Establishing simulation model for optimizing efficiency of CNC machine using reliability-centered maintenance approach

2019 ◽  
Vol 10 (06) ◽  
pp. 1950034 ◽  
Author(s):  
Zahid Hussain ◽  
Hamid Jan
Keyword(s):  
Preventive Maintenance ◽  
Simulation Software ◽  
Time Interval ◽  
Total System ◽  
Cnc Machine ◽  
Effect Analysis ◽  
System Cost ◽  
Reliability Centered Maintenance ◽  
Maintenance Time ◽  
Critical Components

The objective of this work was to enhance the product’s quality by concentrating on the machine’s optimized efficiency. In order to increase the machine’s reliability, the basis of reliability-centered maintenance approach was utilized. The purpose was to establish a planned preventive maintenance strategy to identify the machine’s critical components having a noteworthy effect on the product’s quality. The critical components were prioritized using failure mode and effect analysis (FMEA). The goal of the study was to decrease the ppm time interval for a CNC machine by simulating the projected preventive maintenance time interval. For this purpose, the simulation software ProModel 7.5 was implemented for the current preventive maintenance procedure to choose the best ppm time interval which contributed better norms. Five dissimilar optimization approaches were applied, however, the first approach yielded the prominent total system cost and the shorter ppm interval. The results of the study revealed that there was an increase of USD 1878 as a result of an increase in total system cost from USD 78,365 to USD 80,243. Preventive maintenance costs were reduced from USD 4196 to USD 2248 (46%). The costs associated with good parts increased from USD 8259 to USD 8294 (0.4%) and the costs associated with defective parts reduced from USD 171 to USD 3 (98.25%), respectively.

Development of Computerized Preventive Maintenance Management System with Failure Mode and Effect Analysis for CNC Machine

2014 ◽  
Vol 627 ◽  
pp. 365-371 ◽  
Author(s):  
Em Ardchaya Rungsa ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Failure Mode ◽  
Preventive Maintenance ◽  
Management System ◽  
Maintenance Management ◽  
Risk Priority Number ◽  
Cnc Machine ◽  
Effect Analysis ◽  
Cnc Machines ◽  
Intelligent Maintenance ◽  
Maintenance Plan

In order to realize the intelligent maintenance management system, this paper presents a development of computerized preventive maintenance management system (CPMMS) to manage and record the maintenance information in the database for the CNC machines. The failure mode and effect analysis (FMEA) has been utilized to deal with the computerized preventive maintenance management system in this research. The FMEA is analyzed to determine the risk priority number (RPN) of the CNC machines in order to set the preventive maintenance plan as a standard maintenance. The developed program can generate the next schedule of the preventive maintenance plan automatically, which increases the efficiency and decreases the breakdown. It has been proved that the proposed and developed CPMMS with FMEA program can improve the overall equipment effectiveness (OEE). The RPN has been reduced due to a decrease in the severity and the occurrence.

scholarly journals USULAN PREVENTIVE MAINTENANCE PADA MESIN KOMORI LS440 DENGAN MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM II) DAN RISK BASED MAINTENANCE (RBM) DI PT ABC

2016 ◽  
Vol 3 (02) ◽  
pp. 31
Author(s):  
Destina Surya Dhamayanti ◽  
Judi Alhilman ◽  
Nurdinintya Athari
Keyword(s):  
Failure Mode ◽  
Preventive Maintenance ◽  
Effect Analysis ◽  
Corrective Maintenance ◽  
Reliability Centered Maintenance

