scholarly journals The Proposed Maintenance Task for Plastic Injection Machine Using Reliability and Risk Centered Maintenance (RRCM) method in Manufacturing Industry

2019 ◽  
Vol 10 (2) ◽  
Author(s):  
Liza Nafiah Maulidina ◽  
Fransiskus Tatas Dwi Atmaji ◽  
Judi Alhilman
Keyword(s):  
Manufacturing Industry ◽  
Maintenance Cost ◽  
Time Interval ◽  
Maintenance Policy ◽  
Risk Matrix ◽  
Maintenance Time ◽  
Optimal Maintenance ◽  
Critical Components ◽  
The Cost ◽  
Plastic Injection

The objective of this research was to determine the optimal maintenance time interval for the selected critical components and the total cost of maintenance of a plastic injection machine. In determining the critical components, a risk matrix was used, and three components were selected, namely, hydraulic hose, barrel, and motor. Using the Reliability and Risk Centered Maintenance (RRCM) method, the researchers got a proposed maintenance policy and the total maintenance cost. Based on the result, it shows that there are seven proposed maintenance tasks with three scheduled oncondition tasks and four scheduled restoration tasks with an average maintenance interval of two months. The total maintenance cost proposed is IDR91.595.318. The cost is smaller compared to the actual maintenance costs of the company.

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>

scholarly journals Optimal Maintenance Probabilities and Preventive Replacement Maintenance Policy for Photocopy Machines

2021 ◽  
Author(s):  
Nse Udoh ◽  
Akaninyene Udom ◽  
Fredrick Ohaegbunem
Keyword(s):  
Minimum Cost ◽  
Maintenance Cost ◽  
Logistic Distribution ◽  
Maintenance Policy ◽  
Preventive Replacement ◽  
Maintenance Time ◽  
Replacement Model ◽  
Cumulative Function ◽  
Optimal Maintenance ◽  
Preventive Maintenance Policy

The need for suitable replacement policies are essential to minimize down time, maintenance cost and maximize the availability and reliability of equipment. On this premise, this work models the failure rate of Photocopy machines and obtain its optimal preventive maintenance policy that would prevent damage and its attendant losses to both users and end-product consumers. The failure distribution of the machine was shown to follow the Log-Logistic distribution with shape parameter, αˆ=1.723339368 and scale parameter, βˆ=763.9219635. Optimal probabilities of the distribution were obtained and utilized in both the cumulative failure function and cumulative hazard function-based replacement models to formulate a replacement maintenance policy for the machine. The failure cumulative function-based replacement model was found to be a better model which yields optimal replacement maintenance time of 166 hours at a minimum cost of 113 Naira for maintaining the machine per cycle time with 96% availability, 94% reliability and 0.07% chance of failure occurrence in the machine.

scholarly journals Optimization method of fatigue maintenance for cable-beam anchorage zone of suspension bridge

2020 ◽  
Vol 103 (3) ◽  
pp. 003685042095013
Author(s):  
Hongmei Tan ◽  
Yong Zeng ◽  
Qianping Zhang
Keyword(s):  
Failure Probability ◽  
Life Cycle Cost ◽  
Structural Reliability ◽  
Relative Proportion ◽  
Suspension Bridge ◽  
Optimization Method ◽  
Maintenance Cost ◽  
Time Interval ◽  
Maintenance Time ◽  
Optimal Maintenance

The cable-beam anchorage zone is the vital load-bearing component in suspension bridge. For maintenance of such structure, a method of probabilistic optimization was proposed by combining linear elastic fracture mechanics, structural reliability and life cycle cost analysis. In this method, the optimal maintenance time is obtained by determining the relative proportion between the costs under the condition that the structural reliability is higher than the minimum allowable reliability. While, the minimum total maintenance cost is obtained by determining the maintenance interval. Then, an example is presented to verify this method, with the following conclusions: the reliability index is inversely proportional to the failure probability, the change of maintenance cost and failure cost affects the optimal maintenance time, the optimal maintenance time will be ahead of time when consider the risk cost. And finally, when the maintenance time interval is determined, the optimal maintenance cost is affected by the maintenance probability and the failure probability.

Availability analysis and maintenance optimization for multiple failure mode systems considering imperfect repair

2021 ◽  
pp. 1748006X2110127
Author(s):  
Qingan Qiu ◽  
Baoliang Liu ◽  
Cong Lin ◽  
Jingjing Wang
Keyword(s):  
Failure Modes ◽  
Maintenance Cost ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Cost Rate ◽  
Availability Analysis ◽  
Long Run ◽  
Optimal Maintenance ◽  
Maintenance Policies ◽  
Periodic Inspections

This paper studies the availability and optimal maintenance policies for systems subject to competing failure modes under continuous and periodic inspections. The repair time distribution and maintenance cost are both dependent on the failure modes. We investigate the instantaneous availability and the steady state availability of the system maintained through several imperfect repairs before a replacement is allowed. Analytical expressions for system availability under continuous and periodic inspections are derived respectively. The availability models are then utilized to obtain the optimal inspection and imperfect maintenance policy that minimizes the average long-run cost rate. A numerical example for Remote Power Feeding System is presented to demonstrate the application of the developed approach.

