Reliability Centered Maintenance Research Articles

Determining a Reliability Centered Maintenance (RCM) analysis model for large diameter prestressed concrete water pipelines

Which maintenance task to perform on an asset is generally known but the schedule of when to perform the task may not be well defined. If the task is performed early, while it may benefit the asset, it may also be expending resources that could be better used elsewhere. If the task is not performed soon enough, the asset may fail, or the asset may require more extensive maintenance be performed. Reliability Centered Maintenance (RCM) is an analysis process used to determine the most effective maintenance strategies. RCM analysis can help an agency establish the most cost effective maintenance strategies for an asset and help establish the best schedule for implementing those strategies. The ultimate goal of an RCM is to determine the required function of an asset with the required reliability at the lowest operation and maintenance costs by identifying revealing indicators of potential failures to establish a condition based strategy; essentially, predicting failures and identifying procedures to minimize the risk of the failure. This paper reviews potential models for predicting the progression of distress of prestressed concrete pipe segments for use in an RCM analysis and proposes a regression model operators can use to forecast when to perform maintenance activities. The paper further considers the condition of the drinking water infrastructure in the United States, developing the case for evaluating predictive models to forecast when a pipeline may reach a specified limit state. The results of this study suggest that RCM analyses for large diameter water pipelines can improve reliability, reduce maintenance costs, and extend the useful life of a pipeline regardless of age or material. Further, using a regression style model with gathered data can be used to forecast when specific maintenance thresholds may be reached, prompting predictive maintenance actions.

Identifying critical components for railways rolling stock reliability: a case study for Iran.

Electrical railways constitute a vital component of transportation infrastructure worldwide, with rolling stock representing a key element of these systems. Given the extensive operational hours of such systems, effective maintenance scheduling and asset management are imperative to ensure reliability and safety while mitigating costs. This paper addresses the challenge of optimizing maintenance practices for railway rolling stock by introducing a novel implementation of reliability-centered maintenance (RCM) grounded in the reliability block diagram (RBD) framework. This methodology meticulously incorporates reliability parameters into maintenance strategies, aiming to enhance the operational efficiency of railway systems. Leveraging the criticality index, the study identifies components crucial for train reliability, facilitating cost-effective maintenance management. The proposed approach is applied and validated on the Tabriz line 1 metro in Iran, a system with over six years of operational history. Analysis reveals the bogie subsystem's criticality due to its interconnected components, with parts exhibiting significant mean time to repair (MTTR). Conversely, the brake system emerges as the most reliable subsystem. Additionally, sensitivity analysis demonstrates an inverse relationship between repair rates and component sensitivity, highlighting the pivotal role of efficient repair processes in bolstering system reliability. This research contributes a comprehensive and validated methodology for RCM in railway rolling stock, emphasizing cost reduction, system reliability, and strategic prioritization of maintenance efforts. As the approached method in this research is not limited to the specific case study and can be applied in any system by generating the RBD and reliability parameters of the system we want to study The findings hold significant implications for the global planning and execution of railway maintenance operations, setting a new standard for reliability-centered maintenance practices in the field.

A systematic reliability-centred maintenance framework with fuzzy computational integration – a case study of manufacturing process machinery

