Reliability Centered Maintenance Methodology Research Articles

Analisis interval waktu perawatan preventif pada Paper Machine dengan metode reliability centered maintenance (RCM)

The maintenance process and preventive measures on paper machines need to be studied further, this will affect the production process and paper machine performance. This study aims to determine the criticality of the drying machine failure and determine the preventive measures that must be taken in the maintenance of the dryer and determine the time interval for the maintenance of the dryer machine components. To overcome this problem, this research was made using the Reliability Centered Maintenance (RCM) method. RCM can be interpreted as a process used in determining what to do for the machine, wherein in the RCM methodology there is one FMEA calculation in dealing with critical components in the dryer. Based on data processing and analysis using the RCM method, the maintenance time interval results from the maintenance of the dryer component. The results found are drums/cylinders with maintenance intervals of 82.7 hours, components of all pipes with maintenance intervals of 91.1 hours, and gear components with maintenance intervals of 110.7 hours. The implications for the company's factory regarding preventive maintenance intervals will have an impact on improving the production process and performance of paper machines through early prevention of machine failures that often occur.

Оптимальний комплекс операцій технічного обслуговування і ремонту для підвищення надійності вузлів, систем та агрегатів мобільних машин

The work examines the improvement of the forms and methods of organizing maintenance and repair systems of mobile machines in order to increase their reliability by optimizing diagnostic operations and monitoring the technical condition of their units, systems and units. The proposed centralized system of maintenance and repair of machines includes the principles of production and is characterized by the wide use of technological complexes of operations of the system of maintenance and repair of nodes, systems, aggregates and mobile machines as a whole. A comparison was made of the methodology for implementing the proposed maintenance and repair system and the world-famous RCM (Reliability-centered Maintenance) methodology, focused on a certain level of reliability. Schematics of the technological process of implementing a complex of maintenance and repair operations based on one-stage and multi-stage control of the technical condition of nodes, systems, aggregates and the mobile machine as a whole are presented. A decision-making algorithm has been developed for the processes of a complex of maintenance and repair operations. Clarified technological and information support of complexes of maintenance and repair operations of nodes, systems, units of mobile machines. The role of the operator-diagnostic in relation to the probability of receiving errors of the 1st and 2nd type of defects of parts, as well as the use of computerized workplaces, is revealed. It is shown how these factors affect the level of reliability of nodes, systems, aggregates and mobile machines as a whole. It was determined that in order to reduce the influence of the human factor on the results of the diagnosis of the presence or absence of defects and the distribution of nodes, systems, aggregates according to the technological routes of optimal complexes of maintenance and repair operations, consideration of the repair and maintenance system as an artificial cognitive system can help.

하이브리드 고장률을 이용한 태양광 발전 시스템의 설비 유지보수 시점 결정에 관한 연구

Recently, the PV(Photovoltaic) penetration has increased rapidly in Republic of Korea. And quite a lot of PV systems has been installed in small capacity. And the PV systems have difficult to have its own maintenance planning system due to difficulties in securing economic feasibility. Therefore the maintenance planning method for PV systems that can be generally applied are attracting considerable. Although the age replacement policy, one of the traditional RCM(Reliability Centered Maintenance) methodology, is excellent for determining the replacement cycle of facilities. But It evaluates that the facilities as good as new after maintenance. In this paper, the maintenance planning method for PV system facilities based on RCM has been proposed. To evaluate the failure rate after the imperfective maintenance, hybrid model has been applied. In addition, the economic feasibility of maintenance has been compared by considering investment cost and loss of the implementation for preventive maintenance policy.

Development of Optimized Maintenance Program for a Steam Boiler System Using Reliability-Centered Maintenance Approach

