Development of Computerized Preventive Maintenance Management System with Failure Mode and Effect Analysis for CNC Machine

2014 ◽  
Vol 627 ◽  
pp. 365-371 ◽  
Author(s):  
Em Ardchaya Rungsa ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Failure Mode ◽  
Preventive Maintenance ◽  
Management System ◽  
Maintenance Management ◽  
Risk Priority Number ◽  
Cnc Machine ◽  
Effect Analysis ◽  
Cnc Machines ◽  
Intelligent Maintenance ◽  
Maintenance Plan

In order to realize the intelligent maintenance management system, this paper presents a development of computerized preventive maintenance management system (CPMMS) to manage and record the maintenance information in the database for the CNC machines. The failure mode and effect analysis (FMEA) has been utilized to deal with the computerized preventive maintenance management system in this research. The FMEA is analyzed to determine the risk priority number (RPN) of the CNC machines in order to set the preventive maintenance plan as a standard maintenance. The developed program can generate the next schedule of the preventive maintenance plan automatically, which increases the efficiency and decreases the breakdown. It has been proved that the proposed and developed CPMMS with FMEA program can improve the overall equipment effectiveness (OEE). The RPN has been reduced due to a decrease in the severity and the occurrence.

scholarly journals Identifying preventive maintenance guideline for a combine harvester with application of failure mode and effect analysis technique

2020 ◽  
Vol 319 ◽  
pp. 01004
Author(s):  
Voraya Wattanajitsiri ◽  
Rapee Kanchana ◽  
Surat Triwanapong ◽  
Kittipong Kimapong
Keyword(s):  
Risk Assessment ◽  
Failure Mode ◽  
Preventive Maintenance ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Analysis Technique ◽  
Combine Harvester ◽  
A Chain ◽  
Near Future

The objective of this research was to study a risk assessment of the rice combine harvester using FMEA technique implementation and suggested the procedures to maintain the parts of the rice combine harvester by analyzing the causes of risk assessment of FMEA. The FMEA was also applied to specify failure causes and effects that occurred in the rice harvester. The obtained data were calculated for a risk priority number (RPN) and then sorted to be a descending order. The high RPN part was analyzed for the causes and effects and then suggested a preventive maintenance in near future. The results revealed that the highest RPN of 576 was found when a chain surface was considered and also showed the maximum risk among the considered parts in the rice combine harvester. While, the lowest RPN of 144 was found when a rice sieve part was considered but this RPN was still higher than that of 100 RPN which was required to specify the preventive maintenance.

scholarly journals Analisis Preventive Maintenance Pada Mesin Produksi dengan Metode Fuzzy FMEA

2020 ◽  
Vol 8 (1) ◽  
pp. 13-20
Author(s):  
Sri Susilawati Islam
Keyword(s):  
Failure Mode ◽  
Preventive Maintenance ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Fuzzy Fmea

Kegiatan perawatan mesin (maintenance) merupakan kegiatan yang memiliki peran yang sangat penting untuk menunjang kelancaran proses produksi. Maintenance yang tidak teratur dapat mengakibatkan mesin mengalami gangguan atau kerusakan (downtime), hal ini dapat menghambat kelancaran proses produksi. Agar proses produksi dapat berjalan sesuai dengan perencanaan, maka harus ditunjang dengan keadaan mesin yang handal sehingga diperlukan perencanaan perawatan mesin yang baik. Pereventive maintenance merupakan salah satu perencanaan perawatan yang banyak digunakan untuk memastikan bahwa mesin dapat berjalan sesuai dengan fungsinya. Pada penelitian ini, studi kasus dilakukan di PT PLN Sektor Tello Makassar sebab perusahaan tersebut mempunyai peranan penting dalam menyuplai arus listrik di kota Makassar yaitu sebesar 197,61 MW. Jika terjadi kerusakan mesin maka akan berdampak pada aktivitas ekonomi masyarakat yang dapat menyebabkan kerugian, saat ini perencanaan maintenance yang dilakukan oleh PT PLN Sektor Tello Makassar belum berjalan optimal karena masih terjadinya kerusakan mesin generator saat proses produksi berlangsung. Agar kegagalan mesin dapat dikurangi, maka penelitian ini akan menggunakan metode Fuzzy FMEA (Failure Mode and Effect Analysis) untuk mengidentifikasi kerusakan mesin dan menentukan prioritas mesin dalam proses perawatan serta jenis perawatannya berdasarkan nilai RPN (Risk Priority Number).