PurposeThis study presents a systematic framework for maintenance strategy development of manufacturing process machinery. The framework is developed based on the reliability-centred maintenance (RCM) approach to minimise the high downtime of a production line, thus increasing its reliability and availability. A case study of a production line from the ghee and soap manufacturing industry in Taiz, Yemen, is presented for framework validation purposes. The framework provides a systematic process to identify the critical system(s) and guide further investigation for functional significant items (FSIs) based on quantitative and qualitative analyses before recommending appropriate maintenance strategies and specific tasks.Design/methodology/approachThe proposed framework integrates conventional RCM procedure with the fuzzy computational process to improve FSIs criticality estimation, which is the main part of failure mode effect criticality analysis (FMECA) applications. The framework consists of four main implementation stages: identification of the critical system(s), technical analysis, Fuzzy-FMECA application for FSIs criticality estimation and maintenance strategy selection. Each stage has its objective(s) and related scientific techniques that are applied to systematically guide the framework implementation.FindingsThe proposed framework validation is summarised as follows. The first stage results demonstrate that the seaming system (top and bottom systems) caused 50% of the total production line downtime, indicating it is a critical system that requires further analysis. The outcomes of the second stage provide significant technical information on the subject (seaming system), helping team members to identify and understand the structure and functional complexities of the seaming system. This stage also provides a better understanding of how the seaming system functions and how it can fail. In stage 3, the application of FMECA with the fuzzy computation integration process presents a systematic way to analyse the failure mode, effect and cause of items (components of the seaming system). This stage also includes items’ criticality estimation and ranking assessment. Finally, stage four guides team members in recommending the appropriate countermeasures (maintenance strategies and task selection) based on their priority level.Originality/valueThis paper proposes an original maintenance strategies development framework based on the RCM approach for production system equipment. Specifically, it considers a fuzzy computational process based on the Gaussian function in the third stage of the proposed framework. Adopting the fuzzy computational process improves the risk priority number (RPN) estimation, resulting in better criticality ranking determination. Another significant contribution is introducing an extended item criticality ranking assessment process to provide maximum levels of criticality item ranking. Finally, the proposed RCM framework also provides detailed guidance on maintenance strategy selection based on criticality levels, unique functionality and failure characteristics of each FSI.

Analisis Perawatan Mesin Kapal dengan Metode Reliability Centered Maintenance (RCM) di PT Jasa Armada Indonesia Tbk

Maintenance of the ship is a task aimed at ensuring that the ship continues to operate in a normal and seaworthy condition. This work is related to the ship's machinery system and other equipment on board. If the ship does not receive regular maintenance, it can impact the condition and performance of the ship. By implementing Reliability Centered Maintenance (RCM), information about the steps needed to ensure optimal operation of the engine or equipment can be obtained. RCM is a method used to develop Preventive Maintenance. In Time Directed (TD), there are two components, namely the schottel Asd component and the valve on the cylinder head. In Condition Directed (CD), there are three components found in the three pipe components: fuel pipe, oil, and engine coolant. In Failure Finding (FF), there are four components found in the seachast component, injector pump, fuel filter, and air. Based on the application of the RCM method used, the recommended maintenance actions for the Finding Failure (FF) category include daily, weekly, and monthly inspection activities. Meanwhile, for the Time Directed (TD) category, maintenance actions involve scheduling component replacements based on predetermined intervals. Keywords: FMEA, LTA, Maintenance, RCM

Application of the Reliability Centred Maintenance Method at QGS in PT ABC Dumai

QGS A1 is a powerful crusher and dryer designed based on reference drying equipment with good performance efficiency. It has a very important function in expediting the production process, but this tool often breaks down, which really affects smooth production. In connection with the damage to the tool, it needs to be examined to find out what maintenance should be done. This study aims to find out earlier the damage that affects the smooth production so that it can be known what maintenance actions must be carried out. This study uses the Reliability-Centered Maintenance method, which utilizes information on reliability and weaknesses as well as a list of maintenance actions to choose from. The results of this study found a solution: the QGS A1 treatment run to failure was 81.2%, the direct condition was 18.18%, and the failure finding was 0%.

