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INDUSTRIAL (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
RESEARCH AND DEVELOPMENT (IJIERD)
ABSTRACT
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
1.2 Background
Maintenance is routine recurring work, which is necessary to retain equipment in a
state in which it can perform its intended function. Maintenance is performed to ensure
equipment availability in industry so as to compete in global market. Maintenance has
changed more than any other management discipline during the past twenty years. In early
ages, the maintenance strategy was breakdown maintenance, as there was no awareness of
downtime. But with passage of time, increased complexity of machines led to the prevention
maintenance in second generation, and then maintenance strategies and objectives have
rapidly changed from preventive maintenance to condition monitoring. In this era, the
importance of effectiveness of operational equipment raised, which is dependent on plant
capacity (Raouf, 2004). So, the concluded strategy must have a balance between maintenance
cost and plant reliability.
Usually most of the industries in Pakistan follow preventive maintenance strategy or
scheduled maintenance. According to Herbaty, Preventive maintenance comprises of periodic
activities performed at predetermined time interval or after the specified amount of
equipment usage to keep it in proper working condition and to prevent it from breakdowns
(Herbaty, 1990).
In 1960s, a new concept, Reliability Centered Maintenance (RCM) evolved. Initially
RCM was used in aircraft industries, and it was oriented towards airplanes maintenance
(Dekker, 1996). RCM is a structured framework and a logical process of optimizing
maintenance resources for physical assets maintenance in its operating context. RCM is
focused on preserving system functions, rather than preserving physical asset. RCM analyzes
the functions, potential failures of equipment and it is a seven-review step philosophy to
evaluate inherent reliability, with risk management. RCM is possible with the selection of
an effective maintenance strategy that will offer inherent reliability of equipment (Samanta
et al., 2001).
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
1.4 Objective
The objective of this paper is to study predictive maintenance strategy and the
benefits of its implementation for the equipment at ABC Automobile Company, instead of
preventive maintenance. This study focuses on rotating equipment (e.g. motors, pumps,
conveyors, compressors etc.), where vibration monitoring can be implemented through RCM.
1.7 Methodology
The research approach is qualitative and primary data sources are used to collect data.
The method of data collection is observation (non-participant) and structured interviewing of
maintenance staff of ABC Automobile Company Ltd and condition monitoring Company.
This study primarily describes their existing situation and problems facing with preventive
maintenance strategy on account of the different opinions people have about an issue and
observations, and data analysis with proposals to improve this situation. A test case is
presented to analyze the validity of proposals to improve this situation.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
Sub-
Clear Coat# 2 Exhaust Fan
Equipment Setting Room Exhaust Fan
Monitoring B. B.
Noise Vibr. Noise Vibr. B. Noise B. Cond.
Items Noise Cond.
Standard
None None None T~N~L None None None T~N~L
Rating
I/P Moisture
Moisture
Sub- Valves Trap of
Motor Oil Belt Air tank Compressor Trap of
Equipment Of Man
compressor
Tank Tank
Monitoring Manual Manual
Noise Level Tension Open Pressure Noise
Items Drain Drain
In Table 1, noise, vibration, belt looseness and bearing noise of paint Booth # 1
Exhaust fan is monitored on basis of manual observation of maintenance staff, which is
attribute data and not clarifying quantitative data of these parameters. So it is not guaranteed
to predict equipment condition. Similar inspection is followed in case of new small
compressor and cooling water circulation system.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
Reactive Repair actions Fix it when it Unscheduled/ Upon failure, Not usually Large Unpredictabl
are performed breaks unplanned work stoppage maintenance e asset
after the failure to fix problem budget availability
occurs and immediately and
people wait reliability
until
equipment
fails, and then
maintenance
actions focused
to quickly
make possible
the availability
of equipment.
Preventive In PM, Schedule Pre scheduled Prescribed Not usually Periodic Maintenance
maintenance maintenance / pre planned based on failure but component performed
performed history or test sometimes replacement/ more often
before failure data. manually repair. than may be
occurs, collected necessary.
for equipment To prevent
in which operation Assets often
downtime costs problems that taken off-line
more than lead to failure. time for
preventing service.
incipient
failure.
Predictive In PdM, Repair prior Just in time Prescribed Periodic Monitoring Maintenance
indicators to failure ( planned) based on sample data condition by performed
show the when needed Scheduled as statistical collection. vibration, when
requirement of per need patterns in heat, necessary.
maintenance operating alignment,
actions to take. parameters. wear debris Better asset
So it is a type etc. availability
of maintenance To prevent and
performed on operation reliability.
the basis of problems that
requirement of lead to failure or
machine. reduced
throughput.
