scholarly journals Scheduling Preventive Maintenance on Auto Rooting Machine at Toys Manufacturer Company

2016 ◽  
Vol 5 (1) ◽  
pp. 26
Author(s):  
Anastasia Lidya Maukar ◽  
Ineu Widaningsih Sosodoro ◽  
Rhiza Adiprabowo
Keyword(s):  
Preventive Maintenance ◽  
Cost Model ◽  
Minimum Cost ◽  
Maintenance Cost ◽  
Interval Time ◽  
Maintenance Schedule ◽  
Maintenance System ◽  
Machine Reliability ◽  
The Right ◽  
Time Of Failure

<p>Maintenance cost becomes one of the problems that manufacturing company is facing nowadays due to<br />lack of maintenance system. The main objective of this research is to reduce the maintenance cost on auto<br />rooting machine in toy manufacturer by developing a scheduled preventive maintenance. Data of machine<br />breakdowns and costs related to maintenance, components, and the interval time of failure for each machine<br />were collected. To develop a preventive maintenance system, the interval of component replacement must be<br />determined. The minimum cost model is attained by finding the right interval time. The result of this research<br />shows that by implementing proposed maintenance schedule the machine reliability has 45% increase and<br />maintenance cost decreases by 48%.</p>

Modeling the development of rail corrugation to schedule a more economical rail grinding

2019 ◽  
Vol 234 (4) ◽  
pp. 370-380 ◽  
Author(s):  
Hirofumi Tanaka ◽  
Masashi Miwa
Keyword(s):  
Surface Roughness ◽  
Growth Curves ◽  
Minimum Cost ◽  
Maintenance Cost ◽  
Rail Corrugation ◽  
Maintenance Schedule ◽  
Rail Grinding ◽  
Noise Vibration ◽  
Maintenance Schedules ◽  
The Cost

Rail corrugation should be managed appropriately, as it causes noise, vibration, and degradation of track components and materials. Generally, rail corrugation is managed with the removal of rail surface roughness by rail grinding. However, in many cases, rail corrugation will reoccur after the rail is ground, thereby making the management of the phenomenon difficult for railway operators. For the proper management of rail corrugation, it is necessary to understand the development of rail corrugation and model it mathematically. However, this effort has not been made in previous studies. This paper investigates an efficient method for scheduling a regular grinding maintenance to manage rail corrugation. Using regularly measured data about rail surface roughness on a commercial line, a mathematical model was developed to estimate the growth of rail corrugation. This model was utilized to estimate the effects of the remaining roughness after rail grinding on the maintenance cost and to optimize the maintenance schedule. First, it was confirmed that the development of rail surface roughness of rail corrugation can be expressed in three phases and can be modeled by fitting the functions of growth curves to measurements of rail surface roughness recorded over a long period. Next, the rail grinding strategy was examined by applying this model to realize both effective and economical strategies for the maintenance of rail corrugation. This study confirmed that maintenance costs can be reduced by rail grinding that removes almost all of rail corrugation. In the case of ballasted tracks, it has been found that the optimal grinding schedule can reduce the cost of rail grinding as well as the cost of tamping. These findings can be applied by railway operators tasked with managing maintenance schedules for railway lines at a minimum cost.

scholarly journals USULAN PERAWATAN MESIN SECARA PREVENTIF DENGAN PENDEKATAN MODULARISASI DESAIN PADA PT. BAI

2013 ◽  
Vol 3 (1) ◽  
Author(s):  
Amal Witonohadi ◽  
Tiena Gustina Amran ◽  
Niken Herawati
Keyword(s):  
Preventive Maintenance ◽  
Design Method ◽  
Maintenance Cost ◽  
Treatment Schedule ◽  
Time To Failure ◽  
Large Engine ◽  
Maintenance Costs ◽  
Maintenance Schedule ◽  
Mean Time ◽  
Method Approach

<p>PT. BAI produce polymer filter system components, such as the spin pack, candle filters, leaf<br />discs, gaskets and so forth. Problems that occur in the form of decreased reliability of machine<br />downtime resulting in large engine stalled, causing the production process, the company should have<br />a preventive maintenance schedule in accordance with the conditions of machines on the production<br />floor to reduce machine downtime by using modularity design method approach to reduce<br />maintenance costs. Level of maintenance reliability measured using Overall Equipment Effectiveness<br />(OEE), whereas treatment schedule used to obtain parameter Mean Time to Failure (MTTF) and<br />Mean Time to Repair (MTTR). Maintenance cost calculator is then performed with corrective<br />maintenance, preventive maintenance and preventive maintenance with design modularity. By using<br />modularity design companies can combine several components into a module to do the replacement<br />components simultaneously causing maintenance costs to be as much as 29.1% less than the company<br />doing the corrective maintenance activities.</p>

scholarly journals Integration of maintenance systems

2018 ◽  
Vol 211 ◽  
pp. 03010
Author(s):  
S H Sarje
Keyword(s):  
Preventive Maintenance ◽  
Hazard Rate ◽  
Reduction Factor ◽  
Maintenance Cost ◽  
Cost Ratio ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Maintenance System ◽  
Reliability Centered Maintenance ◽  
High Flexibility