Quantifying the impact of risk mitigation measures using SPAR-H and RCM Approaches: Case study based on VVER-1000 systems

Probabilistic Safety Assessment (PSA) provides a systematic and quantitative approach to assess the risk associated with different components and systems within a nuclear power plant. By quantifying the impact of risk mitigation measures, decision-makers can prioritize and implement solutions that have the most significant impact on reducing risk. Fault Tree Analysis (FTA) is employed as a systematic method within PSA, encompassing all modes of failure across equipment and associated support systems, including unavailability due to maintenance (UDM), human errors (HEs), and common cause failures (CCFs). In the present research, the Extra Borating System (EBS) and the Chilled Water Operating Circuit System (CWOCS) of essential loads are modeled in the SAPHIRE code using VVER-1000 design data. Through importance analysis employing the Fussell-Vesley criterion, the most significant basic events for these two systems are identified. Subsequently, the outcomes of the importance analysis are examined using diversity, SPAR-H, and Reliability Centered Maintenance (RCM) techniques. Recommendations such as the enhancement of diversity, increasing staff training, promoting Human Machine Interface (HMI), reduction of maintenance time, and improvement of power supply reliability are proposed for the most crucial basic events. The ensuing impact of these measures on the reliability of the EBS and CWOCS is subsequently assessed. Through a comparison between the new failure probability and the previous, it is determined that improvements in CCFs contribute a 30% effect; HEs have a 14% effect and UDMs have a 5% effect, with a cumulative impact of 35% on the failure probability of the EBS system. Similarly, for the CWOCS system, enhancements in CCFs contribute 20%, UDMs 17%, and improved power supply reliability 19%, with a cumulative impact of 29%.

IMPLEMENTATION OF RELIABILITY CENTERED MAINTENANCE (RCM) II IN PACKAGING INDUSTRY PRODUCTION MACHINERY MAINTENANCE ACTIVITIES

Along with the increasing need for productivity and the use of high technology in the form of production machines and factories, the need for maintenance functions is also increasing. At PT. Weiss Tech, a packaging machine manufacturer, has problems mainly related to wire cut machine malfunctions which cause interruptions and delays in the production process and reduce machine performance. In overcoming these problems in this study, the Reliability Centered Maintenance (RCM) II method from Failure Modes and Effect Analyze (FMEA) was used. RCM II is one of the methods used to determine which components are due for repairs, while FMEA is defined as a method for identifying the root cause of engine failure. From the results of calculations using FMEA and RCM II, the results of the maintenance interval for the Electromotor component (electric motor) with a maintenance interval of 20 hours, for the Lower and upper nozzle components (upper and lower nozzles) with a maintenance interval of 181 hours, and for the Roller component (drive roller) ) with a treatment interval of 177 hours

Application of Reliability Centred Maintenance in Improving Aircraft Availability with Preventive Maintenance Intervention

Aircraft are intricate flying machines equipped with advanced technologies and state-of-the-art information and communication systems. Maintaining these aircraft to ensure maximum availability and minimal downtime is a critical and challenging task. Therefore, aircraft maintenance, repair, and servicing are of utmost importance. This research work aims to develop a methodology for reliability centred maintenance (RCM) to enhance aircraft availability. An RCM approach with the Multi attribute decision making (MADM) technique for assigning criticality of systems was implemented to improve aircraft availability. Failure mode and effects analysis (FMECA) was utilized for the failure investigation in the aircraft systems. However, instead of the Risk priority number (RPN) due to its inherent flaws, the Analytical hierarchy process (AHP) was utilized to evaluate the criticality of systems. The remedial measures to minimize the failure frequency and downtime were proposed. The improvement in availability, post implementation of proposed preventive maintenance was validated with positive results. An improvement of approximately 6.62% in availability and a reduction of about 15.71% in the total downtime was observed on the implementation of proposed preventive measures. The availability analysis was carried out for aircraft systems; however, the model could also be used for other repairable systems following a similar maintenance philosophy.

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.