scholarly journals Risk Assessment of Horizontal Wet Etching Equipment System in Manufacturing Plant Industry

2020 ◽  
Vol 3 (1) ◽  
Author(s):  
Nor'ain Mohd Ramli ◽  
Siti Aslina Hussain
Keyword(s):  
Manufacturing Industry ◽  
Business Environment ◽  
Wet Etching ◽  
Maintenance Cost ◽  
Process Equipment ◽  
Effect Analysis ◽  
Performance Factors ◽  
Equipment Reliability ◽  
Critical Components ◽  
Mean Time

Maintenance is one of the important roles in the high technology manufacturing industry. It is related to the key performance factors of the company such as quality, productivity, and cost. To achieve these factors, a reliability plan should be implemented which helps to maximise production value by implementing successful asset maintenance. This research project aims to focus on the critical process equipment known as Horizontal Wet Etching Equipment (HWEE) used in the wet etching process. The components in the HWEE system were identified by referring to the process and instrumentation diagram (PID) of the equipment and were categorised in different modes. Data on mean time to repair (MTTR) and mean time between repairs (MTBF) were collected based on previous company records. The data were analysed using MAROS software. Failure Mode and Effect Analysis (FMEA) was done to understand the risk of each of the components. The result shows that piping and gearbox have the highest RPN with 126 and 105, respectively. This study helps to identify critical components and is able to help the company to improve equipment reliability and reduce maintenance cost. Corrective action can be implemented to reduce the RPN for both components. Thus, it would help the industry to increase the key performance and become more competitive in the business environment.

scholarly journals Effective time interval for railway track geometry inspection

2020 ◽  
Vol 53 (1) ◽  
pp. 53-65 ◽  
Author(s):  
Ahmad Kasraei ◽  
Jabbar Ali Zakeri
Keyword(s):  
Decision Making ◽  
Railway Track ◽  
Sensitivity Analyses ◽  
Maintenance Cost ◽  
Time Interval ◽  
Maintenance Policy ◽  
Corrective Maintenance ◽  
Track Geometry ◽  
Inspection Interval ◽  
Geometry Inspection

A proper decision-making scheme for track geometry maintenance requires a knowledge of the real condition of track geometry. Therefore, the track must be inspected by measurement cars at different time intervals. The frequency of track geometry inspection plays a crucial role in decision-making and has always been a big concern for infrastructure managers. The inspection interval should be chosen properly, it means that the small period can decrease the capacity of line and affect the operation of network and the big period can result in low quality of track and in some cases derailments and possible loss of human lives. The aim of this paper is to determine the effective inspection interval such that the total maintenance cost is minimized. In the proposed cost model, the costs of inspection, preventive maintenance, corrective maintenance and the penalty for exceeding the corrective maintenance level are considered. A case study is performed on a real dataset collected from a railway line in Iran. The standard deviation of longitudinal level is considered to measure track geometry degradation. A widely applied linear model is used to model track geometry degradation over time. Monte Carlo technique is used to simulate the track geometry behavior under various track geometry inspection intervals. In addition, a set of sensitivity analyses are carried out to assess the effect of various inspection intervals on different terms of maintenance cost. The results indicate that not only can substantial costs be saved by setting effective inspection intervals, but also the time during which the track suffers from bad conditions is dramatically reduced. The result of this study has shown the appropriate inspection interval for the studied case can result in 13.6 percent decrease in maintenance cost in comparison with the current maintenance policy. Besides, it would lead to more reliable railway track by preventing the system exceed the corrective threshold.

scholarly journals EVALUASI MANAJEMEN PERAWATAN DENGAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) II PADA MESIN BLOWING I DI PLANT I PT. PISMA PUTRA TEXTILE

2016 ◽  
Vol 11 (2) ◽  
pp. 73
Author(s):  
Diana Puspita Sari ◽  
Mukhammad Faizal Ridho
Keyword(s):  
Production Process ◽  
Interval Analysis ◽  
Maintenance Cost ◽  
Maintenance Policy ◽  
Total Cost ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Reduction Cost

