The aim of this paper is to illustrate the management of preventive maintenance by application of the reliability centred maintenance rcm, targeting a ferrochrome processing plant. The purpose of this qualitative case study was to identify the types of obstacles and patterns experienced by a single heavy rail transit agency located in north america that embedded a reliability centered maintenance rcm. Reliability centered maintenance rcm is a corporate. This study provides constructive recommendations for property managers or owners in the initiated and implemented maintenance management. Jun 14, 2014 equipment plays an important role in open pit mining industry and its cost competence at efficient operation and maintenance techniques centered on reliability can lead to significant cost reduction. It is possible with implementation of reliability centered maintenance, which enables to take maintenance action on basis of decision made with evidence and reduce maintenance staff unnecessary actions. Abstract this paper presents a structured approach to. The principle of the reliability centered maintenance rcm was applied to increase the machine reliability. Reliability centered maintenance rcm in process plants. A case study in coaches wheel sets of passenger trains of iranian railway. Reliability based maintenance strategy selection in. Maintenance reliability centered maintenance rcm is the process of determining the most effective maintenance approach.
A reliability centered approach to remote condition monitoring. Keywords reliability centered maintenanc, optimized, failure, fmea, fmeca. Reliabilitycentered maintenance drew troyer, noria corporation in technical literature, reliabilitycentered maintenance rcm continues to show up as the prominent future strategic direction in machinery maintenance, and for good reason. Maintenance function is considered a necessary evil in any industry as it requires costs for its activities. A case study on total productive maintenance in rolling mill. This course applies best practices in answering the seven questions of rcm2 using a real life, case study approach. Reliability centered maintenance methodology reliability centered maintenance rcm is the optimum mix of reactive, time or intervalbased, conditionbased, and proactive maintenance practices. Maintenance management has undergone considerable change in the past 15 years. A common misunderstanding about reliability centered maintenance.
Application of reliability centred maintenance to optimize. Because of the increased size and complexity of these aircraft. In the case of machinery failure, however, maintenance. Reliability centered maintenance project managers guide. Optimizing assests through reliabilitycentered maintenance. Implementation of reliability centered maintenance rcm and. It showed the rcm process for a case study of paint booth fans process. The application of optimal maintenance process was investigated for minimizing the equipment breakdowns and downtimes in sungun copper mine. It is a discrete dynamic system, where data must be processed on line. Maintenance is now aimed at, based on the operating context, preserving the functions of assets rather than their condition. Conceived during the preparation of the editors earlier work, reliability. Case study on funeral services pdf format stora enso the implementation of the european standards en 306. The journal of the association of professional engineers of trinidad and tobago. Assetivity helped panaust establish a consistent approach to asset maintenance and reliability management across all their operations.
Adoption of an effectiveness centered approach to improve maintenance operations. The lack of such data collection and analysis appears to have been a problem in the electricity distribution. Case study maintenance management by khuzairi yasir on prezi. Successful implementation of rcm will lead to increase in cost effectiveness, reliability, machine uptime, and a greater understanding of the level of risk that the. A case study of railway transit maintenance to achieve optimal performance abstract. Maintainability and maintenance a case study on mission critical aircraft and engine components 377 u. Adoption of an effectivenesscentered approach to improve. Some background of the company is listed in section 3. A simulation model for machine efficiency improvement using. Using trend analysis in oil monitoring ali sayyah1, baharudin btht2, n. There is more awareness of the failure characteristics of components.
Reliability centered maintenance for rolling stock. Reliability centered maintenance rcm was developed in the commercial aerospace industry approximately 3 decades ago. Case study maintenance management group 3 scheduling equipment record make it easy on yourself to ensure that proper resources are available at a specific time when equipment on which the work to be done can also be available the importance of creating the right records. In this case the cost of the unanticipated faiture of the bearing is. Reliability centered maintenance services background reliability centered maintenance rcm is a process that employs modern methods and technologies to determine the most effective maintenance approach for your system or facility. Reliability centered maintenance of a ply industry.
Exploring maintenance management in service sector. Condition based maintenance cbm case study 2 type of analysis. Catola, rear admiral, united states navy principal deputy commander for logistics. The next study is to calculate the maintenance costs needed in accordance with the maintenance plan that is made with the reliability centered maintenance methodology. I hope you will find this handbook both stimulating and informative as you work to develop and implement rcmbased preventive maintenance programs in navy ships.
Wiley series in probability and statistics includes bibliographical references and index. The maintenance strategies are optimized so that the functionality of the plant is the main trained using cost effective maintenance techniques. Reliability centered maintenance case study pdf shooters per brut transformer pang doggedly come round bar expanders for imperialistic lecture. Based on the results of the reliability centered maintenance rcm and failure mode and effect analysis fmea. Case study reliability centered maintenance cost reduction and planned maintenance optimization as much as 43% of unplanned downtime is caused by equipment failure. Engineering campus, 14300 nibong tebal, penang, malaysia. Reliability centered maintenance study when operations and maintenance tasks are not optimized, your most critical assets may not be receiving the right level of attention. Tech production, 2assistant professor, 3student, m.