Designing a Reliability Maintenance Plan for Refinery Plants: A Case Study of a Nigerian-Based Refinery and its Power Systems

This study developed a comprehensive and effective reliability maintenance plan for refinery plants. Using a Refinery based in Nigeria as a case study, the research identified key factors affecting the reliability of refinery operations and proposed strategic maintenance measures to enhance operational efficiency and safety. The study utilized reliability centered maintenance (RCM) and failure modes and effect analysis (FMEA). From the evaluation, breaking down the components of the power system in the plant and addressing them individually exposes more vividly the errors in that system. Each failure mode was analyzed in terms of possible consequences on operation, function, or system status. The subject of risk assessment was presented and utilized to develop an approach for implementing the RCM in refinery power systems Finally, a proposed action plan was introduced to reduce the RPN number, thereby increasing the overall reliability and efficiency of the system component. It was observed that by reducing the RPN of each component, the overall efficiency of that component increases saving the company huge maintenance cost.

Reliability centered condition-based maintenance of zinc oxide lightning arresters: concept, process and case study

Introduction: The reliability of power equipment is the foundation for maintaining the reliability of the power grid. As a core device for limiting overvoltage in the power grid, lightning arresters have received widespread attention, and ensuring their reliability is crucial.Methods: To improve the reliability of zinc oxide surge arresters in the power system, the fault characteristics and health assessment methods of zinc oxide surge arresters were studied using reliability centered condition-based maintenance(RCCM). Firstly, the fault characteristic of zinc oxide lightning arresters in operation over years were collected and analyzed from different aspects. Then the effective state quantities corresponding to different types of defects and their detection methods were proposed. The health status evaluation model for zinc oxide lightning arrester was established, and the effectiveness of the evaluation model was verified through fault cases.Results and Discussion: It shows that the proposed state quantities and RCCM method are suitable for the actual operation and maintenance of zinc oxide lightning arresters. It can reduce the workload and improve the efficiency of existing operation and maintenance of lightning arresters.

A three-stage reliability-centered framework for critical feeder identification, failure modes prioritization, and optimal maintenance strategy assignment in power distribution system

In this paper, a three-stage reliability-centered maintenance (RCM) framework for critical feeder identification, failure modes prioritization, and optimal maintenance strategy assignment is presented for the power distribution system. This three-stage methodology addresses a notable gap in the literature by incorporating these three stages together. The first stage ranks critical feeders using the BWM and TOPSIS methods. In the second stage, the failure modes are prioritized using feeder rank, severity, occurrence, and detection factors and are assigned a score representing their priority. Finally, in the third stage, a maintenance strategy assignment, formulated as a mixed-integer linear programming (MILP) optimization problem is proposed. The optimization problem considers three strategies, cold-line, hot-line, and run-to-failure (RTF), assigned to each failure mode. Besides, the possibility of implementing cold-line repairs overlapping with the upstream grid's scheduled outages and the availability of several maintenance crews are taken into account. The objective function is to minimize the total maintenance costs, which include operation, equipment, energy not supplied (ENS), expected energy not supplied (EENS), and future corrective maintenance costs. The proposed approach is implemented on a real distribution system. The results indicate that the proposed RCM framework leads to a 26.32 % reduction in the EENS compared to selecting the RTF strategy for all components. Besides, the proposed optimization-based method leads to a 29 % lower objective function than the business-as-usual maintenance planning, and the proposed three-stage RCM framework outperforms a previously published state-of-the-art method by decreasing the objective function and the EENS.

Optimization of preventive maintenance in production lines: an approach based on reliability statistics

The maintenance strategy must be taken from the results required by the organization, that is, aiming to meet the budgeted costs, the defined quality and the production program. Therefore, it is up to this strategy to seek to maximize effectiveness in the relationship: use of resources, costs and useful life. This article aims to define a preventive maintenance strategy for a production line, using RCM concepts, aiming to determine an optimal periodicity for the execution of this type of maintenance activity and consequently the reduction of business costs. Experimental data were obtained from the previously referenced article, linking them to the concepts of Reliability-Centered Maintenance and the Maximum Likelihood Estimator. With this, it was possible to obtain the optimal stop times for preventive maintenance of the studied machines, assuming a ratio of costs of preventive maintenance and corrective maintenance. By following the reliability techniques covered throughout the article, a company's production line can ensure that its assets are running smoothly and that any potential issues are addressed efficiently.

