Reliability Centered Maintenance Research Articles

A reliability centred maintenance approach for assessing the impact of maintenance for availability improvement of carding machine

The complex nature of modern equipment and systems often leads to failures and, as a consequence, an increase in machine downtime, thus affecting production. The failures of machines cause disruptions in production, resulting in the loss of availability of the system and increase the cost of maintenance. This paper presents a reliability centred maintenance (RCM) methodology to improve the availability of carding machine in textile industry. The main objective of this paper is to present a RCM approach for improving the availability of the carding machine and thus maximise the production output. Failure mode and effect analysis (FMEA) is used for analysing the failures in the machine. The preventive measure to reduce the failure frequency and its impact are proposed. The proposed preventive measures result in reduction of about 26% of the total downtime and availability improvement of approximately 1.7%, as compared with the availability due to current maintenance practices.

Subjectivity in Failure Mode Effects Analysis (FMEA) Severity Classification within a Reliability Centered Maintenance (RCM) Context

Subjectivity in Failure Mode Effects Analysis (FMEA) Severity Classification within a Reliability Centered Maintenance (RCM) Context

Optimal maintenance strategy selection based on a fuzzy analytical network process

Maintenance is one of the most crucial issues in today’s competitive manufacturing environment. Nowadays, productive methods are used in manufacturing plants to improve operations capabilities, which alternatively change business environmental factors leading to a competitive market. Consequently, selection and illustration of an optimal maintenance strategy play a significant role in achieving these goals. Also, lack of an integrated model is felt, one that consists of available criteria and options, a systematic approach in setting maintenance instructions and robust maintenance decision-making. So, based on the fuzzy analytical network process (FANP) method, which composes criteria and options, a new approach to selecting optimal maintenance strategy is proposed in this article. Here, using multi-attribute decision-making in conjunction with application of fuzzy numbers structure has been regarded as an efficacious method for determining the significance of each criterion and option. The criteria that are considered in the FANP method are organization, safety, administration, staff, and technical requirements. The options (strategies) that are taken into consideration in this study are time-based preventive maintenance, corrective maintenance, condition-based maintenance, reliability-centered maintenance, and predictive maintenance. After implementing the method proposed for a 5-MW powerhouse (a case study undertaken for the purpose of this study), the predictive maintenance strategy was selected. According to expert opinions, it is the administrative and staff requirements that must be highlighted for selecting the best strategies.

Reliability-Centered Maintenance: Analyzing Failure in Harvest Sugarcane Machine Using Some Generalizations of the Weibull Distribution

We considered five generalizations of the standard Weibull distribution to describe the lifetime of two important components of sugarcane harvesting machines. The harvesters considered in the analysis harvest an average of 20 tons of sugarcane per hour and their malfunction may lead to major losses; therefore, an effective maintenance approach is of main interest for cost savings. For the considered distributions, mathematical background is presented. Maximum likelihood is used for parameter estimation. Further, different discrimination procedures were used to obtain the best fit for each component. At the end, we propose a maintenance scheduling for the components of the harvesters using predictive analysis.

Identification of Critical Components Using ANP for Implementation of Reliability Centered Maintenance

Identification of critical components and their prioritization for implementation of maintenance is an important task in industry. It is also one of the essential step of reliability-centered maintenance. In this paper, an attempt made is being made to find out the key factors associated with the criticality of components. Five major criteria affecting criticality of components i.e. cost, functional dependency, complexity, maintainability, and safety impact were proposed for criticality analysis. In addition, to identify the critical components a hierarchical network is proposed based on analytic network process. The proposed methodology evaluated with a case study on CNC lathe machine. This study can provide a realistic solution to decision-making problems for maintenance planning in prioritizing the critical component for reliability-centered maintenance.

