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.

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 Evaluasi Manajemen Perawatan dengan Metode Reliability Centered Maintenance (RCM) II pada Mesin Cane Cutter 1 dan 2 di Stasiun Gilingan PG Meritjan - Kediri

Rekayasa ◽  
2017 ◽  
Vol 10 (2) ◽  
pp. 99
Author(s):  
Cahyo Purnomo Prasetyo
Keyword(s):  
Maintenance Cost ◽  
Repair Cost ◽  
Maintenance Policy ◽  
Work Safety ◽  
Maintenance Costs ◽  
Reliability Centered Maintenance ◽  
Optimal Maintenance ◽  
Critical Components ◽  
Optimal Maintenance Policy ◽  
Production Target

<p>Penelitian ini bertujuan untuk menentukan kebijakan perawatan optimal yang dapat mengurangi biaya perbaikan (repair cost) dan biaya konsekwensi operasional (operational consequence cost). Metode yang diterapkan pada penelitian ini adalah Reliability Centered Maintenance (RCM) II. Penelitian ini difokuskan pada mesin Cane Cutter 1 dan 2 dengan pertimbangan beberapa aspek yaitu : pengaruh kegagalan terhadap pencapaian target produksi, resiko keselamatan kerja dan biaya perawatan yang akan ditimbulkan. Dari hasil penelitian dapat diketahui bahwa komponen kritis pada mesin Cane Cutter 1 dan 2 adalah : Pisau dan Baut Pisau. Perawatan yang dilakukan untuk mengantisipasi dan mengatasi kegagalan yang terjadi pada komponen mesin tersebut adalah proactive task yang meliputi : scheduled restoration task dan scheduled discard task. Rata-rata penurunan biaya perawatan total yang didapatkan dengan mengurangkan ‘biaya total pada interval perawatan awal’ dan ‘biaya total pada interval perawatan optimal’ adalah 14,82 %.</p><p>Kata Kunci: cane cutter, downtime, pabrik gula.</p><p><strong> </strong></p><p><strong>ABSTRACT</strong></p><p><em>This research aims to determine the optimal maintenance policy which could reduce repair cost and operational consequence cost. The methods which applied in this research is Reliability Centered Maintenance (RCM) II. This research focuses on Cane Cutter 1 and 2 machines by considering several aspects, such as and effect of any failure on production target achievement, work safety risk and maintenance cost which might be caused by the critical condition. The result showed that some critical components at the Cane Cutter 1 and 2 machines were : Blade and Blade Bolt. The maintenance which could be done to anticipate and deal with any failure occurring in the machine components was called proactive task comprising : scheduled restoration task and scheduled discard task. The average reduction in total maintenance costs which was obtained by subtracting ‘total costs at initial maintenance interval’ and ‘total costs at optimal maintenance interval’ amounted to 14,82 %.</em></p><p><em>Keywords: cane cutter, downtime, sugar factory</em></p>

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.

scholarly journals Condition-Based Maintenance of HVAC on a High-Speed Train for Fault Detection

Electronics ◽  
2021 ◽  
Vol 10 (12) ◽  
pp. 1418
Author(s):  
Lorenzo Ciani ◽  
Giulia Guidi ◽  
Gabriele Patrizi ◽  
Diego Galar
Keyword(s):  
Decision Making ◽  
High Speed ◽  
Failure Modes ◽  
Air Conditioning System ◽  
Suggested Approach ◽  
Reliability Centered Maintenance ◽  
High Speed Trains ◽  
Optimal Maintenance ◽  
The Cost ◽  
Maintenance Plan

Reliability-centered maintenance (RCM) is a well-established method for preventive maintenance planning. This paper focuses on the optimization of a maintenance plan for an HVAC (heating, ventilation and air conditioning) system located on high-speed trains. The first steps of the RCM procedure help in identifying the most critical items of the system in terms of safety and availability by means of a failure modes and effects analysis. Then, RMC proposes the optimal maintenance tasks for each item making up the system. However, the decision-making diagram that leads to the maintenance choice is extremely generic, with a consequent high subjectivity in the task selection. This paper proposes a new fuzzy-based decision-making diagram to minimize the subjectivity of the task choice and preserve the cost-efficiency of the procedure. It uses a case from the railway industry to illustrate the suggested approach, but the procedure could be easily applied to different industrial and technological fields. The results of the proposed fuzzy approach highlight the importance of an accurate diagnostics (with an overall 86% of the task as diagnostic-based maintenance) and condition monitoring strategy (covering 54% of the tasks) to optimize the maintenance plan and to minimize the system availability. The findings show that the framework strongly mitigates the issues related to the classical RCM procedure, notably the high subjectivity of experts. It lays the groundwork for a general fuzzy-based reliability-centered maintenance method.

