper, a study on reliability centered maintenance (RCM) has been conducted to reduce the total number of failures and its effects on the conventional lathe machine. The risk priority number (RPN) is, one of the key factors in determining the critical ranking of a failure mode of the mechanical equipment but there is a drawback in determining the critical ranking from RPN. There might be more than one failure modes which can share the same RPN number and therefore critical ranking cannot be assigned to those failure modes. Initially, the Severity, Occurrence and Detection rating integrating with failure mode and effect analysis (FMEA) is taken from several experts and then RPN is calculated for each of those experts. Then the criticality of the failure mode of the functionally significant items of conventional lathe machine is judged on the basis of mean RPN value as well as using the range. Overall the risk or criticality level of each failure mode is identified. After that, RCM logic is used for selection of a proper maintenance strategy for each failure mode.

scholarly journals Perencanaan Perawatan Mesin Welding Mig Pada Produksi Sub Frame Di PT. XYZ Dengan Metode Reliability Centered Maintenance (RCM)

2021 ◽  
Vol 6 (1) ◽  
pp. 26-38
Author(s):  
Zulkani Sinaga ◽  
Solihin Solihin ◽  
Mochamad Ardan
Keyword(s):  
Failure Mode ◽  
Time To Failure ◽  
Risk Priority Number ◽  
Mean Time To Failure ◽  
Effect Analysis ◽  
Mean Time Between Failure ◽  
Reliability Centered Maintenance ◽  
Mean Time To Repair ◽  
Mean Time

Pemeliharaan merupakan suatu proses yang dilakukan untuk menjaga keandalan, ketersediaan dan sifat mampu merawat komponen atau mesin. Program pemeliharaan yang efektif dan efisien akan mendukung peningkatan produktifitas sistem produksi. PT. XYZ merupakan perusahaan nasional bergerak dibidang karoseri truck mengalami penurunan produktivitas disebabkan belum adanya strategi perawatan khususnya mesin welding jenis MIG sehingga sering terjadi downtime mesin mengakibatkan proses produksi menjadi terhambat. Berdasarkan alasan tersebut dibutuhkan program pemeliharaan yang efektif dan efisien dengan menerapkan analisis menggunakan metode  Reliability Centered Maintenance (RCM) guna menciptakan metode pemeliharaan yang akurat, fokus, dan optimal dengan tujuan mencapai keandalan yang optimal. Penelitian dilakukan dengan mengikuti langkah-langkah perhitungan berdasarkan Failure Mode and Effect Analysis (FMEA) dan penetapan strategi pemeliharaan dengan dibantu menggunakan software minitab 18. Hasil penelitian diperoleh Risk Priority Number (RPN) untuk komponen wire feeder sebesar 611, dengan pola distribusi waktu normal, nilai parameter median 61,9391 dan standar deviasinya 48,6053, nilai Mean Time To Failure (MTTF) sebesar 61,9391 jam dan selang interval waktu penggantian komponen sebesar 10,1349. Berdasarkan hasil perhitungan performance maintenanace diketahui nilai Mean Time Between Failure (MTBF) antara 31,92 ~ 72,09 jam, Mean Time To Repair (MTTR) anatara 1,19 ~ 1,78 jam dan availability antara 94,67% ~ 98,24%, setelah dilakukan tindakan perawatan pencegahan selama periode tersebut dihasilkan nilai availability sebesar 98,01% artinya kerusakan pada komponen wire feeder dapat teratasi.

scholarly journals Preventive risk analysis in the maintenance of patency of the peripherally inserted central catheter

2019 ◽  
Vol 53 ◽  
Author(s):  
Antônio Fernandes Costa Lima ◽  
Amanda Saba ◽  
Simone Berger ◽  
Silvia Sauaia Bianchini ◽  
Fernando Tobal Berssaneti
Keyword(s):  
Risk Analysis ◽  
Failure Mode ◽  
Failure Modes ◽  
Saline Solution ◽  
Hospital Costs ◽  
Peripherally Inserted Central Catheter ◽  
Central Catheter ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Nursing Professional