Improvement of Industrial Maintenance Plans through Assistance-Driven Reliability-Centered Maintenance and Case-Based Reasoning Design

The present work builds on studies where the industrial market is currently characterized by a highly variable demand in terms of the quantities and flexibility of manufacturing or mass customization, which translates into a more demanding production context in terms of the continuous changes that are required in the production systems, the effect of which results in an increase in the fatigue of the machines that make up the production systems. However, current production systems tend to use highly communicative and sensorized cyber–physical systems; these characteristics can be used to integrate them into decision-assisted systems to improve the availability of the industrial plant. The developed assisted system focuses on collecting and taking advantage of historical knowledge of industrial plant failures and breakdowns. By ideally integrating the reliability-centered maintenance (RCM) methodology and case-based reasoning (CBR) algorithms implemented in a Java application, it is possible to design maintenance plans that are adjusted to the real and changing operational context of any industrial plant. As a result, faster and more accurate decisions are made, because they are based on data. This article focuses on improving certain aspects of the developed assisted system by adding more value by incorporating fuzzy logic (FL) techniques. The aim is to improve the way of entering information about risk factors and their relative importance by incorporating natural language instead of a numerical score, resulting in increased precision in the calculation of the risk priority number (RPN) of the new cases that are incorporated into the assisted system. On the other hand, an attempt has been made to correct two of the main inherent and recognized weaknesses in the classic RPN calculation method by implementing an appropriate mix of fuzzy logic techniques.

Analisis Perawatan Mesin Bubut Menggunakan Metode Reliability Centered Maintenance (RCM) Pada CV. Sumber Jaya Makassar

The aim of this research is to analyze the determination of the maintenance system and component replacement time intervals using the Reliability Centered Maintenance (RCM) method. This research was carried out at CV. Sumber Jaya Makassar which is located on Jl. Pioneers of Independence, Biringkanaya District, Makassar City. The data obtained shows that there is one lathe machine component that has a very high level of damage, namely the lathe machine electrical system component. From the results of the Mean Time Between Maintenance (MTBM) calculation, it is found that the maintenance interval for the lathe machine electrical system components is every 223.1111 hours, the lathe machine is every 401.6 hours, the lathe machine's fixed head is every 508 hours, the lathe's removable head is every 669.3333 hours. clock and lathe chuck every 1004 hours. To obtain the performance of a lathe that can operate according to its performance, planned or periodic care or maintenance is needed or what is often called preventive maintenance, namely by carrying out daily, weekly and monthly maintenance.

Implementation of Reliability Centered Maintenance (RCM) with Fuzzy Logic in Eliminating Off-Hangar Maintenance on Narrow Body Aircraft

Aircraft maintenance in remote locations is a prevalent challenge for local airlines in Indonesia, leading to diminished productivity and efficiency in the maintenance division. This issue is substantiated by a significant incidence rate of 36% annually, as reported by a national airline. The current solution needed is the improvement of the Maintenance System to eliminate off-hangar maintenance for Narrow Body aircraft in the national aviation service industry. This study aims to identify the causal factors of aircraft requiring maintenance when located outside the primary maintenance facilities and to reduce these occurrences. The Reliability Centered Maintenance (RCM) method is employed to determine the most effective maintenance approach based on system and equipment reliability, and the fuzzy logic method in FMEA is utilized to address ambiguity and uncertainty in risk assessment. Primary data were obtained from Focus Group Discussions (FGD) with experts working in the airline industry. Secondary data were collected from all aircraft experiencing breakdowns outside the main hangar. The findings reveal that the primary factor for maintenance outside the main facilities is the current maintenance policy of Finding Failure (FF), which leads to unpredictable maintenance activities, resulting in damage outside the main facility areas (Batam, Cengkareng, and Surabaya). Incidents of maintenance outside the main facilities can be eliminated by shifting the policy to Time Directed (TD), enabling the company to reduce costs from an initial IDR 342,681,011,118.60 to IDR 70,370,514,198.60, achieving a cost saving of 79.47%.