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 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 Analisa Perbaikan Manajemen Perawatan Dengan Metode Reliability Centered Maintenance Bagian Cnc Wirecut di PT X

2021 ◽  
Vol 1 (1) ◽  
pp. 22-30
Author(s):  
Mahmud Iqbal Syam ◽  
Cecep Hadiyan ◽  
Tusmin Hardi
Keyword(s):  
Failure Modes ◽  
Manufacturing Companies ◽  
Maintenance Policy ◽  
Effect Analysis ◽  
Reliability Centered Maintenance ◽  
Machine Reliability ◽  
Defining System ◽  
Engine Failure ◽  
Fmea Analysis ◽  
And Function

PT X is one of the manufacturing companies in Indonesia, which specializes in manufacturing molds and dies which offers products to the internal group and the domestic market. This study discusses the policy analysis of machine repair maintenance management using the RCM (Reliability Centered Maintenance) method approach at the PT X manufacturing company. Some of the problems that occur are sudden engine failure, which will cause over production. One machine that is considered critical is the CNC Wirecut K90 machine. With the application of using RCM it is expected to improve machine reliability through several systematic RCM implementations: system selection and information collection, defining system boundaries, system descriptions and function block diagrams, describing system functions and functional failures, compiling Failure Mode and Effect Analysis (FMEA), composing Logic Tree Analysis (LTA), selection of actions. The new policy set by the Realibility Centered Maintenance (RCM) method consists of 14 failure modes that are resolved by time-directed (CD) and 6 failure modes that are overcome by run to failure (RTF). In the FMEA analysis, there are 4 components that most often fail to function, namely the electrode pin, wire guide, filter and contact fit. The determination of this component is based on the RPN value and data in the field. In the RCM analysis, the electrode pin, wie guide and contact fit components are included in the run to failure (RTF) treatment policy category. Meanwhile, the filter component is in the category of condition direction (CD) maintenance policy with an average failure rate of 29,951 days.

Assessment of the Pitting Corrosion Degradation Lifetime: A Case Study of Boiler Tubes

2017 ◽  
Vol 3 (4) ◽  
Author(s):  
Lida Naseh Moghanlou ◽  
Mohammad Pourgol-Mohammad
Keyword(s):  
Monte Carlo ◽  
Pitting Corrosion ◽  
Power Plants ◽  
Failure Modes ◽  
Deterministic Model ◽  
Model Parameters ◽  
Special Focus ◽  
Effect Analysis ◽  
Failure Data ◽  
Boiler Tubes

Corrosion degradation is a common problem for boiler tubes in power plants, resulting in an unscheduled plant shutdown. In this research, degradation of the corrosion is investigated for boiler tubes by estimating the corrosion lifetime. A special focus is made on the corrosion failures, important failure modes, and mechanisms for the metallic boiler tubes via failure modes and effect analysis (FMEA) method, thereby evaluating the pitting corrosion as the most common failure mode in the tubes. Majority of the available approaches estimates lifetime of the pitting corrosion by deterministic approaches, in which the results are valid only for limited conditions. In order to improve deficiencies of available models, a stochastic method is proposed here to study the corrosion life. The temporal behavior of the metal degradation is analyzed in different conditions through the developed approach, and a proper degradation model is selected. Uncertainty intervals/distributions are determined for some of the model parameters. The deterministic model is converted to a probabilistic model by taking into account the variability of the uncertain input parameters. The model is simulated using Monte Carlo method via simple sampling. The result of the life estimation is updated by the Bayesian framework using Monte Carlo Markov Chain. Finally, for the element that is subjected to the pitting corrosion degradation, the life distribution is obtained. The modeling results show that the pitting corrosion has stochastic behavior with lognormal distribution as proper fit for the pitting corrosion behavior. In order to validate the results, the estimations were compared with the power plant field failure data.

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.

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