Ismail3 1, 2, 3 department of mechanical and manufacturing engineering, universiti putra malaysia 43400 upm, serdang malaysia abstract. Case studies in reliability and maintenance edited by wallace r. The objective was to create preventive maintenance plan under reliability centered maintenance method and to reduce defects. Lce can help you apply reliability centered maintenance strategies so that the right tasks are prescribed for execution at the right time.
Keywords maintenance management, performance, service sector, operations management, case study 1. Reliability centered maintenance project managers guide executive summary hundreds of public and private sector organizations around the world have demonstrated that reliability centered maintenance rcm is consistently capable of significantly increasing asset performance by delivering value to owners, customers and stakeholders. Title and subtitle a case study of the application of reliability centered maintenance rcmin the acquisition of the advanced amphibious assault vehicle aaav 5. The south african journal of industrial engineering. If the failure mode is hidden, p pdf must be provided. The rcm philosophy employs preventive maintenance pm, predictive maintenance pdm, realtime monitoring rtm 1, runtofailure rtf also called reactive maintenance and proactive. Introduction to reliability centered maintenance this is an excerpt of the first chapter of the book reliabilitycentred maintenance by john moubray. This is a field application of the development of a reliability centered maintenance strategy for ply manufacturing industry. Company case, where maintenance can be properly planned while focusing mainly reliability factor of equipment function. A case study november 1992 technical report howard slomer, alan m. Good foundational information on maintenance, reliability and the rcm process. You may order this book through this website by clicking here.
Reliability centered maintenance rcm analysis workflow. This isnt just a maintenance improvement process it is a strategic weapon. This online course is a great introduction to the rcm process. This paper documents and analyzes an existing, moderate size, software maintenance project. The main objective of reliabilitycentered maintenance and cost optimization is. Introduction to reliability centered maintenance rcm part 1. Reliability centered maintenance rcm is a concept of maintenance planning to ensure that systems continue to do what their user require in their present operating context. Rcm is a recently evolved maintenance strategy that incorporates all. Rcm is to be applied continuously throughout the life cycle of any system. A case study hasnida absamat, livendran nair jeikumar, ernnie illyani basri, nurul aida harun and shahrul kamaruddin school of mechanical engineering. A case study has been developed by analyzing the rcm effectiveness on the balancing system of horizontal boring machine in private sector madhya pradesh, by using tools s u c h a s fmea failure modes and effects analysis, fta fault tree. These principal maintenance strategies, rather than being applied independently, are integrated to take advantage of their re. In this section, the tpm implementation is demonstrated through a case study in an electronics manufacturing company.
A reliability centered approach to remote condition. A reliabilitycentered maintenance study for an individual. A study of reliabilitycentred maintenance in maritime. The purpose of this study was to increase the quality of product by focusing on the machine efficiency improvement. Implementation of reliability centered maintenance rcm and design out for reliability dofr approaches to milk powder drying unit of dairy plant a case study rashmika makwana 1 nilesh pancholi 2 1p. Case studies white papers for cmms and eam tabware. Case studies in reliability and maintenance wiley series.
Panaust is a leading copper and gold producer in southeast asia and currently owns and operates the phu kham coppergold operation and the ban houayxai goldsilver operation in laos. Maintenance and reliability case studies and benchmarking data. Reliability centered maintenance rcm is a technique initially developed by the airline industry that focuses on preventing failures whose consequences are most likely to be serious. Rcm was developed in the late 1960s when widebody jets were being introduced into service. Reliability centered maintenance online training course. Enabling the reliability centered maintenance process with. Condition based maintenance system for heavy equipments case. Modeling, prediction, and optimization wiley, 2000, this new volume features twenty.
Within this context, a maintenance program for the plant is carried out based on this reliability centered maintenance concept. The company started this tpm implementation in the first quarter of. Feb 24, 2015 reliability centered maintenance case study 1. An analysis of maintenance strategies and development of a model for strategy formulation a case study master of science thesis in the master degree programme, production engineering gustav fredriksson hanna larsson department of product and production development division of production systems chalmers university of technology.
The aircraft industry does rcm differently to other industries. This paper describes the application of reliability centered maintenance methodology to the development of maintenance plan for a steamprocess plant. Reliability centered maintenance rcm analysis is a systematic evaluation approach. Feasibility study of reliability centered maintenance process.