Analysis Of Maintenance Activities On Drag Chain Machines To Optimize Failure Time Intervals Using Reliability Centered Maintenance (RCM) Approach

Drag Chain is a material moving machine whose working method is to deliver material using a continuous dragging method. Drag chain is the optimal choice for cement production, because the chain with conveyor leaves on the right and left side drags along the bottom of the trough to transport the material in a closed state. Under these circumstances the drag chain components will tend to wear out, as the material interacts directly with the chain and can cause problems. This research will explain the maintenance process using the Reliability Centered Maintenance (RCM) approach is a maintenance system which is associated with statistics to find the value of the reliability of a component so that we can prevent failure by a combination of various actions.

Evaluating the Effectiveness of Reliability-Centered Maintenance Programs in Food and Beverage Manufacturing Facilities; A Review.

While reliability-centered maintenance (RCM) boasts widespread success across industries, its efficacy within the complex environment of food and beverage manufacturing remains unclear. This study addresses this gap by analyzing the implementation and outcomes of an RCM program at a representative facility. Leveraging quantitative data, the research demonstrates the program’s transformative impact, including significant reductions in downtime, improved asset reliability, and substantial cost savings. Beyond these metrics, the study delves into the practical challenges encountered during RCM adoption and offers actionable solutions for potential implementers. This research extends beyond its case study, aiming to serve as a catalyst for broader industry adoption. By highlighting the tangible benefits and practical considerations of RCM in a food and beverage context, the study empowers manufacturers to unlock its potential, paving the way for enhanced food safety, optimized production flows, and a more resilient and competitive sector.

Innovation and Application of Reliability-Centered Maintenance Technology for Pumped Storage Power Plant

With the increasing capacity and scale of pumped storage power plant, the maintenance management and resource input of system equipment are continuously increasing. Exploring and establishing a system engineering method that balances safe production and maintenance resource input has become an important issue that enterprises urgently need to solve. Based on the reliability-centered maintenance (RCM) technology, this paper combines the characteristics of pumped storage unit operation and maintenance management and years of maintenance practice experience to improve and innovate the RCM technology method, forming a “reliability-centered pumped storage unit maintenance strategy optimization technology method” applicable to pumped storage power generation units. This technology method has been applied on the system equipment of pumped storage power generation unit. It shows the application of this technology method has made significant contribution to optimizing equipment maintenance strategies, reducing maintenance workload and the overhaul time.

Assessment of Maintenance Performance Using the Maintenance Scorecard Method and Prioritization of Problem Control Strategies with the USG Method

Measuring the performance of machine maintenance becomes very important, serves as a monitoring tool, and triggers increased performance in the production section. Losses due to engine damage will impact the company's profit, which is less than optimal because maintenance can contribute as much as 20-50% of the cost composition of the company's operational costs. This study aimed to measure performance in the maintenance section using the maintenance scorecard (MS) and determine the priority of the performance control strategy using the Urgency, Seriousness, and Growth Method (USG). The research was conducted through case studies on chemical manufacturing companies located in Indonesia. The performance assessment results with the maintenance scorecard method show that the total scorecard maintenance value is in the category of need improvement, which is 63.35. There are 3 KPIs in the very bad category: maintenance costs from a cost-efficiency perspective, work completed from a quality perspective, and self-audit from a learning perspective. The first and foremost strategy that can be done based on USG's priority is to implement reliability-centered maintenance (RCM) to reduce time loss and increase the knowledge and competence of employees. This priority is useful when a company encounters a constraint so that it cannot carry out all strategies simultaneously or can only carry out some strategies while still getting optimal benefits from continuous improvement.