Reliability centered maintenance (RCM) is a new strategic framework for evaluating system maintenance requirements in its operating conditions. Some industries employ predictive maintenance strategies in addition to preventive maintenance (PM) strategies, which increase production costs. As the breakdown maintenance (BDM) technique is used, the maintenance cost increases. The RCM approach is a mixture of these maintenance strategies that can be used to optimize the maintenance costs and to ensure the availability of the system. The RCM method was applied to the steam boiler system used in the textile industries for the research work reported in this paper. The RCM methodology stated in the literature cannot be implemented, as it is in Indian textile industries due to the lack of knowledge of RCM principles, a labor-oriented nature, the use of partially computerized information systems, an inadequate maintenance database, and information about maintenance costs and production loss. To resolve these issues, a modified RCM approach involving a large number of experts is developed. To apply this RCM methodology, critical components are identified through reliability and failure mode effect and criticality analysis (FMECA). Finally, scheduled maintenance strategies and their intervals are recommended to ensure that the system continues to operate properly. According to this study, implementing the RCM technique effectively will increase boiler system reliability and availability by 28.15 percent and 0.16 percent, respectively. Additionally, up to 20.32 percent of the maintenance cost can be saved annually by applying these scheduled maintenance programs.

Fuzzy reliability centered maintenance considering personnel experience and only censored data

The automotive industry uses Reliability Centered Maintenance (RCM) to establish efficient and cost-effective maintenance schedules of equipment (IATF 16949). The RCM methodology is based on equipment reliability which requires collection of failure times. However, in some cases it is not possible to record enough information. Sometimes in the field, only service times are available (these can be classified as “only censored data”). The most commonly found situation waiting until the component fails. In that sense, the RCM methodology mainly uses the classic Weibull model for estimating reliability indexes, which cannot be performed if there are only censored data. The maximum entropy can be used to propose an alternative reliability model that is able to work under the limited information conditions. Nevertheless, the uncertainty of only censored data and the limited information also affect the maximum entropy model. The information available, such as maintenance staff experience, must help provide accuracy to reliability estimation, which can be addressed through fuzzy numbers. Hence, a fuzzy maximum entropy approach is proposed to determine the maximum entropy reliability function considering the uncertainty and the maintenance staff knowledge; therefore, the replacement frequency. Finally, the proposed method was applied to an injection molding machine. Outcomes proved that the alternative model is a useful and reliable option if there are only censored data and personnel experience as available information. The RCM maintenance plan was scheduled using the proposed methodology and its results showed 40% savings in the annual maintenance costs, which represent an important benefit for company.

발전설비용 회전기계의 소급적 신뢰도중심정비 사례 연구

본 논문에서는 소급적 신뢰도중심정비의 방법론을 회전기기의 정비 이력 데이터를 통하여 최적의 정비 주기를 도출한 사례를 소개하였다. 소급적 신뢰도중심정비는 대상 설비의 정비 현황을 분석하고, 설비의 신뢰도를 향상시키기 위하여 고장 라이브러리의 FMEA 결과를 기반으로 누락된 정비를 차기 정비전략에 적용하는 분석 방법이다. 본 연구에서 사례 연구로 활용한 데이터의 대상 설비는 펌프, 팬, 모터이며 사용된 정비 이력은 계획예방정비 정보이다. 사례 연구를 통하여 대상 설비에 대한 MTBF, MTTR, MTTI 의 핵심 지표가 도출되었으며, 이 지표는 정비 전략의 정비 주기를 결정하는 의사결정 알고리즘 변수로 활용되었다. 발전설비의 보수적인 예방정비로 인하여 고장 데이터의 확보가 어려우므로 본 연구에서는 선택적 의사 결정 알고리즘 적용이라는 개념을 도입하여 데이터를 분석하였다. 의사결정 알고리즘은 가용도 기준, 정비 시간 기준, 총 정비 비용 기준 알고리즘으로 구성되어 있으며, 대상 설비의 정비 이력에 따라 최적의 알고리즘을 적용하여 데이터 분석하였다. 또한 각각의 알고리즘은 Weibull Analysis 를 통한 주요 변수를 산출한 후 최적의 정비 주기 또는 검사 주기를 도출하였다.