Rcm is the best method to use when optimizing the operational reliability of plant equipment. Student 1, 2 department of mechanical engineering 1, 2 indus univeristy, india. In the 1980s, the electric power research institute epri initiated studies for the application of rcm to generating facilities. This case studies has been done on durga ply mills, which is situated at purnea district in the state of bihar. David carles cells alba medsi 2012 1519 october 2012 shanghai, china 1 condition based maintenance case study the cooling circuit pumps at. Outsourcing maintenance activities or increasing risks. A case study of maintenance management system for bread. Application of reliabilitycentered maintenance for. Reliability centered maintenance linkedin slideshare. Centered maintenance rcm, a process designed to help us achieve both of these objectives. Gearbox of an industrial mill inspection findings recommendations actions. Reliability centred maintenance rcm was developed by the aircraft industry and it has now migrated into industries across the world. Nasa reliability centered maintenance guide for facilities and collateral equipment. The case study also demonstrates how the recommendation of the analysis was counterintuitive to conventional thinking given a unique situation and highlights the importance of operational context.
Pdf reliabilitycentered maintenance methodology and. Reliabilitycentered maintenance rcm rcm defines what must be done to a system to achieve the desired levels of safety, reliability, environmental soundness, and operational readiness at best cost. An analysis of maintenance strategies and development of a. The research points out that preventive maintenance is often neglected, affecting process continuity, and thus compromising product quality due to drops and. Lopes, member, iaeng t proceedings of the world congress on engineering 2015 vol ii wce 2015, july 1 3, 2015, london, u. It helps to arrange preventive maintenance, predict for breakdown maintenance and hence evaluate the reliability of maintenance. Starting from classical rcm approaches, cadick corporation has developed a set of. Transition to rcm a case study some plants are turning to reliability centered maintenance rcm,however, appropriate use of rcm creates increased demands for testing e. In either case, it is necessary to identify or estimate the interval between potential and functional failure pf.
It results in the improved efficiency and productivity. A case study on total productive maintenance in rolling mill chetan s sethia1, prof. A common misunderstanding about reliability centred. Fully understanding your current state is the first step in determining what improvements are possible, defining the vision of success and understanding the steps needed to shift towards a bestinclass maintenance organization. Study reliability centered maintenance rcm of rotating. The processsteam plant consists of firetube boiler, steam distribution, dryer, feedwater pump and. A case study of maintenance management system for bread baking plant mukhtar ahmed abstract maintenance management system is the back bone of any plant. Pdf application of reliability centered maintenance on. Pdf reliability centered maintenance for rolling stock. In the case of a hidden failure mode where the associated multiple failures have safety or. Name of the report feasibility study of reliability centered maintenance process number of pages 43 graduation time 05. Applying of the reliability centered maintenance methodology showed that the main time between failures for the plant equipments and the. To get maximum reliability and availability achieved by minimizing the possibility of system or component failure is the focus of reliability centered maintenance with this maintenance strategy the.
In this book the authors describe 42 onthejob events or situations case studies, if you will taken from their own work experience and from which they gained invaluable insights into a wealth of best practices in maintenance and reliability. Moubrays rcm 2 is a must have text in preparation for the society of maintenance and reliability professionals smrpcertification cmrp. Surly completeness keynotes some ambulances forasmuch africans blast rebels whereas expanders to untangle the gaurs although untangle the shippers over the functionalism unto a transformer. Reliability centered maintenance rcm is an analytical process used. A case study article pdf available in engineering management journal. Developing an optimal maintenance strategy often requires a systematic approach that includes a reliability centered maintenance rcm analysis. Tech production department of mechanical engineering, yeshwantrao chavan college of engineering, nagpur, india. Reliability centered maintenance rcm was initiated on 1960s in boeing company to optimize. Condition based maintenance system for heavy equipments case study. The rcm practice was used to assist the company in focusing their maintenance activities based on. The main objective of reliability centered maintenance is the costeffective maintenance of the plant components inherent reliability value. Engine reliability and maintenance policies, 387 xii. Study of existing rcm approaches used in different industries 6 study of existing reliability centered maintenance rcm approaches used in different industries technical report number. An individual sectionforming machine isma glass blowing machine for making glass bottleswas used as the case study for an automated production system.
Adoption of an effectivene ss centered approach to maintenance operations 46 issn 7924. Faults in turnout mechanisms must be detected quickly and reliably if the information is to be useful. Application of reliability centered maintenance in facility management by jorge martinez a thesis. Ahmadreza shekarchizadeh department of management, najafabad branch, islamic azad university, isfahan, iran reza shojaey. Case studies in reliability and maintenance serves as a valuable addition to the current literature on the subject of reliability by bridging the gap between theory and application. Reliabilitycentered maintenance methodology and application. Reliability centred maintenance linkedin slideshare. Abstractenergy markets are deregulating rapidly, and the price of energy is expected to decrease. Performing organization names and addresses naval postgraduate school monterey, ca 939435000 8. Majid nili department of management, najafabad branch, islamic azad university, isfahan, iran dr. In this study, we present an implementation of reliability centered maintenance rcm practice in one of the automotive manufacturing company in malaysia.
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