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.

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.

Adaptive and noncyclic preventive maintenance to augment production activities

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sunil Dutta ◽  
Narala Suresh Kumar Reddy
Keyword(s):  
Preventive Maintenance ◽  
Production Scheduling ◽  
Content Type ◽  
Staff Members ◽  
Novel Approach ◽  
The Hours ◽  
Maintenance Activities ◽  
The Moment ◽  
Maintenance Schedules ◽  
Maintenance Model

PurposeProduction schedules, if not met as per timelines may result in heavy losses to a company in terms of its standing and the overall profit. Production scheduling is generally planned by not taking preventive maintenance schedules into consideration. Most of the plants allocate discrete hours/time for preventive maintenance activities. These hours allocated for preventive maintenance will be in addition to the hours which would be lost during breakdown maintenance. These lost hours may be reduced if production scheduling and preventive maintenance activities are integrated. This advocates that we need to devise a methodology which can take care of lost hours.Design/methodology/approachAdaptive and noncyclic maintenance strategy describes the modification of existing maintenance practices, policies and procedures to meet new dynamic tasks/opportunities. It demands a high degree of flexibility and mental agility from maintenance staff members. The maintenance team has to be on a lookout for an opportunity message received from the central server and has to act promptly. The moment an opportunity arises, a message is forwarded to a central maintenance server (opportunity is captured). The central server then assigns individuals/team, based on their expertise and the maintenance task due on that machine/equipment. This action is completely automated and implemented without delay.FindingsThe total man-hours saved by executing adaptive and noncyclic preventive maintenance methodology comes to 705 h during 15 days on 30 machines installed in three different sections. There was a contribution of 71 innovative ideas from the repair teams. Out of these 71 innovative ideas, 16 were found suitable for execution. A quantum jump in the morale and motivation of the maintenance team was noticed from the feedback forms. Mutual understanding and respect for each other among employees has been enhanced. The optimization of resources and infrastructure including tools, gauges, testing equipment, etc. could truly be attained.Practical implicationsThe developed adaptive and noncyclic preventive maintenance model assists in capturing lost hours and make the system proactive and lean. The suggested model optimizes the preventive and predictive maintenance activities and results in substantial saving of efforts, manpower, resources and allocated budget.Originality/valueThe adaptive and noncyclic preventive maintenance model discussed in the article is a novel approach for the optimization of resources. The technique assists in capturing lost hours and utilization of these hours for preventive maintenance tasks. The model will also encourage creative and innovative ideas from employees and take the organization toward Continual Maintenance Optimization.

Criticality-based reliability-centered maintenance for healthcare

2019 ◽  
Vol 26 (2) ◽  
pp. 311-334
Author(s):  
Abdulrahim Shamayleh ◽  
Mahmoud Awad ◽  
Aidah Omar Abdulla
Keyword(s):  
United Arab Emirates ◽  
Preventive Maintenance ◽  
Medical Equipment ◽  
Current Practice ◽  
Failure Modes ◽  
Healthcare Management ◽  
Failure Rates ◽  
Opportunity Identification ◽  
Content Type ◽  
Reliability Centered Maintenance