Analisis Penerapan Overall Equipment Effectiveness Pada Mesin Power Press Combination Forming 60T

Corrective action on the engine damage is a temporary emergency measure, so further action is required by conducting maintenance activities, prevention of damage (Preventive maintenance), and able to detect abnormal symptoms before the machine breakdown occurs. The sudden impact of machine damage resulted in disruption of planned production performance so that it is necessary to identify and analyze the factors that cause the machine damage. Establish maintenance method using Autonomous Maintenance, Preventive Maintenance and Reliability Centered Maintenance (RCM) concept to prevent machine failure from the beginning, through fault tree analysis (FTA) method, failure mode effect, and analysis (FMEA), mean time between failure (MTBF ) is an analytical activity for implementing RCM systems on machines and critical components, able to identify and detect symptoms of malfunction before the machine is damaged. The results of the research get better application of maintenance system so that identification of important components can be anticipated from the symptoms of damage. Overall, there is an increase in performance seen from the increase of Overall Equipment Effectiveness (OEE) value, still expected to continue to increase according to JIPM 85% standard value. In conclusion FMEA, FTA, MTBF analysis method can be used to build autonomous maintenance, preventive maintenance and reliability centered maintenance so as to facilitate the production and maintenance in determining the proper maintenance of the machine.

Implementation of Maintenance Scenario for Critical Subsystem In Aircraft Engine: Case Study NTP CT7 Engine

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect. The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $ 7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got $1.885.612, 82.
 

Maintenance Task Allocation And Planning In KT. X Tugboat Using Reliability Centered Maintenance Method

Reliability Centered Maintenance (RCM) as one of the processes that used to decisive action which should be performed to ensure any physical components or a system can work optimally in accordance with the function desired by its users. Basically, RCM used a risk management principles of the failure of the components so that it can be determined the type of maintenance properly. With the appropriate type of maintenance, then the failures that may occur can be prevented at once to be able to be detected before they occur. Appropriate implementation of RCM, capable of delivering cost savings, the impact on both the cost of maintenance as well as repair costs due to the occurrence of failure. In this paper, the components become the object of research is the main engine of the KT. X tugboat belongs to Pelindo Marine Service (PMS) Surabaya. KT. X tugboat has the lowest level of availability of the entire company-owned tugboat 80.01 percent. Tugboat is one of the main assets of PMS who support the economy of the company. Therefore, it is imperative for a company to further enhance the efficiency of activities of its operations. These include the efficiency of human resources, as well as economic analysis of system reliability of company assets. It is used in order to keep abreast of competition at the world maritime national and globally. Implementation of RCM process on main engine KT. X, priority levels can be specified against the failure of components that have critical consequences. So it can be a planned maintenance system generated properly and efficiently.

Tamping and Renewal Optimization of Ballasted Track Using Track Measurement Data and Genetic Algorithm

AbstractAlthough reliability centered maintenance (RCM) has been used widely in the maintenance and renewal (M&R) of railway infrastructures, M&R methods and maintenance frequencies still require c...

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.

Risk-Based Maintenance Scheduling with application to naval vessels and ships

Maintenance scheduling for naval vessels and ships requires ongoing improvement to manage rising maintenance costs within availability constraints. Existing maintenance scheduling approaches are not optimal as maintenance costs continue to rise without an improvement in vessel availability. This paper reviews the Risk-Based Maintenance Scheduling (RBM) framework as applied to ships and naval vessels, and provides a critical analysis of Risk Assessment and Maintenance Scheduling techniques used. Further, objectives and considerations are defined for future applications for ships and naval vessels, and the framework evaluated as an improvement on existing Preventative Maintenance (PM) and Reliability Centered Maintenance (RCM) methods. A probabilistic approach supported by condition monitoring data in combination with Decision Theory is suggested for the Risk Assessment and Maintenance Scheduling elements comprising an RBM Scheduling framework. Implementation of this framework from both periodic PM and RCM is presented. Development of applications from the component level upwards is suggested. Availability and overall maintenance cost are suggested as evaluation metrics against existing methods. The development of an application is formalized within a proposed framework. The development of an application within the RBM Scheduling framework is expected to result in reduced maintenance costs while meeting availability requirements for ship and naval vessel applications.

Availability-Based Reliability-Centered Maintenance Scheduling: Case Study of Domestic (Building-Integrated) Hot Water Systems

AbstractThis study investigates the availability-based reliability-centered maintenance scheduling of domestic (building-integrated) hot water (DHW) of HVAC systems. The keeping system availability...

Performance-Based Reliability-Centered Maintenance Planning for Hospital Facilities

AbstractThe deteriorating state of the built environment has affected numerous sectors, and hospitals are no exception. Hospitals are relatively unique compared with other facilities because of the...

