Abstract
Problem statement: Today, in many automotive manufacturing companies, maintenance management is an important factor to maintain the plant operation and production equipments. Approach: In this study, we present an implementation of Reliability Centered Maintenance (RCM) practice in one of the automotive manufacturing company in Malaysia. The RCM practice was used to assist the company in focusing their maintenance activities based on the criticalities of the equipments by applying the Failure Modes and Effects Analysis (FMEA). The implementation of RCM was carried out in 4 stages; preparation, system analysis, decision making and feedback. The aim of RCM was to reduce the number of maintenance checklist and to improve significantly the integrity of maintenance practice. Results: As a result, the new RCM framework was generated where Class A equipment was at the top of the monthly maintenance frequency priority, followed by Class B and Class C equipment which had lesser critical value. Conclusion: The new RCM framework is used to conduct visible guideline and propose a new maintenance schedule. The guideline is useful for future maintenance strategy improvement. After the implementation, it can be ascertained that our proposed RCM is useful in reducing maintenance personnel burden and this leads to improvement of productivity.
Highlights
In the last three decades, manufacturing industries had experienced an unprecedented degree of changes such as product specifications, process technologies, supplier attitudes and customer’s requirements (Ahuja et al, 2006)
The decision making tool that has been widely implemented is Reliability Centered Maintenance (RCM) that was initially oriented towards maintaining airplanes and used by aircraft manufacturers, airlines and the government (Dekker, 1996)
The test was conducted as a binary evaluation which is decided as YES (1) or NO(0) answers
Summary
In the last three decades, manufacturing industries had experienced an unprecedented degree of changes such as product specifications, process technologies, supplier attitudes and customer’s requirements (Ahuja et al, 2006) This rapid changes environment had forced the manufacturers to enhance and improve effectively their performance by focusing on cost reduction, productivity levels increment, high quality products and prompt deliveries in order to satisfy customers (Balan, 2011). The decision making tool that has been widely implemented is Reliability Centered Maintenance (RCM) that was initially oriented towards maintaining airplanes and used by aircraft manufacturers, airlines and the government (Dekker, 1996). It is a systematic consideration of system functions, failure analysis and a priority-based consideration of safety and economics. In order to ascertain the effectiveness of the proposed RCM, feedbacks from
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