Purpose Medical technologies and assets are one of the main drivers of increasing healthcare cost. The rising number and complexity of medical equipment have forced hospitals to set up and regulate medical equipment management programs to ensure critical devices are safe and reliable. The purpose of this paper is to gain insights into maintenance management-related activities for medical equipment. The paper proposes applying a tailored reliability-centered maintenance (RCM) approach for maintenance activities selection for medical equipment. Such approach will support assets management teams in enhancing operation, decrease risk and cost, and ultimately improve health of patients served by these equipment. Design/methodology/approach The traditional RCM approach will be used with a focus on criticality reduction. By criticality, the authors refer to the severity of failures and occurrence. The proposed method relies on the use of reliability growth analysis for opportunity identification followed by a thorough failure mode and effect analysis to investigate major failure modes and propose ways to reduce criticality. The effectiveness of the proposed method will be demonstrated using a case of one of the leading obstetric and gynecological hospitals in United Arab Emirates and in the Gulf Cooperation Council region. Findings The case examines the relationship between the current practice of planned preventive maintenance and the failure rates of the equipment during its life span. Although a rigorous preventive maintenance program is implemented in the hospital under study, some critical equipment show an increasing failure rates. The analysis highlights the inability of traditional time-driven preventive maintenance alone in preventing failures. Thus, a systematic RCM approach focused on criticality is more beneficial and more time and cost effective than traditional time-driven preventive maintenance practices. Practical implications The study highlights the need for utilizing RCM approach with criticality as the most important prioritization criterion in healthcare. A proper RCM implementation will decrease criticality and minimize the risk of failure, accidents and possible loss of life. In addition to that, it will increase the availability of equipment, and reduce cost and time. Originality/value This paper proposes a maintenance methodology that can help healthcare management to improve availability and decrease the risk of critical medical equipment failures. Current practices in healthcare facilities have difficulty identifying the optimal maintenance strategy. Literature focused on medical maintenance approach selection is rather limited, and this paper will help in this discussion. In addition to that, the Association for the Advancement of Medical Instrumentation supports the initiative of adopting RCM on a large scale in healthcare. Therefore, this paper address the gap in the literature for medical equipment maintenance and the work is in line with the recommendation of leading healthcare association. The paper also presents statistical review of the total number of received maintenance work orders during one full year in the hospital under study. The analysis supports the need for more research to examine current practice and propose more effective maintenance approaches.

Reability Centered Maintenance (RCM), Gain and Results 3 Years After Implementation

2004 ◽  
Author(s):  
Robison Tirre Ribeiro ◽  
Nancy Flora Alves Pinto
Keyword(s):  
Failure Modes ◽  
High Reliability ◽  
Point Of View ◽  
Reliability Centered Maintenance ◽  
Critical Facilities ◽  
Maintenance Activities

TBG – Transportadora Brasileira Gasoduto Boli´via Brasil S.A. — Started in 2000, a program of studies based on the methodology of Reliability Centered Maintenance (RCM) with a goal of analyzing its main and more critical facilities and systems according to this methodology seeking to guarantee a high reliability by means of the maintenance. This studies presented quite expressive results: it allowed to the participants to know in depth the systems and devices of the facilities; identify through a FMEA (Failure Modes and Effects Analysis) all the main manners of failures of the functions of the several systems and devices; to evaluate the consequences of the failures and its impact under safety’s point of view, environment and operation of the station; to determine the maintenance activities (preventive, predictive and of search of failures) necessary to the maintenance of the reliability of the station; to identify opportunities of improvements in the project of the installation seeking the increment of its reliability; to identify needs of implementation of operation procedures and maintenance or modification in the existent ones.

scholarly journals ANALISIS PEMELIHARAAN MESIN CCO (CRUDE COCONUT OIL) STUDI KASUS PADA PT. SPO AGRO RESOURCES

2020 ◽  
Vol 6 (1) ◽  
pp. 10-19
Author(s):  
Dewi Sartika ◽  
Asngadi Asngadi ◽  
Syamsuddin Syamsuddin
Keyword(s):  
Preventive Maintenance ◽  
Quantitative Methods ◽  
Coconut Oil ◽  
Maintenance Cost ◽  
Maintenance Costs ◽  
Machine Maintenance ◽  
Time Period ◽  
Calculation Results ◽  
Maintenance Activities ◽  
Maintenance Policies