Continuous/ Monitoring
Condition It is performed Repair prior Just in time Prescribed real time condition by Maintenance
Based as per to failure ( planned) based on sensor vibration, performed
requirement condition statistical monitoring heat, when
and use based patterns in and data alignment, necessary.
sophisticated operating collection. wear debris
equipments to parameters. etc. Highest asset
detect signs of availability
imminent To prevent and
failure. So operation reliability.
maintenance is problems that
performed lead to failure or It is an on-
when need reduced line
arises. throughput monitoring
system, and
generally
continuous.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
Reactive Maintenance
Preventive Maintenance
Predictive Maintenance
Proactive Maintenance.
1. Performance monitoring,
2. Monitoring through Diagnostic equipment.
Machine vibration
Wear debris analysis
Infrared thermography
Laser alignment
Oil analysis
Noise survey
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
1. Detection
2. Analysis
3. Correction
In initial phase, it involves a detailed survey of the plant and its equipment. Then
critical and non critical equipment is classified and an RCM strategy is selected which is
appropriate for improving reliability and availability of these equipment. In case of predictive
maintenance, parameters are selected to monitor health of machines. Acceptable condit conditions
(limits) are set and to collect data to record and analyze data. Detection means identifying any
abnormality in collected data of a particular parameter. It involves measuring and trend
analysis at marked points on each machine on a regular (scheduled
(scheduled)) basis. Analysis helps to
find out the root cause of the abnormality detected. It is basically a diagnosis of machine
problem, so that corrective action can be taken. Corrective action can be easily planned to
keep machine downtime at an absolute minimum. Its implementations main objective is to
alarm about developing problems. The below flowchart illustrates each step clearly;
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
PLANT SURVEY
CLASSIFYING EQUIPMENTS
CRITICAL NO
SELECT PREVENTIVE
EQUIPMENT MAINTENANCE
YES
SELECT PREDICTIVE
MAINTENANCE
SELECT PARAMETERS TO
MONITOR
SET ACCEPTABLE
CONDITION LIMITS
COLLECT DATA
TREND ANALYSIS OF
FAULT DETECTION
REMEDIAL ACTION
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
Vibration monitoring requires higher start up investment cost for instruments and skill
development of maintenance personnel, but it is in-service powerful information source for
detecting imminent failure and monitoring machine health. It is easy to record data and
transfer it to analyze, with portable and versatile instruments. It has accuracy to diagnose
problem and permits effective planning of corrective action, planned shutdown time, skilled
maintenance personnel and spare parts requirement. According to survey data of American
Society of Mechanical Engineers (ASME), upto 82 percent of malfunctions of the mechanical
equipment can be detected with the help of vibro-monitoring and vibro-diagnostic methods.
(Parida et al., 2000)
2.5 Summary
In ABC Automobile Company, preventive maintenance system enables it to prevent
malfunctioning of critical equipment. In this system, condition monitoring of critical
equipment is performed through manually collected data on the basis of senses of sight,
smell, touch and hearing. For example the data of Paint booth fans just shows whether
abnormal noise exists or not. This system has limitation of actual parameter measurement and
authenticity of information.
Secondly it enables to alarm or indicate imminent failure and to take remedial action
before failure occurs. After the deep analysis with the help of RCM, it is concluded to follow
predictive maintenance system for critical equipment. In plant survey, equipment are
classified into critical and non critical categories and then proposed predictive maintenance
for critical components. For predictive maintenance, parameters are selected for each
machine, and to collect data and analyze. This analysis or trend data indicates imminent
failure and give alarms to take remedial action before failure occurs.
Predictive maintenance basically focuses on the future problem and helps to monitor
condition on-line. This on line condition monitoring helps to perform well planned
maintenance tasks and eliminates consequential losses. Through this system ABC
Automobile Company cannot perform unneeded maintenance and reduces overall
maintenance cost. To check the validity of the proposal a test case is taken of Paint Booth
process and vibration monitoring technique used on its fans to collect data to predict
imminent failure.
Test Case:
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
stop filters hold paint particles which are decomposed from air. Spray booth contains diesel
burner and fan-motor
motor units. A channel connection to units for air circulation
circulation is executed and
installed on the facility floor.
The most important and critical function of a spray booth is managing its airflow
maintaining uniform velocity in unidirectional layers. The managed airflow results in two
advantages,
Maximum efficiency of the paint sprayed in the Paint booth,
And improved finish quality through directing overspray away from the painted
finish.
Air supply house supplies air to the booth after conditioning and filtering, minimizing
temperature variations and removing particulates that compromise finish quality.
Intake air moving across the painting operation conveys the overspray into the water
curtain and the water wash apparatus, which then works to move the water in such a way as
to trap and separate the particulate
articulate from the recycling water.
Process flow of paint booth is shown in fig 5, with sequence of operation and
sequence of equipment.