PT ABC merupakan perusahaan cetak dalam skala nasional. Produk yang dihasilkan oleh perusahaan merupakan buku ajar, majalah, surat kabar, dan lain sebagainya. Kegiatan maintenance yang ada PT ABC terbagi menajadi dua, yaitu preventive maintenance setiap senin dan kamis serta kegiatan corrective maintenance yang dilakukan jika mesin mengalami kegagalan fungsi. Kegagalan fungsi pada mesin Komori masih cukup tinggi. Oleh karena itu, diperlukan kegiatan pecegahaan untuk meningkatkan reliabilitas mesin. Metode yang dilakukan adalah Reliability Centered Maintenance, yaitu dengan menganalisis failure yang terjadi dengan menggunakan analisis Failure Mode and Effect Analysis dan Decision Worksheet. Hasil dari analisis ini merupakan preventive task masing-masing komponen. Sedangkan untuk menganalisis risiko yang diakibatkan jika mesin mengalami gagal fungsi, yaitu dengan metode Risk Based Maintenance. Hasil yang diperoleh dari nilai risiko yang ditanggung perusahaan ketika mesin mengalami failure, yaitu sebesar Rp965.904.899,36. Berdasarkan hasil pengolahan data pada subsistem kritis diperoleh kesimpulan bahwa enam komponen dilakukan dengan task scheduled on condition, tiga komponen dengan task scheduled restoration, dan enam komponen dengan task scheduled discard. Sedangkan untuk interval waktu dalam pengerjaan preventive maintenance pada komponen tersebut disesuaikan dengan task yang diperoleh. Setelah mendapatkan interval waktu perawatan, kemudian ditentukan biaya perawatan usulan yang dikeluarkan perusahaan, yaitu sebesar Rp971.567.519,69.

scholarly journals IMPLEMENTASI PREVENTIVE MAINTENANCE UNTUK MENINGKATKAN KEANDALAN PADA KOMPONEN KRITIS BOILER DI PEMBANGKIT LISTRIK TENAGA UAP

2021 ◽  
Vol 2 (2) ◽  
pp. 73-78
Author(s):  
Iing Pamungkas ◽  
Heri Tri Irawan ◽  
T.M Azis Pandria
Keyword(s):  
Power Plant ◽  
Performance Improvement ◽  
Preventive Maintenance ◽  
Steam Power ◽  
Electricity System ◽  
Maintenance Time ◽  
Preventive Activity ◽  
Strategic Role ◽  
And Performance ◽  
Critical Components

This paper uses a preventive maintenance approach in improving the performance reliability of critical boiler components at the Nagan Raya Steam Power Plant (PLTU Nagan Raya). PLTU currently has a strategic role in the electricity system in Indonesia, one of which is PLTU Nagan Raya which is located in Aceh. In its implementation, PLTU Nagan Raya often experiences interference in its production system. The boiler is one part that often experiences interference, where corrective maintenance is one of the causes of the interference. Evaluation and performance improvement in terms of reliability are needed to minimize future failures. The purpose of this research is to determine the preventive maintenance time based on the reliability value of critical boiler components to increase the reliability value in the future. Preventive maintenance is a preventive activity before a machine breakdown occurs. The reliability value will be calculated in advance before the implementation of preventive maintenance. The results of the implementation of preventive maintenance in an effort to increase the reliability of the nine critical components of the boiler obtained maintenance results ranging from 14 days to 47 days with a reliability value of 60%.

scholarly journals RCM (RELIABILITY CENTERED MAINTENANCE): THE IMPLEMENTATION IN PREVENTIVE MAINTENANCE (CASE STUDY IN AN EXPEDITION COMPANY)

2020 ◽  
Vol 1 (02) ◽  
pp. 197-212
Author(s):  
Fathurohman Fathurohman ◽  
Slamet Triyono
Keyword(s):  
Steering System ◽  
Maintenance Policy ◽  
Power Steering ◽  
Reliability Centered Maintenance ◽  
Coupling System ◽  
Maintenance Time ◽  
Critical Components ◽  
Fmea Method ◽  
And Function ◽  
System Coupling

Expedition truck is a vehicle that serves to transfer goods from one place to another. Previously maintenance policy was periodic, depending on the run distance and Run To Failure, maintain the trucks after the occurrence of component damage then system failure. Analysis in maintenance management based on system and critical components do optimize truck performance by using RCM (Reliability Centered Management) method. There are 5 systems in a truck: electrical system, power steering system, cooling machine system, coupling system, and brake system. Interaction and function of the components from each system are analyzed, evaluated the failure mode (FMEA method), and categorized the level of critical damage and adjusted the maintenance time (LTA method).  The results of the RCM method for 16 component functions from the 5 systems are 5 component functions with Time Directed (TD), 6 Condition Directed (CD), 3 Failure Finding (FF), and 2 component functions by Run To Failure (RTF).