This  study  aims  to  determine  and  analyze  machine  maintenance carried  out  by  PT.  SPO  Agro Resources and to find out whether the presence of preventive maintenance policies can improve the effectiveness  of  time  and  costs.  This  research  uses  qualitative methods  by  describing  maintenance activities carried out by PT. SPO Agro Resources, as well as using quantitative methods in the form of mathematical  statistics  as  a  tool  to  help  decide  policies  to  be taken  at  a  certain  time  period  and efficiency  measurements  using descriptive  percentages.  The  results  showed  preventive  maintenance costs  once  a  month  Rp.138,012,968, - efficiency  value  was  39.63%, preventive  maintenance  costs every two months Rp.196,689,315, - efficiency value was 56.48%, preventive maintenance costs every three months  Rp.  258,731,341, - the  efficiency  value  is  74.29%,  repair maintenance  costs Rp.247,164,000, - the efficiency value is 70.97%. Based on the calculation it is known that the policy that  makes maintenance  costs  efficient  is  maintenance  once  a  month  because this  policy  is  the smallest maintenance cost compared to other policies, where the percentage value is smaller which is 39.63%,  according  to table  2 which  states  if  the  calculation  results  are  below 60%  said  to  be  very efficient. Penelitian  ini bertujuan  untuk  mengetahui  dan  menganalisis pemeliharaan  mesin  yang  dilakukan oleh PT. SPO Agro Resources dan untuk mengetahui apakah dengan adanya kebijakan pemeliharaan pencegahan  dapat  meningkatkan  efektivitas  waktu  dan  biaya. Penelitian  ini menggunakan metode kualitatif dengan menjabarkan aktivitas kegiatan pemeliharaan yang dilaksanakan oleh PT. SPO Agro Resources, serta  menggunakan  metode  kuantitatif  berupa  statistik matematik  sebagai  alat  untuk membantu  memutuskan  kebijakan yang  akan  diambil  pada jangka  waktu  tertentu  dan pengukuran efisiensi  menggunakan deskriptif  presentase.  Hasil  penelitian menunjukkan  biaya pemeliharaan pencegahan sebulan sekali Rp.138.012.968,- nilai efisiensinya 39,63%,  biaya pemeliharaan pencegahan  dua  bulan  sekali  Rp.196.689.315,- nilai  efisiensinya 56,48%,  biaya pemeliharaan pencegahan  tiga  bulan  sekali Rp.258.731.341,- nilai  efisiensinya 74,29%, biaya pemeliharaan perbaikan Rp.247.164.000,- nilai  efisiensinya 70,97%.  Berdasarkan perhitungan diketahui bahwa kebijakan yang mengefisiensikan  biaya pemeliharaan  yaitu pemeliharaan  sebulan  sekali karena kebijakan ini biaya  pemeliharaannya paling  kecil  dibandingkan  dengan  kebijakan yang  lain, dimana nilai  persentasenya  lebih  kecil  yaitu  39,63%, sesuai  dengan tabel  2 yang  menyatakan  apabila  hasil perhitungan di bawah 60% maka dikatakan sangat efisien.

PERANCANGAN PENJADWALAN PERAWATAN MESIN BUBUT DENGAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) DI BENGKEL PEMESINAN SMK NEGERI 1 KEDIRI

2019 ◽  
Vol 1 (1) ◽  
pp. 13
Author(s):  
Adi Sukopriyatno ◽  
Sri Rahayuningsih ◽  
Ana Komari
Keyword(s):  
Factor Analysis ◽  
Reliability Analysis ◽  
Preventive Maintenance ◽  
Failure Modes ◽  
Electrical System ◽  
Maintenance System ◽  
Reliability Centered Maintenance ◽  
Maintenance Time ◽  
System Components ◽  
Mean Time