Analisis Perawatan Mesin dengan Pendekatan RCM dan MVSM

Maintenance system at UMKM ED Aluminum Yogyakarta is using preventive and corrective maintenance program, but the implementation of this program still have many problems. The problem occurs because there is no maintenance system program and the company doesn’t have Standard Operational Procedure (SOP) in maintenance to overcome machine failures resulted in the increase of the downtime value. To cope the problems, in this paper we used application of SOP and appropriate task maintenance selection using Maintenance Value Stream Map (MVSM) method supported by Reliability Centered Maintenance (RCM). Beside task selected among all products that have been produced, there is one machine that gives the biggest profit to the company. The product is feet infusion. Kondia milling machine is one of machines produces the feet infusion that has the longest downtime which was 17,75 hour during January 2016 until October 2016. RCM consist of Failure Mode Effect Analysis (FMEA), Pareto diagram, decision worksheet RCM, whereas the MVSM describes the maintenance activity. Based on Pareto analysis, the critical components on the Kondia milling machine were the magnetic contactor, relay, fuse, cutter, dynamo and bearing. The result of RCM decision worksheet proposed the appropriate action for the critical components cares. The Standard Operational Procedure (SOP) for the maintenance system on the operation of Kondia milling machine are suggested to the company for getting more significant outcome.

Evaluasi Kinerja Pemeliharaan Mesin PLTD dengan Menggunakan Pendekatan Reliability Centered Maintenance (RCM)

Diesel Powered Electric Generator is a Electric Generator where using Diesel Machine as primer mover, which function to produce mechanical energy required to rotate the rotor generator to produce the electricity. The problem faced is found a lot of damage whice is make engine machine does not operate and high repair costs that result the company suffered losses. Reliability Centered Maintenance is a method where used to find “what should you do” to determine effective treatment. The result Showed that the machine has a major constraint on the machine RUSTON 1 is Injection Pump and Cylinder Linier Infection Pump with maintenance intervals about 44.24 hours. The Failure factor of the engine components are the supply of engine’s fuel is not optimal. Total cost for cumulative maintenance of two critical components reach Rp. 831.263.531. Keywords: Maintenance, Reliability Centered Maintenance (RCM)

Developing Simulation Based Optimization Mechanism for Novel Stochastic Reliability Centered Maintenance Problem

This research investigates joint scheduling of maintenance and production planning. This novel integrated problem takes benefit of reliability-centered maintenance (RCM) for monitoring and managing maintenance function of a stochastic complex production-planning problem namely flexible job shop scheduling problem (FJSP). The developed RCM works based on stochastic shocking of machines during their process time. In fact, it implements condition based maintenance approach regulated according to stochastic reliability concept. Comparison of the system reliability with critical levels determines the failure statues of the machines. It activates two main types of reaction called preventive and corrective maintenance. Considering breakdown of the system between inspection intervals makes the proposed model more realistic. Moreover, maintenance activity times and their duration are considered stochastically. Because of the high complexity level for this joint system, simulation-based optimization (SBO) approach is proposed for solving the problem. This SBO searches the feasible area through genetic algorithm (GA) and biogeography based optimization (BBO) algorithm. Different test problems, statistical methods, novel visualizations are used to discuss the problem and the algorithm explicitly.

Implementing Reliability-centered Maintenance Model for Porcelain Housed Components of Loading and Tie Transformers

A proper maintenance action of power transformer porcelain housed components with improved system reliability is needed by electric utilities. The porcelain housed components including bushing and lightning arrester are key components of the transformer. Their failure occurrence is unacceptable as catastrophic consequences affect the transformer and the power network. Thus, this paper aims to implement a reliability-centered maintenance model of the porcelain housed components of loading and tie transformers. The risk model that combines component condition and network characteristics is developed by applying the score and weight technique. The condition assessment is focused on electrical test and visual inspection while the network assessment focuses on the operating characteristics of the transformer. Loading and tie transformers are selected in the analysis. Finally, transformer risk is reduced and system reliability is improved by the reliability- centered maintenance model of the porcelain housed components.