Reliability-centered maintenance and cost optimization for offshore oil and gas components

Reliability-Centered Maintenance (RCM) is widely used for enterprise asset management in the Oil and Gas sector. The traditional RCM process encompasses the development of equipment hierarchy, the determination of the functional failure of assets, identification of the critical failure modes and the development of suitable maintenance strategies for these failure modes through RCM logic tree analysis. However, the current industry standards and conditions call for greater strides of production availability and reliability of the assets. The aim of the paper is to deliver RCM oriented cost optimization framework for the assets through the implementation of probabilistic and statistical analysis. Probabilistic analysis of the most critical components predicts the failure over time. The mean time to failure, mean time between failure and mean time to repair parameters are determined from the failure history. The parameters of the probability distribution, for instance, the shape and scale parameters of Weibull distribution determine the failure pattern of the failure mode over time. The cost optimization modules allow the analyst to determine the optimum intervals for maintenance or replacement of the maintainable items. The integrated RCM methodology, therefore, provides quantitative and cost-effective solutions for asset maintenance and management. A case study of an equipment in the Oil and Gas sector will be presented to illustrate the optimization framework.

Improvements of a Failure Database for Marine Diesel Engines Using the RCM and Simulations

Diesel engines are widely used in marine transportation as a direct connection to the propeller and as electrical principal or auxiliary generator sets. The engine is the most critical piece of equipment on a vessel platform; therefore, the engine’s reliability is paramount in order to optimize safety, life cycle costs, and energy of the boat, and hence, vessel availability. In this paper, the improvements of a failure database used for a four-stroke high-speed marine diesel engine are discussed. This type of engine is normally used in military and civil vessels as the main engine of small patrols and yachts and as an auxiliary generator set (GENSET) for larger vessels. This database was assembled by considering “failure modes, effects, and criticality analysis (FMECA),” as well as an analysis of the symptoms obtained in an engine failure simulator. The FMECA was performed following the methodology of reliability-centered maintenance (RCM), while the engine response against failures was obtained from a failure simulator based on a thermodynamic one-dimensional model created by the authors, which was adjusted and validated with experimental data. The novelty of this work is the methodology applied, which combines expert knowledge of the asset, the RCM methodology, and the failure simulation to obtain an accurate and reliable database for the prediction of failures, which serves as a key element of a diesel engine failure diagnosis system.

Reliability Centered Maintenance Methodology (RCM) Considering Equipment Taxonomy, Data Bases and Effects Criticality

El mantenimiento centrado en confiabilidad (RCM por sus siglas en inglés) es una metodología ampliamente reconocida y de uso extendido para elaborar planes de mantenimiento de equipos industriales basándose en asegurar las funciones del equipo para la satisfacción del usuario o propietario. Actualmente existen varias metodologías de RCM, sin embargo la esencia de esta metodología está contenida en la norma SAE JA1011. En este trabajo se propone una metodología RCM aumentada, que además de incluir los pasos que señala la norma SAE JA1011, incluye algunos pasos adicionales que facilitan la aplicación. La metodología propuesta se obtuvo después de analizar las normas SAE JA1011 y SAE JA1012 para RCM, la metodología de análisis de modos de falla y efectos (FMEA por sus siglas en inglés) de la norma SAE J1739, la norma ISO 14224, la base de datos OREDA y algunos casos de estudio. Se obtuvo una metodología de RCM aumentada que incluye pasos adicionales tales como: recopilación de información, utilización de la norma ISO 14224 para uniformizar la información del equipo, utilización de bases de datos como OREDA para las causas de falla y la evaluación de efectos de falla para definir los números de prioridad de riesgo (NPR) y jerarquizar las fallas. Se presenta y analiza de forma breve un caso de aplicación de la metodología propuesta.

Developing of Reliability-Centered Maintenance Methodology in Second Power Plant of South Baghdad

Electric equipments of power station must be operated in the state of high reliability with its responsibility in the seamless power supply. Maintenance is one of the important and most costly phases in the lifecycle of any power generation systems, to improve maintenance management and system reliability and maintain the continuity of work of the system. Reliability-Centered Maintenance (RCM) is one of the most recent maintenance techniques. In this research, an enhanced RCM methodology based on quantitative relationships implemented at system component level and the overall system reliability was applied to identify the distribution components that are critical to system reliability. Only unit one of the Second Power Plant of South Baghdad were selected as a case study in this research application. The major contribution of the study is to create a maintenance plan through applying statistical, historical data to generate a failure probability distribution model by using the combined methods of Failure Mode of Effects and Criticality Analysis (FMECA) and Fault Tree Analysis (FTA). Evaluation criteria and matrixes of criticality are used to evaluate the criticality level of failure modes. The overall approach developed offers a cost-effective model, which can be applied prior to testing and inspection procedures during the RCM application. The results obtained from this case study show that the application of proposed RCM methodology based on preventive maintenance planning will decrease the total cost value of maintenance about 463469.85 $. That Indicates saving about 59% of the total downtime cost compared with current maintenance. As well as Proposed maintenance program reduce the required time to repair the plant components annually at a rate 6 day so that represent that the labor cost will minimized about 6424 $.

