scholarly journals Analisis Penerapan Overall Equipment Effectiveness Pada Mesin Power Press Combination Forming 60T

2017 ◽  
Vol 1 (2) ◽  
pp. 99
Author(s):  
Adi Rusdi Widya
Keyword(s):  
Preventive Maintenance ◽  
Fault Tree Analysis ◽  
Production Performance ◽  
Analysis Method ◽  
Machine Failure ◽  
Reliability Centered Maintenance ◽  
Emergency Measure ◽  
Standard Value ◽  
Critical Components ◽  
Mean Time

Corrective action on the engine damage is a temporary emergency measure, so further action is required by conducting maintenance activities, prevention of damage (Preventive maintenance), and able to detect abnormal symptoms before the machine breakdown occurs. The sudden impact of machine damage resulted in disruption of planned production performance so that it is necessary to identify and analyze the factors that cause the machine damage. Establish maintenance method using Autonomous Maintenance, Preventive Maintenance and Reliability Centered Maintenance (RCM) concept to prevent machine failure from the beginning, through fault tree analysis (FTA) method, failure mode effect, and analysis (FMEA), mean time between failure (MTBF ) is an analytical activity for implementing RCM systems on machines and critical components, able to identify and detect symptoms of malfunction before the machine is damaged. The results of the research get better application of maintenance system so that identification of important components can be anticipated from the symptoms of damage. Overall, there is an increase in performance seen from the increase of Overall Equipment Effectiveness (OEE) value, still expected to continue to increase according to JIPM 85% standard value. In conclusion FMEA, FTA, MTBF analysis method can be used to build autonomous maintenance, preventive maintenance and reliability centered maintenance so as to facilitate the production and maintenance in determining the proper maintenance of the machine.

scholarly journals Manajemen Perawatan Menggunakan Metode RCM di Mesin Produksi Kertas

2020 ◽  
Vol 19 (1) ◽  
pp. 12
Author(s):  
Hery Hamdi Azwir ◽  
Arri Ismail Wicaksono ◽  
Hirawati Oemar
Keyword(s):  
Preventive Maintenance ◽  
Fault Tree Analysis ◽  
Time To Failure ◽  
Effect Analysis ◽  
Paper Production ◽  
Reliability Centered Maintenance ◽  
The Press ◽  
Cost Calculations ◽  
Packaging Paper ◽  
Mean Time

One of the leading manufacturers in packaging paper in Indonesia has six production machines. To keep the production machine always in the best condition, then the role of maintenance is significant. One of the production machines, namely paper production machine 2 (PM2), has experienced increasing the number of breakdowns significantly, resulting in increased downtimes. Sudden failure causes a lengthy repair time and results in considerable production loss. The corrective maintenance method that is running at this time still not effectively reduce downtime. To minimize the number of downtimes, preventive maintenance is needed, and therefore the Reliability Centered Maintenance (RCM) method is selected. Besides applying quantitative analysis such as Mean Time To Repair (MTTR), Mean Time To Failure (MTTF), reliability, and preventive cost calculations. This method also conducts qualitative analysis such as Functional Block Diagrams (FBD), critical engine analysis, Fault Tree Analysis (FTA), and Failure and Mode Effect Analysis (FMEA). After implementing the preventive maintenance, there is an increase in reliability in the sub-system of the press section of the paper production machine 2 from only 43% to 56%, while the repair cost has been reduced by Rp 393,258,670 from Rp 5,724,825,736 to Rp 5,331,567,066 each time replacement of components in the press section. This decrease in costs will contribute to the profits earned by the company because it saves maintenance costs.

A Dynamic Reliability-Centered Maintenance Analysis Method for Natural Gas Compressor Station Based on Diagnostic and Prognostic Technology

2015 ◽  
Vol 138 (6) ◽  
Author(s):  
Dengji Zhou ◽  
Huisheng Zhang ◽  
Yi-Guang Li ◽  
Shilie Weng
Keyword(s):  
Natural Gas ◽  
Preventive Maintenance ◽  
Condition Based Maintenance ◽  
Equipment Management ◽  
Analysis Method ◽  
Dynamic Reliability ◽  
Maintenance Schedule ◽  
Reliability Centered Maintenance ◽  
Maintenance Decision ◽  
Maintenance Model

The availability requirement of natural gas compressors is high. Thus, current maintenance architecture, combined periodical maintenance and simple condition based maintenance, should be improved. In this paper, a new maintenance method, dynamic reliability-centered maintenance (DRCM), is proposed for equipment management. It aims at expanding the application of reliability-centered maintenance (RCM) in maintenance schedule making to preventive maintenance decision-making online and seems suitable for maintenance of natural gas compressor stations. A decision diagram and a maintenance model are developed for DRCM. Then, three application cases of DRCM for actual natural gas compressor stations are shown to validate this new method.