Usulan Perawatan Sistem Boiler dengan Metode Reliability Centered Maintenance (RCM)

Pembangkit Listrik Tenaga Uap (PLTU) PT Indo Pusaka Berau is a PLN work unit that provides electricity to consumers. The problem of the company is the frequent damage to boiler engine components. The company uses corrective maintenance system. On the problem, it is necessary to develop a machine maintenance system with Reliability Centered Maintenance (RCM) approach. The objective of the study was to select a boiler system maintenance action based on the RCM method and component replacement interval to minimize Total Minimum Downtime (TMD). Results of data processing RCM method, component in category Condition Directed (CD) is El Bow component. Components in Time Directed category (TD) are gland seal steam and check valve. Components in the Time Directed category are calculated for component replacement intervals on TMD criteria. The calculation result from component replacement interval was obtained 37 days for gland seal steam component and 58 days for check valve component. The proposed treatment of RCM method can reduce downtime by 11.33% of the company's maintenance methods.

Fired equipment safety in the oil & gas industry A review of changes in practices over the last 50 years

This paper reviews how the requirements of safety, availability, energy efficiency and environmental compliance have influenced the design and operation of fired equipment over the last 50 years. It presents the various norms and standards relevant to the classes of fired equipment used in the Oil & Gas industry and highlights the differences between prescriptive norms and performance based standards. The main hazards and common causes of accidents of process heaters, petrochemical furnaces and boilers are described. Finally, this paper reviews the evolution of the risk mitigations and design best practices over the last decades. It discusses in particular the particular challenges of improving the safety performance of existing equipment.Before the first oil crisis of 1973, the price of refinery fuels was very low and it was common practice to run heaters inefficiently with high excess air (e.g. 5 to 8 % O2 in the flue gas) and high draft to reduce the probability of sub-stoichiometric combustion and positive pressure in the combustion chamber. Since the safety margin was provided by operating with high excess air and high draft, control improvements were considered unnecessary. Fired equipment safety was essentially distributed between operator response to alarms (e.g. process upset conditions), instrumented protective functions programmed in the safety instrumented system and solutions such as explosion doors and snuffing steam to mitigate the consequence of explosions.In the last 25 years, the drive for safer operation with higher energy efficiency, lower NOx emissions and fewer nuisance trips has led operating companies to adapt their approach to fired equipment safety. The modern approach to fired equipment safety is to distribute the risk across independent protection layers. These safety barriers rely on a comprehensive control system with constraints and a safety instrumented system, but also on operational excellence with well-trained operators, good operating procedures and reliability-centered maintenance and risk-based inspection. As an important benefit, constraint controls with automated fuel cutbacks have proven effective at minimizing nuisance trips by keeping the heater within operational limits.

Application of IoT for the Maintaining Rolling Stocks

Purpose: This paper presents a framework for simulation on IoT based CBM (condition based monitoring) for rolling stocks. This enables to allocate maintenance resources effectively while satisfying preventive maintenance requirements.Methodology/Approach: We exploits Reliability centered maintenance (RCM) based on KTX (Korea Tran eXpress, Korea’s high-speed rail system) motor reduction unit failure data for three years by utilising the internet of things (IoT) and RAMS (Reliability, Availability, Maintainability, Safety) methods.Findings: We come up with the predictive maintenance indicator; reliability functions as to the desired service level; and the failure and defect prediction indicator takes the form of cumulative failure function in the form of probability distribution function, which aim to realise the real-time condition monitoring and maintaining technical support services. Internet of Things (IoT) has been an important apparatus to improve the maintenance efficiency.Research Limitation/implication: This paper has limitations that the data are collected from references, not actual data; the detailed descriptions of IoT application to the railway rolling stocks are omitted, and it is not dealt in depth how maintenance efforts and performance are improved through the suggested reliability centered maintenance.Originality/Value of paper: This study has the academic importance in a sense that it integrates RAMS based maintenance methods and IoT. RAMS centered maintenance provides powerful rules for deciding a failure management policy; when it is technically appropriate; and for providing precise criteria for deciding how often routine tasks should be carried out. It will lead to the improved cost efficiency, sustainability and maintainability of railway maintenance system since the staff do not have to visit installation sites frequently. Lately, there is general agreement that prevention was better than inspection and that an increase in preventive cost was the means of reducing total quality costs. In connection with this issue, we will address the way of reducing failure costs and prevention costs with IoT: new appraisal method.