scholarly journals Implementation of Maintenance Scenario for Critical Subsystem In Aircraft Engine: Case Study NTP CT7 Engine

2017 ◽  
Vol 1 (02) ◽  
pp. 52
Author(s):  
Fransiskus Tatas Dwi Atmaji ◽  
Anna Annida Noviyanti ◽  
Widia Juliani
Keyword(s):  
Aircraft Engine ◽  
Maintenance Cost ◽  
Optimal Time ◽  
Time Interval ◽  
Performance Loss ◽  
Maintenance Schedule ◽  
Failure Data ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Critical Subsystem

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect. The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $ 7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got $1.885.612, 82.

scholarly journals A Reliability-Centered Maintenance Study for an Individual Section-Forming Machine

Machines ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 50 ◽  
Author(s):  
Samuel Okwuobi ◽  
Felix Ishola ◽  
Oluseyi Ajayi ◽  
Enesi Salawu ◽  
Abraham Aworinde ◽  
...  
Keyword(s):  
Failure Modes ◽  
Special Focus ◽  
Effect Analysis ◽  
Automated Production ◽  
Individual Section ◽  
Reliability Centered Maintenance ◽  
Maintenance Program ◽  
To Come ◽  
Critical Components ◽  
Functional Components

This study investigated the breakdown trend in an automated production with an aim to recommend the application of reliability-centered maintenance (RCM) for improved productivity via a new preventive maintenance (PM) program. An individual section-forming machine (ISM)—a glass blowing machine for making glass bottles—was used as the case study for an automated production system. The machine parts and the working mechanisms were analysed with a special focus on methods of processes and procedures. This will enable the ISM maintenance department to run more effectively and achieve its essential goal of ensuring effective machine operation and reduction in machine downtime. In this work, information is provided on the steps and procedures to identify critical components of the ISM using failure modes and effect analysis (FMEA) as a tool to come up with an optimal and efficient maintenance program using the reliability data of the equipment’s functional components. A relationship between the failure rate of the machine components and the maintenance costs was established such that using the recommended PM program demonstrates evidence of an improvement in the machine’s availability, safety, and cost-effectiveness and will result in an increase in the company’s profit margin.

scholarly journals Usulan Perawatan Mesin Stitching Dengan Metode Reliability Centered Maintenance

2017 ◽  
Vol 16 (2) ◽  
pp. 83
Author(s):  
Rizki Arga Kurniawan ◽  
Heri Mujayin Kholik
Keyword(s):  
Block Diagram ◽  
Production Quality ◽  
Main Concern ◽  
Logic Tree ◽  
Effect Analysis ◽  
Machine Maintenance ◽  
Reliability Centered Maintenance ◽  
System Maintenance ◽  
Critical Components ◽  
And Function

Based on industrial competition nowadays,  production quality occurs to be the main concern of severals top companies. Method of machine maintenance is a way to incresing their production quality. Nowadays, several companies still using a corrective maintenance to maintain their machine, which is all of machine maintenance only be performed if the machine damaged. This thesis only  focus to high frequency stitching machine. This thesis using Reability centered maintenance method  to obtain optimum maintenance interval. This method gathers 7 step of data processing, starting from data selection, determinating restricions of the system, descripting the system and function of block diagram, and then FMEA (Failure Mode Effect Analysis) and LTA (Logic Tree Analysis). The result of this method is a correct maintenance action for critical components that included in condition directed and time directed categories. Qulitative analysis for Reliability Centered Maintenance  method includes types indectification of maintenance, cause of damage and the occuring failure. Resul of the research contain several maintenance actions for critical components using condition directed method and critical component replace schedule using time directed method. From the suggested system maintenance simulation with RCM method, downtime can be decrease until 47,83%.

scholarly journals Penentuan Interval Waktu Preventive Maintenance Pada Nail Making Machine Dengan Menggunakan Metode Reliability Centered Maintenance (RCM) II