ABSTRACT This theoretical and reflexive study analyzed the risks related to the maintenance of patency of the Peripherally Inserted Central Catheter with the use of saline solution in comparison with saline-filled syringes, through the application of the Healthcare Failure Mode and Effect Analysis - HFMEA. The process was mapped, detailing the failure modes of each step. For the calculation of the Risk Priority Number, the severity and probability of the failure modes were analyzed. This analysis gave rise to the severity and probability matrix. Finally, actions to reduce the failure modes in the maintenance of patency were proposed, considering the use of saline-filled syringes in comparison to the use of saline ampoules. It was verified that the use of saline ampoules is associated with a greater risk, since it requires four stages more than saline-filled syringe does not, increasing the risk of contamination and the level of three different risks, which would result in additional hospital costs. The use of the saline-filled syringe would avoid risks that could negatively affect the patient’s health, the nursing professional and the health institution.

scholarly journals Application of Failure Mode Effect Analysis for Improved Scheduling in Maintenance of Machines

2020 ◽  
Vol 9 (6) ◽  
pp. 895-899
Keyword(s):  
Failure Mode ◽  
Work Flow ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Mode Effect ◽  
Lathe Machine ◽  
Complete Failure ◽  
Fmea Method ◽  
Effective Analysis ◽  
Failure Mode Effect Analysis

Maintenance of machines is crucial measures in order to have stable and improved work flow. Any kind of failure might result in complete failure of the machine. Hence it becomes essential to identify the vulnerable failures that might occur in the components of any machine. The present work is carried out in order to improve the scheduling in maintenance of a lathe machine. Different components of the machine are studied in this research. “Failure mean effective analysis (FMEA)” method is applied to identify the failures associated with the components of the machine. Risk priority number is calculated based on which the components are provided with ranks. The rank signifies the flow of maintenance for all the components. The results reveal that the flexure bearing needs the least maintenance as it has the highest rank.

Integrating TOPSIS and DEMATEL Methods to Rank the Risk of Failure of FMEA

2014 ◽  
Vol 13 (06) ◽  
pp. 1229-1257 ◽  
Author(s):  
Kuei-Hu Chang ◽  
Yung-Chia Chang ◽  
Yu-Tsai Lee
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Iso 9000 ◽  
Decision Makers ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Analysis Techniques ◽  
Risk Of Failure ◽  
Quality Certification ◽  
Order Preference

Failure mode and effect analysis (FMEA) is one of the risk analysis techniques recommended by international quality certification systems, such as ISO 9000, ISO/TS 16949, CE, and QS9000. Most current FMEA methods use the risk priority number (RPN) value to evaluate the risk of failure. The RPN value is the mathematical product of the three parameters of a failure mode that is rated between 1 and 10 in terms of its severity (S), occurrence (O), and detection (D), respectively. However, the RPN method has been found with three main drawbacks: (1) high duplicate RPN values, (2) failure to consider the ordered weights of S, O, and D, and (3) failure to consider the direct and indirect relationships between the failure modes and causes of failure. Therefore, this paper integrates the technique for order preference by similarity to ideal solution (TOPSIS) and the decision-making trial and evaluation laboratory (DEMATEL) approach to rank the risk of failure. A case of an inlet plate ring that has been drawn from a professional mechanical factory is presented to further illustrate the proposed approach. After comparing the result that was obtained from the proposed method with the conventional RPN and DEMATEL methods, it was found that the proposed method can resolve the abovementioned RPN ranking issues and give a more appropriate risk assessment than other listed approaches to provide valuable information for the decision makers.

scholarly journals Failure Mode and Effect Analysis (FMEA) for confectionery manufacturing in developing countries: Turkish delight production as a case study

2012 ◽  
Vol 32 (3) ◽  
pp. 505-514 ◽  
Author(s):  
Sibel Ozilgen
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Chemical Contamination ◽  
Risk Priority Number ◽  
Analysis Model ◽  
Production Potential ◽  
Effect Analysis ◽  
Potential Failure

The Failure Mode and Effect Analysis (FMEA) was applied for risk assessment of confectionary manufacturing, in whichthe traditional methods and equipment were intensively used in the production. Potential failure modes and effects as well as their possible causes were identified in the process flow. Processing stages that involve intensive handling of food by workers had the highest risk priority numbers (RPN = 216 and 189), followed by chemical contamination risks in different stages of the process. The application of corrective actions substantially reduced the RPN (risk priority number) values. Therefore, the implementation of FMEA (The Failure Mode and Effect Analysis) model in confectionary manufacturing improved the safety and quality of the final products.