Excellence in maintenance is imperative in highly competitive market because it resulted into minimum maintenance cost, high equipment effectiveness, maximum reliability of the system, high quality of the products, low delivery time, high flexibility, safety etc. Any maintenance system such as Total Productive Maintenance (TPM) or Reliability Centered Maintenance (RCM) or Condition Based Maintenance (CBM) alone cannot achieve the excellence in maintenance but its integration may do. In this paper, an integration of TPM, RCM and CBM is proposed with a maintenance policy to take advantage of their respective strengths. A continuously monitored system subject to degradation due to the imperfect maintenance, where a hybrid hazard rate based on the concept of age reduction factor and hazard rate increase factor to predict the evolution of the system reliability in different maintenance cycles has been assumed.A quantitative decision making model for an integrated maintenance system is derived in order to assess the performance of the proposed maintenance policy. Numerical examples of calculation of optimal preventive maintenance age x and preventive maintenance number N* for the given cost ratio of corrective replacement and predictive preventive maintenance are given.

The Preventive Maintenance Schedule: A Case Study at Aman Sales and Services Sdn. Bhd. and Ladang Sabah Palm Oil Mill.

2014 ◽  
Vol 660 ◽  
pp. 995-999
Author(s):  
Abdullah Mohd Tahir ◽  
Jamrin Jasmin ◽  
Alfero Sualin ◽  
Noor Ajian Mohd-Lair ◽  
Abdul Kadir bin Abdul Rahman
Keyword(s):  
Palm Oil ◽  
Preventive Maintenance ◽  
Study Data ◽  
Maintenance Schedule ◽  
Machine Maintenance ◽  
Maintenance System ◽  
Breakdown Time ◽  
Palm Oil Mill ◽  
Maintenance Schedules

Maintenance is crucial to system performance and reliability of a machine for an industry. Machine maintenance system in small and medium industries in Malaysia usually consists of manual file management system, which records all the conducted maintenance works. However, a maintenance system should be more complex to include the scheduling of maintenance activities. This paper presents the findings of studies on the implementation of preventive maintenance schedule conducted at Aman Sales And Services Sdn. Bhd. and Ladang Sabah Palm Oil Mill both located in Sabah, Malaysia. In this study, data form previous maintenance works or activities were collected from both companies. The data were then analyzed. The analysis indicates that reduction in time can be obtained by combining similar or repetitive tasks guided by recommendation from the machines’ manuals. This analysis provides foundation for developing an improved preventive maintenance schedule for each company. The new preventive maintenance schedules are found to be able to reduce the breakdown time ranging from as low as 25% to as high as 50%. This reduction signifies the efficiency of the proposed maintenance schedule.

scholarly journals THE EFFECT OF IMPLEMENTATION PREVENTIVE MAINTENANCE SYSTEM AND THE VALUES OF AVAILABILITY, PERFORMANCE AND QUALITY TOWARDS OVERALL EQUIPMENT EFFECTIVENESS (Case Study in PT. Astra Honda Motor)

2017 ◽  
Vol 11 (2) ◽  
pp. 121
Author(s):  
Dicky Kurniawan
Keyword(s):  
Multiple Regression ◽  
Preventive Maintenance ◽  
Activity Data ◽  
System Effect ◽  
Maintenance Activity ◽  
Average Data ◽  
Maintenance System ◽  
Performance Quality ◽  
The Right

The background of this research refers to many companies that cannot identify about the system effect and overall equipment effectiveness (OEE) values, and cannot implement the right system continuously. So that, this research is to investigate some factors that influence the OEE values. <br />The objective of this research were to investigate the effects of preventive maintenance to OEE and to decide whether of availability, performance, quality that most contribute to OEE values at PT. <br />Astra Honda Motor. <br />The design of this research applies case study to examine all hypothesis in this study. The methods used in this study was simple and multiple regression between independent variables and dependent variable. Data analysis used in this research were collected from preventive maintenance activity data and machining crank case production data. There were 91 average data of preventive maintenance activity and usable for analyzed by simple regression and 578 average data of machining crank case production completed and usable for analyzed by multiple regression. <br />The result of research indicated that the first, preventive maintenance has no significant impact to OEE values. The second, availability give more contribution to OEE values than performance and quality.

scholarly journals Maintenance System of Universal Goss Printing Machine based on failure data using RCM and RCS method