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 Determination of Production Instrumentation Equipment Maintenance Intervals In the Paper Industry

2021 ◽  
Vol 4 (1) ◽  
pp. 23-31
Author(s):  
Nurma M. Hidayatulloh ◽  
Tedjo Sukmono
Keyword(s):  
Power Supply ◽  
Manufacturing Industry ◽  
Raw Materials ◽  
Paper Industry ◽  
Control Valve ◽  
Machine Failure ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Fmea Method

PT. XYZ is a manufacturing industry engaged in paper processing with afval raw materials. The problem faced is machine failure that occurs suddenly without predictability, this is because there is no scheduled maintenance (preventive main-tenance). The object of this research is focused on production instrumentation equipment. This study uses the Failure Mode and Effect Analyzer (FMEA) method to identify the causes of failure and the effects of these failures by determining the critical value of the component, namely the Risk Priority Number (RPN) which is the largest, then the Reliability Centered Maintenance (RCM) II Decision Worsheet method for determine maintenance intervals of production instrumentation equipment. Based on the results of RPN calculations in the FMEA method to determine the critical components of the Instrumentation equipment, namely the Control Valve, it can be seen that the highest total RPN value is found in three components, namely Restrictor with an RPN value of 390, Power Supply with RPN of 297, and also a Pilot Positioner. with an RPN value of 240. And with optimum maintenance intervals, among others, the Restrictor every 40 hours, the Power Supply every 41 hours, and the Pilot Positioner every 47 hours.

A Dynamic RCM Analysis Method for Natural Gas Compressor Station Based on Diagnostic and Prognostic Technology

2015 ◽  
Author(s):  
Dengji Zhou ◽  
Huisheng Zhang ◽  
Yi-Guang Li ◽  
Shilie Weng
Keyword(s):  
Natural Gas ◽  
Preventive Maintenance ◽  
Condition Based Maintenance ◽  
Equipment Management ◽  
Analysis Method ◽  
Dynamic Reliability ◽  
Maintenance Schedule ◽  
Reliability Centered Maintenance ◽  
Maintenance Decision ◽  
Maintenance Model

The availability requirement of natural gas compressors is high. Thus, current maintenance architecture, combined periodical maintenance and simple condition based maintenance, should be improved. In this paper, a new maintenance method, Dynamic Reliability-centered Maintenance (DRCM), is proposed for equipment management. It aims at expanding the application of Reliability-centered Maintenance (RCM) in maintenance schedule making to preventive maintenance decision making online and seems suitable for maintenance of natural gas compressor stations. A decision diagram and a maintenance model are developed for DRCM. Then three application cases of DRCM for actual natural gas compressor stations are shown to validate this new method.

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.  

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%

Failure Analysis of the Tripping Operation and its Impact on Well Control

2015 ◽  
Author(s):  
Majeed Abimbola ◽  
Faisal Khan ◽  
Vikram Garaniya ◽  
Stephen Butt
Keyword(s):  
Human Error ◽  
Integrated Control ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Well Control ◽  
Lost Circulation ◽  
Critical Elements ◽  
Open Hole ◽  
Critical Components ◽  
The Cost

As the cost of drilling and completion of offshore well is soaring, efforts are required for better well planning. Safety is to be given the highest priority over all other aspects of well planning. Among different element of drilling, well control is one of the most critical components for the safety of the operation, employees and the environment. Primary well control is ensured by keeping the hydrostatic pressure of the mud above the pore pressure across an open hole section. A loss of well control implies an influx of formation fluid into the wellbore which can culminate to a blowout if uncontrollable. Among the factors that contribute to a blowout are: stuck pipe, casing failure, swabbing, cementing, equipment failure and drilling into other well. Swabbing often occurs during tripping out of an open hole. In this study, investigations of the effects of tripping operation on primary well control are conducted. Failure scenarios of tripping operations in conventional overbalanced drilling and managed pressure drilling are studied using fault tree analysis. These scenarios are subsequently mapped into Bayesian Networks to overcome fault tree modelling limitations such s dependability assessment and common cause failure. The analysis of the BN models identified RCD failure, BHP reduction due to insufficient mud density and lost circulation, DAPC integrated control system, DAPC choke manifold, DAPC back pressure pump, and human error as critical elements in the loss of well control through tripping out operation.

scholarly journals Filling machine preventive maintenance using age replacement method in PT Lucas Djaja

2018 ◽  
Vol 154 ◽  
pp. 01056
Author(s):  
Fifi Herni Mustofa ◽  
Ria Ferdian Utomo ◽  
Kusmaningrum Soemadi
Keyword(s):  
Maintenance Cost ◽  
Time To Failure ◽  
High Failure Rate ◽  
Corrective Maintenance ◽  
Replacement Method ◽  
Critical Components ◽  
Age Replacement ◽  
Engine Maintenance ◽  
A Company ◽  
Mean Time

PT Lucas Djaja is a company engaged in the pharmaceutical industry which produce sterile drugs and non-sterile. Filling machine has a high failure rate and expensive corrective maintenance cost. PT Lucas Djaja has a policy to perform engine maintenance by way of corrective maintenance. The study focused on the critical components, namely bearing R2, bearing 625 and bearing 626. When the replacement of the failure done by the company is currently using the formula mean time to failure with the result of bearing R2 at point 165 days, bearing 625 at a point 205 days, and bearing 626 at a point 182 days. Solutions generated by using age replacement method with minimization of total maintenance cost given on the bearing R2 at a point 60 days, bearing 625 at the point of 80 days and bearing 626 at a point 40 days.

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