Introduction to reliability centered maintenance rcm part 1. Reliability centered maintenance case study pdf shooters per brut transformer pang doggedly come round bar expanders for imperialistic lecture. Nasa reliability centered maintenance guide for facilities and collateral equipment. A case study of maintenance management system for bread baking plant mukhtar ahmed abstract maintenance management system is the back bone of any plant. The maintenance strategies are optimized so that the functionality of the plant is the main trained using cost effective maintenance techniques. Tech production, 2assistant professor, 3student, m. Reliability centered maintenance methodology reliability centered maintenance rcm is the optimum mix of reactive, time or intervalbased, conditionbased, and proactive maintenance practices. Reliability centered maintenance rcm analysis is a systematic evaluation approach. In the 1980s, the electric power research institute epri initiated studies for the application of rcm to generating facilities. Conceived during the preparation of the editors earlier work, reliability. Introduction to reliability centered maintenance 1. 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.
Case studies white papers for cmms and eam tabware. 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. Condition based maintenance cbm case study 2 type of analysis. Case study on funeral services pdf format stora enso the implementation of the european standards en 306. Case studies in reliability and maintenance edited by wallace r. Condition based maintenance system for heavy equipments case. The south african journal of industrial engineering. An analysis of maintenance strategies and development of a. It results in the improved efficiency and productivity.
Enabling the reliability centered maintenance process with. Case study maintenance management by khuzairi yasir on prezi. Application of reliabilitycentered maintenance for. The lack of such data collection and analysis appears to have been a problem in the electricity distribution. 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. The research points out that preventive maintenance is often neglected, affecting process continuity, and thus compromising product quality due to drops and. It showed the rcm process for a case study of paint booth fans process. Feb 24, 2015 reliability centered maintenance case study 1. 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.
In either case, it is necessary to identify or estimate the interval between potential and functional failure pf. Optimizing assests through reliabilitycentered maintenance. 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. In the case of a hidden failure mode where the associated multiple failures have safety or. The purpose of this study was to increase the quality of product by focusing on the machine efficiency improvement.
Reliability centered maintenance linkedin slideshare. A case study of railway transit maintenance to achieve optimal performance abstract. Feasibility study of reliability centered maintenance process. Centered maintenance rcm, a process designed to help us achieve both of these objectives. Reliability centered maintenance online training course. Rcm is a recently evolved maintenance strategy that incorporates all. Outsourcing maintenance activities or increasing risks. Majid nili department of management, najafabad branch, islamic azad university, isfahan, iran dr. Ismail3 1, 2, 3 department of mechanical and manufacturing engineering, universiti putra malaysia 43400 upm, serdang malaysia abstract. Exploring maintenance management in service sector. Reliability centered maintenance rcm analysis workflow. In this section, the tpm implementation is demonstrated through a case study in an electronics manufacturing company.
Pdf reliability centered maintenance for rolling stock. A case study on total productive maintenance in rolling mill. The principle of the reliability centered maintenance rcm was applied to increase the machine reliability. The rcm philosophy employs preventive maintenance pm, predictive maintenance pdm, realtime monitoring rtm 1, runtofailure rtf also called reactive maintenance and proactive.
It addresses the whole issue of how we fly and fight and eliminates problems of operating and maintaining weapons systems. 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. The journal of the association of professional engineers of trinidad and tobago. Engineering campus, 14300 nibong tebal, penang, malaysia. David carles cells alba medsi 2012 1519 october 2012 shanghai, china 1 condition based maintenance case study the cooling circuit pumps at. Starting from classical rcm approaches, cadick corporation has developed a set of. The processsteam plant consists of firetube boiler, steam distribution, dryer, feedwater pump and.
Company case, where maintenance can be properly planned while focusing mainly reliability factor of equipment function. 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. Maintenance management has undergone considerable change in the past 15 years. Pdf reliabilitycentered maintenance methodology and.
Rcm is to be applied continuously throughout the life cycle of any system. Lopes, member, iaeng t proceedings of the world congress on engineering 2015 vol ii wce 2015, july 1 3, 2015, london, u. Introduction to reliability centered maintenance this is an excerpt of the first chapter of the book reliabilitycentred maintenance by john moubray. Maintainability and maintenance a case study on mission critical aircraft and engine components 377 u. This paper documents and analyzes an existing, moderate size, software maintenance project. 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.
It is a discrete dynamic system, where data must be processed on line. 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. Study reliability centered maintenance rcm of rotating. Implementation of reliability centered maintenance rcm and. Adoption of an effectivenesscentered approach to improve.
A common misunderstanding about reliability centered maintenance. The program established a foundation of processes and procedures to ensure. The application of optimal maintenance process was investigated for minimizing the equipment breakdowns and downtimes in sungun copper mine. A case study hasnida absamat, livendran nair jeikumar, ernnie illyani basri, nurul aida harun and shahrul kamaruddin school of mechanical engineering.
Reliability centered maintenance rcm in process plants. A case study article pdf available in engineering management journal. 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. A case study november 1992 technical report howard slomer, alan m. Abstract this paper presents a structured approach to.
Condition based maintenance system for heavy equipments case study. Reliabilitycentered maintenance methodology and application. Some background of the company is listed in section 3. A reliability centered approach to remote condition. 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. Maintenance reliability centered maintenance rcm is the process of determining the most effective maintenance approach. 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. The main objective of reliability centered maintenance is the costeffective maintenance of the plant components inherent reliability value. In the case of machinery failure, however, maintenance. Within this context, a maintenance program for the plant is carried out based on this reliability centered maintenance concept. Reliability based maintenance strategy selection in. Keywords reliability centered maintenanc, optimized, failure, fmea, fmeca.