Fig 5:
5 Process flow of paint booth
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
1. What are the functions and associated desired standards of performance of the asset in its
present operating context (functions)?
Delivery of air into the booth or circulation of it is provided by fans, having the capacity
of 360 m / min. In this unit air is delivered to the booth after being filtered by a pre-filter.
Additionally output air is controlled by a damper in the output air channel.
Delivery of the air into the booth or 1. Unable to rotate at 1460 rpm
circulation of it is provided by fans while 2. Unable to meet quality standards
meeting all quality, health, safety, and 3. Unable to meet health, safety, and
environmental standards. environmental standards.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
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Bad company image will be associated with shipment delays and poor quality
Occupational hazards and human discomfort
5. What should be done to predict or prevent each failure (proactive tasks and task
intervals)?
Monitoring the vibration characteristics of a machine gives us an understanding of the
health condition of the machine. We can use this information to detect problems that might
be developing. Operating a machine until it breaks down might be acceptable if the machine
was a disposable one. Most machines, however, are not disposable due to their cost.
6. What should be done if a suitable proactive task cannot be found (default actions)?
Default actions are may be routine preventive maintenance at predetermined
schedules and cleaning of fan blades or allowed to breakdown.
This RCM seven Question process helps to determine the causes of system failures
and develop activities targeted to prevent them. The questions are designed to focus on
maintaining the required functions of the system and help to conclude proactive maintenance
strategy.
The answers of first four questions, which are related to functional failure, causes and
effects, are recorded in RCM information sheet as shown in table 4.
In table 5 answers of remaining question is recorded which is decision worksheet.
Decision worksheet is recorded with the help of answering question in RCM decision
diagram related to failure consequences, preventive tasks and default actions as shown in
Fig 6.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
F FF FM H S E O N1 N2 N3 H4 H5 S4
1 A
(a) Y N N Y N Y - - - - Schedule restoration
Legends :
FF= H= Hidden E=
Functional FM= Failure failure S= safety Environmental
Y= Yes N= No F= Failure failure Mode consequences consequences consequences
H2/S2/O2/N2
O= N =Non H1/S1/O1/N1 Scheduled
Operational Operational On condition restoration H3/S3/O3/N3 H4= Default H5= Default S4= Default
consequences consequences Task Task Discard Task action action action
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
PLANT SURVEY
PAINT BOOTH
SELECTED
FANS NO
SELECTED AS SELECT PREVENTIVE
CRITICAL MAINTENANCE
YES
SELECT PREDICTIVE
MAINTENANCE
VIBRATION MONITORING
SELECTED
COLLECT DATA
TREND ANALYSIS OF
FAULT DETECTION
REMEDIAL ACTION
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
The data collected (Table 6 and Fig 9) is plotted in given below graph, and analysis
performed on these reading revealed operation at alarm level.
TREND DATA
0.7
0.6
0.5
0.4
0.3
TREND DATA
0.2
0.1
So for, the remedial action of cleaning has been performed to remove buff deposits
from blades and deteriorated bearings were replaced. Fan was then rotated and found
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
TREND DATA
0.54
0.52
0.5
0.48
0.46
TREND DATA
0.44
0.42
0.4
In this way, vibration monitoring data provided very detailed assessment of fault
causes, and selected repair action performed as per need of equipment condition. Since then,
the fans are running smoothly and uninterruptedly.
The paper highlights application of predictive maintenance strategy and the benefits
of its implementation for the equipment at ABC Automobile Company, instead of preventive
maintenance. This study focuses on rotating equipment (e.g. motors, pumps, conveyors,
compressors), where vibration monitoring can be implemented through RCM.
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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976
6979(Print), ISSN 0976 6987(Online), Volume 5, Issue 1, January - February (2014), IAEME
The comprehensive literature review is presented of maintenance, its types and the
interfacing topics. The qualitative data is collected and analyzed with determining the
effectiveness of existing maintenance strategy. Predictive maintenance is proposed in
addition to preventive maintenance, and its previewed benefits compared. To preserve
function of equipment, RCM seven question analyses performed in test case and vibration
monitoring data is collected for fan of paint booth. That data trend is analyzed and used to
identify causes of imminent damage. So, equipment is repaired before failure and reliability
is increased by eliminating root causes.
In this way, RCM helps to plan scheduled maintenance and scarce economic
resources on critical equipment having high risk of failure. The paper reveals that the ABC
Automobile Company Ltd can achieve enhanced manufacturing performance leading to
competitive advantage with successful RCM implementation through predictive maintenance.
Due to limited resources and time, the paper showed only test case of fan of paint
booth, but in case it will implemented on all critical equipment then it will further clarify the
differences and benefits of predictive maintenance strategy over other. So, it is strongly
recommended to implement this proposal and analyze the situation differences to explore
effective Reliability Centered Maintenance.
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