RCM implementation on plastic injection molding machine considering correlated failure modes and small size sample

Maintenance has become an important support for ensuring equipment availability, on-time deliveries and quality of products. In that sense, reliability-centered maintenance (RCM) could be used due to its basic characteristics like cost-effectiveness and accuracy. The RCM methodology is based on equipment reliability, which is estimated assuming that all failure modes are independent. However, in some cases, this assumption is not always satisfied. This paper seeks to show the effect of considering dependence for different failure modes; a comparison between traditional reliability models and copulas model is made. An injection molding process is considered for application in order to assess the proposed model and define a maintenance activities’ program. Including dependence between failure modes in reliability estimation allowed 75% savings in the annual maintenance costs, which represent a direct benefit for company.

Integration between RCM and RAM: a case study

Purpose – The purpose of this paper is to propose a practical method of performing maintenance in the offshore industry where engineers have to manage problems such as the high cost of operations, assuring an high availability of the plant, safety on board and environmental protection. Indeed an efficient maintenance method it is necessary in order to offer methods and criteria to select the rights maintenance strategies keeping in to account the environmental, safety and production constrains. Design/methodology/approach – The paper provides an overview of reliability centered maintenance (RCM) and reliability, availability, maintainability methodologies and an integration of the two methodologies in a particular case study in the oil and gas sector. Findings – This paper suggests an improvement of the well-established RCM methodology applicable to industries with high priority level. It is proposed an integration between a reliability analysis and an availability analysis and an application on the offshore oil and gas industry. Practical implications – The methodology provides an excellent tool that can be utilized in industries, where safety, regulations and the availability of the plant play a fundamental role. Originality/value – The proposed methodology provides a practical method for selecting the best maintenance strategy considering the equipment redundancy and sparing, the asset’s performance over long time scales, and the system uptime, downtime and slowdowns.

Maintenance Management:A Study of Reliability-CenteredMaintenance for Irrigation System

<abstract> <b><i>Abstract. </i></b> Irrigation systems constantly experience new developments, and decision makers are always concerned with their efficient management. Routine maintenance must be performed to ensure that the system fulfills the functions for which it was designed. Irrigation systems include many subsystems and to ensure proper functioning, a maintenance plan should be followed. System failures can have negative consequences for irrigated crops. This study demonstrates the implementation of RCM (reliability-centered maintenance) in an irrigation system for a real-world case. By implementing RCM in an irrigation system, it is possible to plan maintenance activities and make guided decisions within a structured plan. An efficient maintenance management framework for irrigation systems is the only way both to ensure the continued availability of the irrigation systems and to extend their useful life span. To these ends, the RCM methodology has achieved positive results in several areas of this study. The results indicated that the RCM methodology implemented for irrigation systems brought about greater accuracy in the maintenance decisions and activities applied to these systems, where the decision-maker of the irrigation system can define, based on the demand of a specific crop, the most appropriate maintenance actions for each consequence of failure. The use of this methodology highlights that effective maintenance management has to be aligned with the specificities of a crop and the functions and features of the system. In cases that do not use a standard maintenance policy, money and time is wasted, when non-effective maintenance is carried out unnecessarily, in addition to which total loss of a crop could result from not undertaking necessary maintenance activities.

APLICACIÓN DE UN SISTEMA DE GESTIÓN DEL MANTENIMIENTO BASADO EN UN RCM ADAPTADO

RESUMEN: En este articulo se presenta el resultado de la aplicacion de una version adaptada de la metodologia RCM (Reliability Centered Maintenance), mediante la cual tres empresas de distintos sectores han podido establecer un programa de mantenimiento preventivo a medida de cada caso, realizando aportaciones al mantenimiento autonomo. De esta manera han conseguido reducir la carga de trabajo de mantenimiento sin reducir la disponibilidad de las instalaciones. El trabajo realizado ha servido a dichas empresas para poder establecer las bases de la implementacion o mejora de un programa de gestion del mantenimiento asistido por ordenador. PALABRAS CLAVE: Mantenimiento, RCM.