So far, the engineering department has not implemented a good maintenance system. Therefore we need a maintenance schedule to meet the need for maintenance. The method for the analysis function is: reliability analysis and maintainability factor analysis. From the application of the reliability centered maintenance system approach, it is concluded that the critical components and the compilation of the failure modes and effect analysis tables. Whereas from the results of the reliability analysis in the form of the rate of damage, the average time between the damage and the maintainability factor analysis, it is concluded that the average corrective maintenance, the average prevention time, the average maintenance time, the average active maintenance time, the maintenance frequency and the time. the average down time of the lathe electrical system components. The results of the calculation of Mean Time Between Maintenance obtained maintenance intervals of lathe electrical system components every 223.1 hours, lathe erosion every 401.6 hours, fixed head of lathe every 502 hours, lathe head off every 669.3 hours and lathe chuck every 1004 hours. Need to get (preventive maintenance), namely daily maintenance, weekly maintenance and monthly maintenance. Pentingnya fungsi pemeliharaan dalam jurusan pemesinan merupakan hal yang tak terbantahkan. Dengan tidak disadari akan berdampak besar terhadap proses pembelajaran jika pemeliharaan tidak dilakukan seperti, operasi mesin yang tidak aman, kemacetan mesin, kerugian daya, berhentinya proses pembelajaran dan berbagai fungsi sarana lain yang tidak diketahui untuk masa yang lama. Jurusan pemesinan selama ini belum menerapkan suatu sistem pemeliharaan yang baik. Dimana saat ini masih menerapkan suatu pemeliharaan yang bersifat darurat atau perawatan yang dilakukan apabila ada kerusakan (corective maintenance). Oleh karena itu dibutuhkan suatu jadwal pemeliharaan dalam memenuhi kebutuhan akan suatu pemeliharaan. Metode yang digunakan dalam pembentukan jadwal tersebut adalah dengan menerapkan pendekatan sistim yaitu reliability centered maintenance. Dan juga menerapkan fungsi analisa yaitu : analisa reliability dan analisa maintainability faktor. Dari penerapan pendekatan sistem reliability centered maintenance disimpulkan komponen kritis dan penyusunan tabel failure modes and effect analisis. Sedangkan dari hasil analisis reliability disimpulkan berupa laju kerusakan, waktu rata – rata diantara kerusakan dan analisa maintainbility faktor disimpulkan berupa rata – rata pemeliharaan korektif, waktu rata – rata pencegahan, waktu rata – rata pemeliharaan, waktu rata – rata pemeliharaan aktif, frekuensi pemeliharaan dan waktu rata – rata down time dari komponen sistem kelistrikan mesin bubut. Dari hasil perhitungan Mean Time Between Maintenance (MTBM)  didapatkan interval pemeliharaan atau perawatan untuk komponen sistem kelistrikan mesin bubut setiap 223,1111 jam, eretan mesin bubut setiap 401,6 jam, kepala tetap mesin bubut setiap 502 jam, kepala lepas mesin bubut setiap 669,3333 jam dan chuck mesin bubut setiap 1004 jam.  Jika melihat dari interval perawatan dan pemeliharaan diatas maka mesin bubut  perlu mendapatkan perawatan berkala atau terencana (preventive maintenance), yaitu perawatan harian, perawatan mingguan dan perawatan bulanan.  

scholarly journals Reliability Centered Maintenance to Determine Priority of Machine Damage Mode

2019 ◽  
Vol 125 ◽  
pp. 22005 ◽  
Author(s):  
Indah Rizkya ◽  
Ikhsan Siregar ◽  
Khawarita Siregar ◽  
Rahim Matondang ◽  
Enrico Waldo Henri
Keyword(s):  
Production Process ◽  
Preventive Maintenance ◽  
Positive Impact ◽  
Maintenance Planning ◽  
Damage Mode ◽  
Risk Priority Number ◽  
Damage Level ◽  
Reliability Centered Maintenance ◽  
Maintenance Activities ◽  
Fmea Method

High machine downtime results in the production process being disrupted. The average engine breakdown in the sterilizer production is 35.66 hours/month. The corrective maintenance method has not been able to guarantee a smooth production process. This study will plan preventive maintenance activities in order to increase the reliability of production machinery and also maintain the smooth production process. The study was carried out by identifying the damage level of a sterilizer machine with the FMEA method. Based on the result of the FMEA method, maintenance planning of the production machine using the Reliability Centered Maintenance (RCM). FMEA indicates that there are 5 highest risk priority number values, namely the IGBT, Mosfet, bearing bushings, rool former and v-block components. For the maintenance planning using the RCM method, the results obtained were the Total Minimum Downtime (TMD) criteria indicates that the optimum turnover interval of Roll Former, Mosfet, V-Block, IGBT, and Bearing Bushing components is 24 days, 23 days, 25 days, 26 days, and 22 days. The recommendation of the RCM maintenance method has the potential to have a positive impact, namely a decrease in the average critical component downtime of 37,103 % and also an increase in reliability.