МЕТОД ОЦІНКИ РИЗИКІВ У ВИРОБНИЧІЙ ЛАБОРАТОРІЇ МОЛОКОПЕРЕРОБНИХ ПІДПРИЄМСТВІ НА ОСНОВІ LEAN

2021 ◽  
pp. 35-39
Author(s):  
Ю.І. Сеник
Keyword(s):  
Failure Mode ◽  
Risk Priority Number ◽  
Effect Analysis

У роботі розглянуто застосування модифікованого до системи ощадливого виробництва методу оцінки ризиків FMEA для виробничих лабораторій молокопереробних підприємств. Описано алгоритм реалізації failure mode and effect analysis та вказано основні принципи розрахунку S (значимість потенційних збоїв у роботі), O (ймовірність виникнення збою у роботі), D (ймовірність виявлення збою) та RPN (risk priority number). Розглянуто два основні недоліки класичного підходу методики FMEA та для їх усунення використано модифікацію, запропоновану Rapinder Sawhney та ін., яка полягає у використанні інтегрального показника «значення оцінки ризиків». Для аналізу ризиків виробничої лабораторії згідно з модифікованою методикою FMEA вибрано окремий шаблон таблиці, представлений у тексті статті. Він містить як елементи FMEA, так і спосіб вирішення критичних показників згідно з принципами LEAN. Такий підхід до роботи лабораторії є вкрай важливим, адже саме від оперативності та точності проведених досліджень залежатиме можливість уникнення прямих утрат для підприємства та випуску безпечної та якісної продукції.

scholarly journals Environmental risk assessment of low density polyethylene unit using the method of failure mode and effect analysis

2012 ◽  
Vol 18 (1) ◽  
pp. 103-113 ◽  
Author(s):  
Parinaz Salati ◽  
Seyed Jozi
Keyword(s):  
Risk Assessment ◽  
Failure Mode ◽  
Environmental Risk ◽  
Environmental Risk Assessment ◽  
Environmental Parameters ◽  
Low Density Polyethylene ◽  
Low Density ◽  
Risk Priority Number ◽  
Environmental Aspects ◽  
Effect Analysis

The ninth olefin plan of Arya Sasol Petrochemical Company (A.S.P.C.) is regarded the largest gas Olefin Unit located on Pars Special Economic Energy Zone (P.S.E.E.Z). Considering the importance of the petrochemical unit, its environmental assessment seems necessary to identify and reduce potential hazards. For this purpose, after determining the scope of the study area, identification and measurement of the environmental parameters, environmental risk assessment of the unit was carried out using Environment Failure Mode and Effect Analysis (EFMEA). Using the noted method, sources causing environmental risks were identified, rated and prioritized. Beside, the impacts of the environmental aspects derived from the unit activities as well as their consequences were also analyzed. Furthermore, the identified impacts were prioritized based on Risk Priority Number (RPN) and severity level of the consequences imposed on the affected environment. After performing statistical calculations, it was found that the environmental aspects owing the risk priority number higher than 15 have a high level of risk. Results obtained from Low Density Polyethylene Unit revealed that the highest risk belongs to the emergency vent system with risk priority number equal to 48. It is occurred due to imperfect performance of the reactor safety system leading to the emissions of ethylene gas, particles, and radioactive steam as well as air and noise pollutions. Results derived from secondary assessment of the environmental aspects, through difference in calculated RPN and activities risk levels showed that employing modern methods and risk assessment are have remarkably reduced the severity of risk and consequently detracted the damages and losses incurred on the environment.