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

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.

Application of reliability centred maintenance methodology to develop maintenance program for a heavy duty hydraulic stretching machine

Application of reliability centred maintenance methodology to develop maintenance program for a heavy duty hydraulic stretching machine

Reliability-centered maintenance methodology for goliath crane of transmission tower

Reliability centered maintenance (RCM) methodology was originally developed by the U.S. commercial airlines industry in the year of 1960 for identifying applicable and effective preventive maintenance tasks. Safety systems are usually stand by systems and they are periodically to reveal and repair failures that may have occurred since the previous activation or inspection.RCM approach has been applied to the goliath crane system of transmission tower industry for research work reported in this paper.RCM methodology can be applied to Indian industry for reduction of breakdowns as well as optimization of preventive maintenance cost. In the present study preventive maintenance task suggested for power transmission subsystem, guiding and transportation subsystem, hydraulic subsystem and supply current subsystem in goliath train. Keywords-Goliath crane system, optimization ,rcm, transmission tower

Application of Reliability Centered Maintenance in a Hydrocracker

The paper presents a case study: the review of the reliability centered maintenance (RCM) methodology realized in a hydrocracker. Applying of the reliability centered maintenance methodology, it finds 495 failure modes and ranks risk priorities for the 98 rotating machineries in the hydrocracker. According to the results of risk analysis, it provides customized maintenance strategies for each component of the hydrocracker, which would improve the safety of the hydrocracker effectively. The review provides helpful reference for other equipments in refinery factories.

Development and introduction of information technologies for supporting the management of maintenance and repairs at nuclear power stations

The results obtained from introduction of information technologies for supporting the management of maintenance and repairs at nuclear power stations operated by the Rosenergoatom Concern are analyzed. It is shown that the list of promising lines in which information support can be implemented for maintenance and repairs and for managing the main assets of nuclear power stations taking their technical state into account includes introduction of an information system of the EAM class, the reliability-centered maintenance methodology, and other approaches for optimizing the strategies of repair activities, the technology of 3D simulation of elements, and use of 3D models for optimizing repair costs, including the development of interactive technological manuals and teaching systems, as well as integration with the automated process control system and introduction of the project management methodology.

On aircraft scheduled maintenance program development

PurposeThe purpose of this paper is to present issues and challenges of scheduled maintenance task development within the maintenance review board (MRB) process, and to find potential areas of improvement in the application of the MSG‐3 methodology for aircraft systems.Design/methodology/approachThe issues and challenges as well as potential areas of improvement have been identified through a constructive review that consists of two parts. The first part is a benchmarking between the Maintenance Steering Group (MSG‐3) methodology and other established and documented versions of reliability‐centred maintenance (RCM). This benchmarking focuses on the MSG‐3 methodology and compares it with some RCM standards to identify differences and thereby find ways to facilitate the application of MSG‐3. The second part includes a discussion about methodologies and tools that can support different steps of the MSG‐3 methodology within the framework of the MRB process.FindingsThe MSG‐3 methodology is closely related to the RCM methodology, in which the anticipated consequences of failure are considered for risk evaluation. However, MSG‐3 considers neither environmental effects of failures nor operational consequences of hidden failures. Furthermore, in MSG‐3, the operational check (failure‐finding inspection) is given priority before all other tasks, whereas in RCM it is considered as a default action, where there is no other applicable and effective option. While RCM allows cost‐effectiveness analysis for all failures that have no safety consequences, MSG‐3 just allows it for failures with economic consequences. A maintenance program that is established through the MRB process fulfils the requirements of continuous airworthiness, but there is no foundation to claim that it is the optimal or the most effective program from an operator's point‐of‐view. The major challenge when striving to achieve a more effective maintenance program within the MRB process is to acquire supporting methodologies and tools for adequate risk analysis, for optimal interval assignments, and for selection of the most effective maintenance task.Originality/valueThe paper presents a critical review of existing aircraft scheduled maintenance program development methodologies, and demonstrates the differences between MSG‐3 and other RCM methodologies.