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 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.

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 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.

Failure mode and effect analysis (FMEA) to improve collaborative project-based learning: Case study of a Study and Research Path in mechanical engineering

2021 ◽  
pp. 030641902199904
Author(s):  
Elena Bartolomé ◽  
Paula Benítez
Keyword(s):  
Active Learning ◽  
Failure Mode ◽  
Mechanical Engineering ◽  
Failure Modes ◽  
Collaborative Study ◽  
Project Based Learning ◽  
Educational Process ◽  
Effect Analysis ◽  
Questions And Answers

Failure Mode and Effect Analysis (FMEA) is a powerful quality tool, widely used in industry, for the identification of failure modes, their effects and causes. In this work, we investigated the utility of FMEA in the education field to improve active learning processes. In our case study, the FMEA principles were adapted to assess the risk of failures in a Mechanical Engineering course on “Theory of Machines and Mechanisms” conducted through a project-based, collaborative “Study and Research Path (SRP)” methodology. The SRP is an active learning instruction format which is initiated by a generating question that leads to a sequence of derived questions and answers, and combines moments of study and inquiry. By applying the FMEA, the teaching team was able to identify the most critical failures of the process, and implement corrective actions to improve the SRP in the subsequent year. Thus, our work shows that FMEA represents a simple tool of risk assesment which can serve to identify criticality in educational process, and improve the quality of active learning.

Fuzzy risk assessment for electro-optical target tracker

2016 ◽  
Vol 33 (6) ◽  
pp. 830-851 ◽  
Author(s):  
Soumen Kumar Roy ◽  
A K Sarkar ◽  
Biswajit Mahanty
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Linear Equations ◽  
Mode Analysis ◽  
Failure Behavior ◽  
Membership Functions ◽  
Design And Development ◽  
Effect Analysis ◽  
Content Type ◽  
Criticality Analysis

Purpose – The purpose of this paper is to evolve a guideline for scientists and development engineers to the failure behavior of electro-optical target tracker system (EOTTS) using fuzzy methodology leading to success of short-range homing guided missile (SRHGM) in which this critical subsystems is exploited. Design/methodology/approach – Technology index (TI) and fuzzy failure mode effect analysis (FMEA) are used to build an integrated framework to facilitate the system technology assessment and failure modes. Failure mode analysis is carried out for the system using data gathered from technical experts involved in design and realization of the EOTTS. In order to circumvent the limitations of the traditional failure mode effects and criticality analysis (FMECA), fuzzy FMCEA is adopted for the prioritization of the risks. FMEA parameters – severity, occurrence and detection are fuzzifed with suitable membership functions. These membership functions are used to define failure modes. Open source linear programming solver is used to solve linear equations. Findings – It is found that EOTTS has the highest TI among the major technologies used in the SRHGM. Fuzzy risk priority numbers (FRPN) for all important failure modes of the EOTTS are calculated and the failure modes are ranked to arrive at important monitoring points during design and development of the weapon system. Originality/value – This paper integrates the use of TI, fuzzy logic and experts’ database with FMEA toward assisting the scientists and engineers while conducting failure mode and effect analysis to prioritize failures toward taking corrective measure during the design and development of EOTTS.

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