Application of Reliability Centred Maintenance Methodology to Develop Maintenance Program for a Heavy Duty Hydraulic Stretching Machine

Abstract

The application of reliability centred maintenance (RCM) methodology for developing the maintenance plan for heavy duty hydraulic stretching machine is illustrated in this paper. This machine is used for straightening and stretching of high strength aluminium alloys of various cross-sections. The main objective of RCM is cost effective maintenance with due considerations to environmental management and safety. To undertake the RCM program, functions, functional failures, failure modes and effects of this machine are identified. Breakdown history of the plant for last 2 years has been studied. Total downtime was 1004 hours in a year whereas the loss of production owing to this downtime is estimated to be Rs. 47.44 crore which excludes the cost of maintenance.. The main objective of present study is to minimise the above figures by implementing the RCM methodology. To achieve this, an RCM methodology suggested by John Moubray has been adopted. Cost benefit analysis done at the end on expected results indicates that about 16.83% and 18.62% savings can be achieved in equipment downtime and associated costs respectively.