Risk Priority Analysis for Engine Based on Fuzzy Weighted Geometric Mean

2012 ◽  
Vol 463-464 ◽  
pp. 1160-1164 ◽  
Author(s):  
Ying Kui Gu ◽  
Xin Chong Luo ◽  
Shun Yun Tang
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Geometric Mean ◽  
Computational Process ◽  
Occurrence Probability ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Fuzzy Fmea ◽  
Alpha Level ◽  
Theory Failure

Fuzzy risk priority numbers (FRPNs) were proposed for assessment of the probabilistic risk by synthetically using fuzzy set theory, failure mode and effect analysis. The priority rank of failure modes is evaluated by fuzzy risk priority number in the fuzzy failure mode and effect analysis, where occurrence probability ranking, effect severity ranking and detection difficulty ranking are all fuzzy weighted geometric mean, and the FRPN can be computed using alpha-level set and optimization model. An engine example was provided to illustrate the proposed fuzzy FMEA and the detailed computational process of the FRPNs.

scholarly journals A Research on Failure Mode and Effect Inquiry on Tea Leaves Processing - Leaf Shredder Machine

2019 ◽  
Vol 8 (9S2) ◽  
pp. 414-416
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Study Data ◽  
Risk Priority Number ◽  
Total Quality ◽  
Tea Leaves ◽  
Effect Analysis ◽  
Entire Process ◽  
Cutting Knife ◽  
Functional Components

India is a large exporter of tea leaves and has industries involving in Tea Leaves processing. There are generally three stages in the processing of tea leaves and many machines are involved that cater to various process to convert the raw tea leaves to usable products. In the first stage there is a machine titled Leaf Shredder that is critical in the process as the entire process is a product based and a breakdown of this machine in particular affects the entire process from that point. This study focuses on the failure modes of the Leaf Shredder machine and its effect. The Total Quality Management (TQM) tool - Failure Mode and Effect Analysis (FMEA) is used in this study. The critical functional components of the Leaf Shredder are five in number. Through the study, data has been collected and the Risk Priority Number has been calculated. Based on the Risk Priority Number value it is seen that the Cutting Knife, Main Shaft and the Bearing are the components that are having a tendency to fail. The Reason of failure was analyzed. From the analysis it is seen that the main cause of failure is due to improper maintenance of the components and unbalancing of the cutting knife weight. A well thought of plan of action to maintain the Tea Leaf Shredder will bring down the failure rate and improve the reliability of the product layout

scholarly journals ANALISIS PERAWATAN AC (AIR CONDITIONER) UNIT SPLIT DUCT MENGGUNAKAN METODE FAILURE MODE AND EFFECT ANALYSIS FMEA DI HOTEL HARRIS YELLO

2020 ◽  
Vol 3 (1) ◽  
pp. 67
Author(s):  
Dwi Suryanto
Keyword(s):  
Failure Mode ◽  
Goodness Of Fit ◽  
Printed Circuit Board ◽  
Circuit Board ◽  
Air Conditioner ◽  
Risk Priority Number ◽  
Goodness Of Fit Test ◽  
Effect Analysis ◽  
Printed Circuit ◽  
Reliability Centered Maintenance

