Abstract
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.
Highlights
The high level of competition among industries and businesses has made the survival battle tremendously strong
The function of the pusher mechanism is to transfer fully formed wares from the pusher dead plate on to the machine conveyor where they are transferred for further processing
Excessive vibration as indicated in Cause 17 in Table 5 has the effect of bringing about work loosening of the assembled bolted joint or leading to Cause 13, i.e., overtightening of the part, having the effect of inappropriate operation and external leakages
Summary
The high level of competition among industries and businesses has made the survival battle tremendously strong. Producers are striving to further reduce production time loss as production time has cost implications while customers are more concern about the safety and reliability of the products [1]. This quest includes employees who desire a safe work environment [2]. The focus is on anticipating the factors that lead to failure and ensure that such factors are prevented from occurring frequently using a robust design [3] To reach this goal, the decrease in the cost of operation is set as a high priority [4]. The study of reliability and maintainability in any manufacturing outfit plays a crucial role in ensuring the smooth running of the production process because it ensures production continuity as well as product quality [5]
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