2019 ◽  
Vol 2 (2) ◽  
pp. 49
Author(s):  
Muhammad Arizki Zainul Ramadhan ◽  
Tedjo Sukmono
Keyword(s):  
Preventive Maintenance ◽  
Failure Modes ◽  
Engine Performance ◽  
High Technology ◽  
Time Interval ◽  
Machine Maintenance ◽  
Reliability Centered Maintenance ◽  
The Hours ◽  
Motor Component ◽  
Maintenance Activities

With the increasing needs of productivity and the use of high technology in the form of machines and production facilities, the need for maintenance functions is growing. At PT. Surabaya Wire that produces nails and wires of problems that arise especially related to damage to nail making machine, it causes the hours to stop (downtime) and delay in the production process so that the engine performance becomes less effective. The purpose of the research is to determine the time interval schedule of care and know the action or maintenance activities to be done. To solve the problem in this research using Reliability Centered Maintenance (RCM) II method with Failure Modes and Effect Analyze (FMEA) calculation. RCM II defined a process used to determine what should be done for machine maintenance, whereas for FMEA it is defined as a method to identify the highest failure form on any machine malfunction. From the calculation result using FMEA and RCM II, we got treatment interval result on side shaft component (metal handlebar) with maintenance interval for 63 hours, for crank shaft component (metal road) with maintenance interval for 81 hours, and for Electric motor component with maintenance interval for 374 hours.

Optimal Opportunistic Maintenance of a k-out-of-n:G System

1997 ◽  
Vol 04 (04) ◽  
pp. 369-386 ◽  
Author(s):  
Hongzhou Wang ◽  
Hoang Pham
Keyword(s):  
Preventive Maintenance ◽  
Aircraft Engine ◽  
Opportunistic Maintenance ◽  
Corrective Maintenance ◽  
System Cost ◽  
Cost Rate ◽  
Decision Variables ◽  
Maintenance Time ◽  
Engine Maintenance

The opportunistic maintenance of a k-out-of-n:G system is studied in this paper. In many applications, it spends less cost and time to perform maintenance on several components jointly than on each component separately. Based on this fact, two new (τ, T) opportunistic maintenance models with the consideration of reliability requirements are proposed. In these two models with two decision variables τ ≤ T, only minimal repairs are performed on failed components before time τ, and corrective maintenance of all failed components are combined with preventive maintenance (pm) of all functioning but deteriorated components after τ; if the system survives to time T without perfect maintenance, it will be subject to pm at time T. Considering maintenance time, asymptotic system cost rate and availability are derived. The results obtained generalize and unify some previous research in this area. Application to aircraft engine maintenance is presented.

scholarly journals A Reliability-Centered Maintenance Study for an Individual Section Forming Machine

2018 ◽  
Author(s):  
Samuel Okwuobi ◽  
Felix Ishola ◽  
Oluseyi Ajayi
Keyword(s):  
Failure Modes ◽  
Special Focus ◽  
Effect Analysis ◽  
Automated Production ◽  
Individual Section ◽  
Reliability Centered Maintenance ◽  
Maintenance Program ◽  
Optimal Maintenance ◽  
Critical Components ◽  
Functional Components

This study investigated the breakdown trend in an automated production with an aim to recommend the application of Reliability-centered maintenance (RCM) for an improved productivity via a new preventive maintenance (PM) program. Individual Section-forming machine (ISM): a glass blowing machine for making glass bottles was used as the case study of an automated production system. The machine parts and the working mechanisms were analysed with a special focus on methods of processes and procedures that will enable the ISM maintenance department run more effective and achieve its essential goal of ensuring effective machine operation and reducing machine downtime. In this work, information is provided on the steps and procedures to identify critical components of the ISM using Failure Modes and Effect Analysis (FMEA) as a tool to develop an optimal maintenance program based on the reliability data of the equipment’s functional components. A relationship was established between the failure rate of the machine components and the maintenance costs such that using the recommended PM program, an evidence of improvement in the machine’s availability, safety and cost-effectiveness will result into an increase in the company’s profit margin.

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