Pemeliharan merupkan hal yang penting yang harus dilakukan olehs etiap perusahaan, karen apemelihraan dapatmempengaruhi prose sproduksi yang sedang berjlana adakanya mesin terhenti dikarenakan adanya gangungan yang disebabkan mesin mengalami keruskan pada sala satu komponen, hal ini terjadi biasanya karena mesin kurang atau tidak dijaga maka dari itu perusahaan haru smelakukan pemelihraan yang baik agar tidak terjadi kegagaglan pada mesin, yang menimbulkan juga dalam produktivitas yang menurun. Hal ini juga dialami oleh hotel haris diman pada hotel haris tersedia jumlah aitr condirtioner yang nbanyak jumlahnya, jika ac atau air conditioner tidak dirawata maka besar kemungkinan keandalan pad aac tersebut dapat terganggun diakibatkan daanya ganggunan pada ac yang menyenbabkan konsumen tidak puas akan pelayana yang diberikan oleh hotel haris, kejadiian seperti ini bukan hanya terjadi sekali dua kali tetapi sering nya keajdian kegagalan yang membuat reoutasi perusahaan terganggu, maka dari itu perlu adanya erawatan yang baik pada mesin AC agarar tercapai kondisi yang prima. Salah satu metode yang biasa digunakan dalam merebcanakan perbaikan yaitu metode RCM atau kepanjangan dari reliability centrered  maintenance metode ini biasa digunakan dalam merencanakan perawatan mesin yang terpadu.  Berdasarkan hasil penelitian Masalah yang paling dominan terjadinya kegagalan atau kerusakan yang sering terjadi adalah komponen Kompresor, Printed Circuit Board (PCB) dan Dinamo Motor Indoor di lihat dari hasil Risk Priority Number (RPN) dengan menggunakan metode Failure Mode And Effect Analsis (FMEA).  Kemudian Faktor yang menyebabkan terjadi kegagalan pada komponen kompresor adalah Refrigant berkurang atau adanya kebocoran gas, sehingga kompresor tidak berjalan normal dan bearing yang diatas stationary blade macet terkena partikel karat menimbulkan debu tercampur  sehingga kompresor menjadi panas terjadilah kemacetan akibat kurangnya oli dan Refrigant. Adapun Tindakan perbaikan yang harus dilakukan adalah interval waktu penjadwalan berdasarkan metode Reliability Centered Maintenance (RCM), pada bagian komponen Kompresor. Pada bagian ini dengan hasil maksimum dari uji kesesuaian Goodness Of Fit Test distribusi Weibull waktu Maen Time To Repair (MTTR) adalah 99 jam atau 4 hari untuk kegagalan yang tidak dapat diprediksi dengan melakukan upaya tindakan condition monitoring yaitu seperti melakukan pengecekan suhu udara diruang lobby atau remote indoor AC, guna mengurangi terjadinya gangguan-ganguan yang mengurai kualitas kapasitas dan fasilitas Hoter Harris Yello.

scholarly journals Managing Transformers Risk through Failure Codification

2020 ◽  
Vol 69 (3) ◽  
pp. 25-33
Author(s):  
Abdullah Mohammed Al Qabtan ◽  
Mohammed Said Dad Allah AlZadjali ◽  
Omran Omar AL Balushi
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Cost Effective ◽  
Service Organizations ◽  
Order System ◽  
Maintenance Strategy ◽  
Effect Analysis ◽  
Holistic View ◽  
Fast Development ◽  
Asset Class

The fast development and expansion of any service organizations which followed by increases in the asset numbers that’s need to have a proper maintenance strategy which should be cost effective. The aim of any strategy is to have a plan that contribute to improve asset performance by reducing downtime of asset failures.The aim of this paper is to set plan that determine the processes of creating failure code that can create a library of failure modes with its consequences and risk. This allow service provider to quickly understand the problem and any action that can be taken which have already proven by failure mode effect analysis. Also it’s identify most of the functional failures that might happened in the critical asset in the OETC’s network. In this study the transformer asset class was taken into the consideration for full failure mood and fault tree analysis.Defining failure codes can give specific instructions to complete a task to reduce the main time to wait in any failure from the total main time to repair, and any smiler failure mode from other assets the corrective action will remain consistent. The selective processes of creating a failure code give the organization a more holistic view of transformers risk which will be used to improve maintenance strategy by integrate those codes into work order system like CMMS

Sign in / Sign up

Export Citation Format

Share Document