scholarly journals Implementation of Failure Mode and Effect Analysis and Fault Tree Analysis in Paper Mill: A Case Study

2020 ◽  
Vol 9 (3) ◽  
pp. 171-176
Author(s):  
Nurul Retno Nurwulan ◽  
Wilcha Anatasya Veronica
Keyword(s):  
Quality Control ◽  
Failure Mode ◽  
Fault Tree Analysis ◽  
Paper Mill ◽  
Control Methods ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Increase Productivity ◽  
Prevention Methods

A good quality control system is important to be implemented to increase productivity and minimize defects in products. One of the quality control methods is failure mode and effect analysis (FMEA). This study uses the FMEA to identify the causes of the defects and recommend the prevention methods to overcome the causes of the defects in an Indonesian paper mill. The risk priority number (RPN) is calculated by multiplying the severity, occurrence, and detection of the failures that have been determined. Unsymmetrical and tainted products are the most dominant defects in the paper mill. An inappropriate machine setting is the cause of unsymmetrical products with the highest RPN of 343. The second highest RPN is problems with bleaching machines that caused tainted products with an RPN value of 216. This study offers suggestions to Indonesian paper mill to prevent and minimize defective products. 

scholarly journals Usulan Pengendalian Kualitas Produksi Benang Carded dengan Metode Six Sigma

2018 ◽  
Vol 4 (1) ◽  
pp. 38
Author(s):  
Abdul Manan ◽  
Firdanis Setyaning Handika ◽  
Ahmad Nalhadi
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Six Sigma ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Sigma Level ◽  
Mode Effect ◽  
Target Set ◽  
Failure Mode Effect Analysis

A yarn company strives to produce good and quality products, but the production process that is carried out by each person will produce products targeted at a target that has been set at 5%. This study uses the Six Sigma method but only until the improvement stage. The research is to determine the DPMO value and sigma level in the spinning production process, to know what factors cause defects and new parameters to reduce the defect. Based on the results of the study that the DPMO on the type of CD thread in the spinning section is 17,130 and the sigma level is 3,6. The level of sigma that has dominated the Indonesian industry average, but has a defect of 8.7%, the target set at 5%. Damaged and dirty apron, clogged trumpet, and leaky hose are factors that plan defects. Furthermore, with Failure Mode Effect Analysis (FMEA), the highest value of Risk Priority Number (RPN) in tangled defects is that the apron is damaged (140) and clogged trumpet (120), while the highest RPN value is gross dirty, i.e., dirty apron (150) and hose leaking lubricant (120).

scholarly journals ANALISIS PERBAIKAN PROSES PRODUKSI PADA PT SUMBER TEKNIK SENTOSA

2019 ◽  
Vol 8 (1) ◽  
Author(s):  
Damar Suryo Bowo
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Time Function ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Cause And Effect ◽  
Function Mapping

This study aimed to analyze the production process of Dies Forging Piston Wheel Cylinder and to suggest the improvement for the production. The data were analyzed by Time-Function Mapping, Cause and Effect, and Failure Mode and Effect Analysis (FMEA). The findings showed that there were seven production phases of Dies Forging Piston Wheel Cylinder. After figuring out the troubled phase, the next step was searching for the cause and the solution of the problem using FMEA. The FMEA calculation indicated 4 problems i.e. the employees working on another product, vibrating clamp machines, employees producing jig, and unavailability of jig. The main problem was detected based on the highest score of Risk Priority Number (RPN) that calculation indicator was severity, occurrence, and detection. 

scholarly journals USULAN PREVENTIVE MAINTENANCE PADA MESIN KOMORI LS440 DENGAN MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM II) DAN RISK BASED MAINTENANCE (RBM) DI PT ABC

2016 ◽  
Vol 3 (02) ◽  
pp. 31
Author(s):  
Destina Surya Dhamayanti ◽  
Judi Alhilman ◽  
Nurdinintya Athari
Keyword(s):  
Failure Mode ◽  
Preventive Maintenance ◽  
Effect Analysis ◽  
Corrective Maintenance ◽  
Reliability Centered Maintenance