A simulation model for machine efficiency improvement using. The main objective of reliabilitycentered maintenance and cost optimization is. Case studies in reliability and maintenance wiley series. The aircraft industry does rcm differently to other industries. 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. Reliability centered maintenance rcm was developed in the commercial aerospace industry approximately 3 decades ago. Reliability centered maintenance of a ply industry. Name of the report feasibility study of reliability centered maintenance process number of pages 43 graduation time 05. Catola, rear admiral, united states navy principal deputy commander for logistics. Adoption of an effectiveness centered approach to improve maintenance operations. There is more awareness of the failure characteristics of components. Reliability centered maintenance in schedule improvement. This online course is a great introduction to the rcm process. This course applies best practices in answering the seven questions of rcm2 using a real life, case study approach.
Abstractenergy markets are deregulating rapidly, and the price of energy is expected to decrease. 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. This is a field application of the development of a reliability centered maintenance strategy for ply manufacturing industry. Rcm is the best method to use when optimizing the operational reliability of plant equipment. 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. This isnt just a maintenance improvement process it is a strategic weapon. It helps to arrange preventive maintenance, predict for breakdown maintenance and hence evaluate the reliability of maintenance. Application of reliability centered maintenance in facility management by jorge martinez a thesis. The rcm practice was used to assist the company in focusing their maintenance activities based on. A reliability centered approach to remote condition monitoring. Reliability centered maintenance rcm is a corporate. 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. Good foundational information on maintenance, reliability and the rcm process.
Faults in turnout mechanisms must be detected quickly and reliably if the information is to be useful. In this case the cost of the unanticipated faiture of the bearing is. Ahmadreza shekarchizadeh department of management, najafabad branch, islamic azad university, isfahan, iran reza shojaey. Developing an optimal maintenance strategy often requires a systematic approach that includes a reliability centered maintenance rcm analysis. Reliability centered maintenance rcm is an analytical process used. These principal maintenance strategies, rather than being applied independently, are integrated to take advantage of their re. This study provides constructive recommendations for property managers or owners in the initiated and implemented maintenance management.
Engine reliability and maintenance policies, 387 xii. Case study reliability centered maintenance cost reduction and planned maintenance optimization as much as 43% of unplanned downtime is caused by equipment failure. A case study of maintenance management system for bread. Using trend analysis in oil monitoring ali sayyah1, baharudin btht2, n. Assetivity helped panaust establish a consistent approach to asset maintenance and reliability management across all their operations. 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. Adoption of an effectivene ss centered approach to maintenance operations 46 issn 7924. A common misunderstanding about reliability centred. The objective was to create preventive maintenance plan under reliability centered maintenance method and to reduce defects. 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. 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. A reliabilitycentered maintenance study for an individual. A study of reliabilitycentred maintenance in maritime. Maintenance function is considered a necessary evil in any industry as it requires costs for its activities.
Performing organization names and addresses naval postgraduate school monterey, ca 939435000 8. Based on the results of the reliability centered maintenance rcm and failure mode and effect analysis fmea. Tech production department of mechanical engineering, yeshwantrao chavan college of engineering, nagpur, india. Reliability centered maintenance project managers guide. Because of the increased size and complexity of these aircraft. The company started this tpm implementation in the first quarter of. 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. In this study, we present an implementation of reliability centered maintenance rcm practice in one of the automotive manufacturing company in malaysia. Application of reliability centred maintenance to optimize. Wiley series in probability and statistics includes bibliographical references and index. Title and subtitle a case study of the application of reliability centered maintenance rcmin the acquisition of the advanced amphibious assault vehicle aaav 5. This paper describes the application of reliability centered maintenance methodology to the development of maintenance plan for a steamprocess plant.
An individual sectionforming machine isma glass blowing machine for making glass bottleswas used as the case study for an automated production system. Rcm was developed in the late 1960s when widebody jets were being introduced into service. 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. 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. Maintenance and reliability case studies and benchmarking data. 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. Maintenance is now aimed at, based on the operating context, preserving the functions of assets rather than their condition. 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 for rolling stock. Keywords maintenance management, performance, service sector, operations management, case study 1. 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.
Applying of the reliability centered maintenance methodology showed that the main time between failures for the plant equipments and the. Modeling, prediction, and optimization wiley, 2000, this new volume features twenty. Student 1, 2 department of mechanical engineering 1, 2 indus univeristy, india. Lce can help you apply reliability centered maintenance strategies so that the right tasks are prescribed for execution at the right time. Reliability centered maintenance rcm was initiated on 1960s in boeing company to optimize. 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. If the failure mode is hidden, p pdf must be provided. Gearbox of an industrial mill inspection findings recommendations actions. A case study in coaches wheel sets of passenger trains of iranian railway.
Moubrays rcm 2 is a must have text in preparation for the society of maintenance and reliability professionals smrpcertification cmrp. You may order this book through this website by clicking here. Reliability centred maintenance rcm was developed by the aircraft industry and it has now migrated into industries across the world. This case studies has been done on durga ply mills, which is situated at purnea district in the state of bihar. A case study on total productive maintenance in rolling mill chetan s sethia1, prof. Reliability centred maintenance linkedin slideshare. 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. Pdf application of reliability centered maintenance on.