Fuzzy methodology application for risk analysis of mechanical system in process industry

Abstract

This research work reviews and expounds application of fuzzy methodology based integrated approach for risk analysis of milling system in Sugar Plant. As sugar plant is a complex process system, therefore, its effective maintenance planning without proper risk identification and prioritization is a major issue. In this research work, conventional FMEA approach was used for prioritizing critical components based on risk priority number (RPN). To remove limitations of conventional FMEA, fuzzy decision support system and fuzzy grey relation analysis were used for estimating RPN scores. These scores were compared with conventional RPN scores for realistic prioritization and decision making. From analysis, twenty-four (24) causes of failures were identified for milling system of sugar plant. Out of those, fourteen (14) causes of failure were found critical to the system. The excessive cyclic loading on shaft, impact loading on tear rod, improper lubrication, foreign particle inclusions, insufficient gaps and pressure between rollers, loose fittings and couplings, wear and tear of nut and bolt were some of the causes of failures with high prioritization. As immediate attention was required, these results were forwarded to the system analyst and management of sugar industry for intelligent and effective maintenance planning and implementation.