PT ABC merupakan perusahaan cetak dalam skala nasional. Produk yang dihasilkan oleh perusahaan merupakan buku ajar, majalah, surat kabar, dan lain sebagainya. Kegiatan maintenance yang ada PT ABC terbagi menajadi dua, yaitu preventive maintenance setiap senin dan kamis serta kegiatan corrective maintenance yang dilakukan jika mesin mengalami kegagalan fungsi. Kegagalan fungsi pada mesin Komori masih cukup tinggi. Oleh karena itu, diperlukan kegiatan pecegahaan untuk meningkatkan reliabilitas mesin. Metode yang dilakukan adalah Reliability Centered Maintenance, yaitu dengan menganalisis failure yang terjadi dengan menggunakan analisis Failure Mode and Effect Analysis dan Decision Worksheet. Hasil dari analisis ini merupakan preventive task masing-masing komponen. Sedangkan untuk menganalisis risiko yang diakibatkan jika mesin mengalami gagal fungsi, yaitu dengan metode Risk Based Maintenance. Hasil yang diperoleh dari nilai risiko yang ditanggung perusahaan ketika mesin mengalami failure, yaitu sebesar Rp965.904.899,36. Berdasarkan hasil pengolahan data pada subsistem kritis diperoleh kesimpulan bahwa enam komponen dilakukan dengan task scheduled on condition, tiga komponen dengan task scheduled restoration, dan enam komponen dengan task scheduled discard. Sedangkan untuk interval waktu dalam pengerjaan preventive maintenance pada komponen tersebut disesuaikan dengan task yang diperoleh. Setelah mendapatkan interval waktu perawatan, kemudian ditentukan biaya perawatan usulan yang dikeluarkan perusahaan, yaitu sebesar Rp971.567.519,69.

scholarly journals Manajemen Risiko Rantai Pasok Ikan Bandeng Kelompok Tani Tambak Bungkak dengan Integrasi Metode Analytic Network Process (ANP) dan Failure Mode and Effect Analysis (FMEA)

2020 ◽  
Vol 22 (2) ◽  
pp. 88-107
Author(s):  
Akhmad Wasiur Rizqi ◽  
Moh Jufriyanto
Keyword(s):  
Failure Mode ◽  
Analytic Network Process ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Analytical Network Process ◽  
Network Process

Ikan bandeng merupakan ikan yang memiliki kaya akan kandungan gizi. Ikan bandeng memiliki kandungan protein yang tinggi dan rendah lemak. Salah satu kelompok yang melakukan budidaya ikan bandeng yaitu kelompok tani tambak bungkak. Kelompok tani ini bergerak penyaluran distribusi pasokan ikan bandeng ke pedagang pengumpul dan industri pengolahan ikan.  Permasalahan yang terjadi pada kelompok tani tersebut yaitu pengelolaan masih tradisional, produktivitas rendah serta risiko rantai pasok seperti harga, lingkungan yang berpengaruh pada proses keberlanjutan bisnisnya. Penelitian ini bertujuan untuk mengidentifikasi risiko-risiko dan melakukan pengendalian risiko pada rantai pasok ikan bandeng. Metode yang digunakan adalah ANP (Analytical Network Process) dan FMEA (Failure Mode and Effect Analysis). Kedua metode tersebut dilakukan integrasi sehingga diperoleh nilai WRPN (weighted risk priority number) untuk prioritas risiko untuk dilakukan perbaikan. Hasil penelitian diperoleh bahwa prioritas tertinggi yaitu risiko produksi dengan nilai WRPN sebesar 186,26. Pengendalian risiko yang dilakukan yaitu edukasi luas lahan budidaya ikan bandeng dan pemberian pinjaman untuk memperluas lahan, pembuatan waduk untuk penampungan air untuk mempermudah pengairan, dan pemberian nutrisi tambahan untuk ikan dan mengatur kondisi air

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