2018 ◽  
Vol 2 (02) ◽  
pp. 57-62
Author(s):  
Judi Alhilman ◽  
Fransiskus Tatas Dwi Atmaji ◽  
Valinouski Aulia
Keyword(s):  
Preventive Maintenance ◽  
Spare Part ◽  
Spare Parts ◽  
Critical System ◽  
Maintenance Schedule ◽  
Maintenance System ◽  
Failure Data ◽  
Reliability Centered Maintenance ◽  
Engine Failure ◽  
Printing Machine

Over time a machine will get experience a decrease in reliability, causing the engine to be damaged at the time of operation, thus disrupting the production line. To maintain a machine remains reliable then a good maintenance system is required. In this research, we will use Reliability Centered Maintenance (RCM) and Reliability Centered Spare (RCS) analysis on the critical system of Goss Universal printing machine based on engine failure data. The result of RCM analysis obtained the optimal preventive maintenance schedule and the type of treatment, while based on the RCS analysis obtained spare part needs following the maintenance schedule. With the result of this analysis, is expected where the machine will keep good and will continue to operate without a sudden breakdown under the production schedule's need. Based on RCM analysis for each critical subsystem obtained interval preventive maintenance for transfer roller 127.60 hours, Ink fountain roller 24.45 hours, ink form roller 29.23 hours respectively, and the wash-up device is no scheduled maintenance. For spare parts inventory strategies the result using RCS method are: transfer roller104 units, ink fountain roller requires 32 units, ink form roller 36 units and are holding spare policy required, and a wash-up device no holding spare parts. Keywords— Failure data, Maintenance System, RCM, RCS

scholarly journals Optimal Preventive Maintenance of Wind Turbine Components with Imperfect Continuous Condition Monitoring

Energies ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3801 ◽  
Author(s):  
Ahmed Raza ◽  
Vladimir Ulansky
Keyword(s):  
Wind Turbine ◽  
Condition Monitoring ◽  
Preventive Maintenance ◽  
False Negative ◽  
Maintenance Cost ◽  
Arbitrary Distribution ◽  
Average Lifetime ◽  
True Negative ◽  
Degradation Failure ◽  
Lifetime Maintenance

Among the different maintenance techniques applied to wind turbine (WT) components, online condition monitoring is probably the most promising technique. The maintenance models based on online condition monitoring have been examined in many studies. However, no study has considered preventive maintenance models with incorporated probabilities of correct and incorrect decisions made during continuous condition monitoring. This article presents a mathematical model of preventive maintenance, with imperfect continuous condition monitoring of the WT components. For the first time, the article introduces generalized expressions for calculating the interval probabilities of false positive, true positive, false negative, and true negative when continuously monitoring the condition of a WT component. Mathematical equations that allow for calculating the expected cost of maintenance per unit of time and the average lifetime maintenance cost are derived for an arbitrary distribution of time to degradation failure. A numerical example of WT blades maintenance illustrates that preventive maintenance with online condition monitoring reduces the average lifetime maintenance cost by 11.8 times, as compared to corrective maintenance, and by at least 4.2 and 2.6 times, compared with predetermined preventive maintenance for low and high crack initiation rates, respectively.

Das intelligente Instandhaltungssystem/The intelligent maintenance system - An approach for the self-learning structuring of maintenance libraries

2017 ◽  
Vol 107 (07-08) ◽  
pp. 530-535
Author(s):  
T. Miebach ◽  
M. Schmidt ◽  
P. Prof. Nyhuis
Keyword(s):  
Collaborative Research ◽  
The Self ◽  
Research Centre ◽  
Maintenance System ◽  
Intelligent Maintenance ◽  
Product Engineering ◽  
The Right ◽  
Self Learning ◽  
Intelligent Maintenance System

Der Fachbeitrag stellt eine Methode vor, mit der sich Bibliotheken von Instandhaltungsmaßnahmen selbstlernend gestalten lassen. Die „Intelligenz“ solcher Systeme bietet mehrfachen Nutzen, einerseits durch die Auswahl der passenden Instandhaltungsmethode zum richtigen Zeitpunkt, andererseits durch die damit verbundene Erhöhung des kompletten Abnutzungsvorrates. Die Ergebnisse sind im Sonderforschungsbereich 653 „Gentelligente Bauteile im Lebenszyklus – Nutzung vererbbarer, bauteilinhärenter Informationen in der Produktionstechnik“ entstanden. &nbsp; This article describes a method to design a self-learning maintenance library. The benefit derived from the intelligence of those systems refers to the right choice of maintenance measures at the right time and the enhancement of the whole wear margin. The results are part of the Collaborative Research Centre 653: Gentelligent components in their lifecycle – Utilization of inheritable component information in product engineering.

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