PT. Pisma Putra Textile adalah perusahaan yang bergerak di bidang pemintalan benang yang memiliki berbagai macam mesin produksi yang cukup sering mengalami kerusakan ketika digunakan pada proses produksi. Oleh karena itu, dibutuhkan kebijakan perawatan optimal yang dapat mengurangi frekuensi kerusakan dan menurunkan biaya perawatan mesin.. Metode yang diterapkan pada penelitian ini adalah Reliability Centered Maintenance (RCM) II. Penelitian difokuskan pada mesin Blowing I, karena memiliki downtime tertinggi. Berdasarkan frekuensi kerusakan mesin komponen yang paling sering rusak yaitu flat belt dan apron berpaku. Perawatan yang diperlukan dilakukan pada permukaan belt bergelombang, belt putus, kayu apron patah, dan paku-paku apron patah dengan scheduled discard task dengan interval perawatan dan Total Cost optimal berurutan yaitu 580 jam dengan TC Rp. 14661546,36, 465 jam dengan TC Rp 18350303,77, 490 jam dengan TC Rp 18966057,60, dan 450 jam dengan TC Rp 13419317,27. Sedangkan perawatan untuk kerusakan karet kendor adalah scheduled restoration task dengan interval perawatan 340 jam dan TC Rp 16338431,41. Total penurunan biaya keseluruhan sebesar Rp 21.587.975,45 atau  20,89% dari biaya perawataan perusahaan. Abstract PT. Pisma Putra Textile is a yarn spinning company which have various  production machines which often breakdown on production process. So, the company should have optimum maintenance policy which could reduce breakdown frequency and maintenance cost. The methods which applied in this research is Reliability Centered Maintenance (RCM). Based on data which was given, it shows that Blowing I Machine have the highest downtime so the research focuses on Blowing I Machine. Based on data which was given, it shows that Blowing I Machine have the highest downtime so the research focuses on Blowing I Machine. Based on machine’s breakdown frequency and total downtime, the results shows that the critical components on Blowing I Machine are flat belt and Apron berpaku component. Based on maintenance interval analysis and optimum total cost shows that maintenance for bumpy flat belt surface, flat belt cut-off, spike lattice wood cut-off, spike lattice cut-off with scheduled discard task is 580 hours and Rp 14.661.546,36 ; 465 hours and Rp. 18.350.303,77 ; 490 hours and Rp. 18.966.057,6 ; 450 hours and Rp. 13.419.317,27 respectively. Then, maintenance interval analysis and optimum total cost for flat belt looses with scheduled restoration task is 340 hours and Rp. 16.338.431,41. So, there's a reduction cost Rp. 21.587.975,45 or 20,89% lower than the company's maintenance cost.

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.

Bi-Criteria Optimization for Finding the Optimal Replacement Interval for Maintaining the Performance of the Process Industries

2016 ◽  
pp. 643-675 ◽  
Author(s):  
Harish Garg
Keyword(s):  
Maintenance Cost ◽  
Time Interval ◽  
Process Industries ◽  
Component System ◽  
Optimal Replacement ◽  
Maintenance Program ◽  
Optimal Maintenance ◽  
Maintenance Decision ◽  
System Life ◽  
Multi Component System

The optimization of the maintenance decision making can be defined as an attempt to resolve the conflicts of decision situation in such a way that variable under the control of the decision maker take their best possible value. One of the most important controllable parameters is the time interval between maintenance. Most of the researchers have kept the fact that whenever the suitable maintenance interval is reached, the system is replaced with the original one. However the improvement of a system life not only depends on the replacement of deteriorated components, but also on the effectiveness of the maintenance. Taking care about this fact, the effects of maintenance of a multi-component system by combining the three main different PM actions, namely (1a), (1b) and (2p)-maintenance actions. Thus, the main purpose of an effective maintenance program is to present a technique for finding the optimal maintenance interval for the system by considering the multiple goals of the organization viz. maximum availability, minimum maintenance cost.

Penentuan Interval Waktu Pemeliharaan Pencegahan pada Peralatan Sub-Unit RKC 3 di PTX Pabrik Tuban

2017 ◽  
Vol 2 (2) ◽  
Author(s):  
Fesa Putra Kristianto ◽  
Bobby O.P. Soepangkat
Keyword(s):  
Preventive Maintenance ◽  
Operating Time ◽  
Maintenance Cost ◽  
Time Interval ◽  
Maintenance Policy ◽  
Cost Rate ◽  
Total Labor ◽  
Finish Mill ◽  
Unit Plant ◽  
Reliability And Availability

PT X Tuban Plant has four plants (unit), namely Tuban I, Tuban II, Tuban III and Tuban IV. Each unit plant has three sub units, i.e., Crusher Operations Sub-Unit, Raw Mill, Kiln and Coal Mill (RKC) Sub-Unit and Finish Mill Sub-Unit. RKC 3 Sub-Unit in Tuban III has the highest number of equipment downtime and production loss. Therefore, it was necessary to optimize the time interval of preventive maintenance ( ) and total labor force as part of the company maintenance policy, would also fulfill the required reliability and availability of RKC 3 Sub-Unit. There were two steps in determining Tp optimum. The first step was to obtain the best distribution of the time between failures (TBF) and time to repair (TTR). The next step was to iterate the operating time (Ti) and Tp to determine the minimum preventive maintenance cost rate, reliability and maintainability.This iteration was applied to sub-units of RKC 3 that possesses a series system. Tp at the lowest rate of maintenance costs was the optimum Tp. The optimum Tp for RKC 3 Sub-Unit is 3743,28 hour. The preventive maintenance cost rate for optimum Tp is Rp33.100/hour and the reliability and availability of sub unit are 96,7% and 99,86% respectively.Keywords: reliability, availability, preventive maintenance cost rate, and preventive maintenance

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