scholarly journals Proposed Policy Preventive Maintenance Machine Moriseiki NH 4000 DCG Method of Reliability Center Maintenance (RCM) And Risk Based Maintenance (RBM) Case Study PT Pudak Scientific

2018 ◽  
Vol 2 (02) ◽  
pp. 9-17
Author(s):  
Fachri Husaini ◽  
Judi Alhilman ◽  
Nurdinintya Athari
Keyword(s):  
Preventive Maintenance ◽  
Production Capacity ◽  
Cost Of Care ◽  
Maintenance Policy ◽  
Performance Loss ◽  
Reliability Centered Maintenance ◽  
Acceptance Set ◽  
Maintenance Activities ◽  
And Performance ◽  
The Cost

PT Pudak Scientific is a company engaged in the manufacture of aircraft parts industry. Meeting the precise and timely demand of aerospace parts from customers becomes a major corporate responsibility. However, Loss Revenue often occurs due to engine breakdown. So that cause because the production target is not achieved, the product reject, and the delay of delivery. One of the machines that often experience breakdown is Mori seiki NH4000 DCG. Mori seiki NH4000 DCG is the finishing machine for Blank fork End product. The demand for this part is quite large, making it a tough task for the Mori Seiki NH4000 DCG machine. But because the breakdown of the machine is high enough to cause production targets every month are often not met. In addition, Maintenance activities that have not noticed the characteristics of engine damage, as well as the distribution of historical data of the machine causing less effective and efficient actions resulted in substantial Maintenance costs. Based on the results of risk analysis of Mori Seiki NH4000 DCG engine damage, in terms of performance loss system caused by a large enough that is 3.773% of machine production capacity per year. This figure exceeds the risk acceptance criteria by the company that is 2%. Therefore it is necessary to find the appropriate Maintenance policy for the Mori Seiki NH4000 DCG machine. The approach is to use Reliability Centeres Maintenance and Risk Based Maintenance. Based on the above two approaches obtained the appropriate interval time so that the Maintenance activities more effective and can improve the efficiency of treatment by reducing the cost of care previously Rp167.506.286, - per year, to Rp 96.147.061, - per year. With the policy is expected to reduce engine breakdown and performance loss caused. So the number of risks that arise for the future are within the criteria of acceptance set by the company.   Keywords: Preventive Maintenance, Reliability centered Maintenance, risk based Maintenance, Performance loss

An Application of Reliability Centered Maintenance Technique for Preventive Maintenance in Refinery Plant

2016 ◽  
Vol 848 ◽  
pp. 244-250
Author(s):  
Itthipol Nakamanuruck ◽  
Sompoap Talabgaew ◽  
Vichai Rungreunganun
Keyword(s):  
Preventive Maintenance ◽  
Risk Level ◽  
Reliability Engineering ◽  
Machine Maintenance ◽  
Machine Failure ◽  
Reliability Centered Maintenance ◽  
Maintenance Program ◽  
Refinery Plant ◽  
Maintenance Plan

This research aims for guidance in improving the productivity of the machines in case study of refinery plant based on the principle of preventive maintenance of machinery applications. This is to increase the availability and improve the reliability and overall equipment effectiveness (OEE) of the machines. From the data collected showed that high cost of maintenance is quite high caused by non-standard maintenance and no prioritization of machine maintenance. Therefore, the researchers proposed a maintenance program developed based on reliability engineering with failure mode and effects analysis (FMEA). FMEA was the first brought to analyze the root causes of machine failure and to evaluate the risk priority number (RPN). The data was performed preventive maintenance plan standardized the maintenance system in order to optimize maintenance task and maximize the efficiency of machinery. After applying FMEA, the result showed that the chance of failure in equipment was very low (1 time in 12 years) after the scheduled maintenance plan and opportunities to detect damage in advance was moderate to high. Therefore, the equipment with a moderate to high risk is likely more damage than the first round of maintenance (5 years). Moreover, the average of the residual risk level analysis of the machine decreased by 59.165% and overall equipment effectiveness (OEE) increased from 92.66% to 98%

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