Reliability Centred Maintenance Case Study
ENGLISH ABSTRACT: High productivity in industry requires high equipment reliability and plant availability. 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 research points out that preventive maintenance is often neglected, affecting process continuity, and thus compromising product quality due to drops and fluctuations in operating temperature. These breakdowns tend to be frequent and longer, thus affecting production targets. Start-up failures are also experienced after carrying out maintenance. The maintenance department is affected by the unpredictability of the equipments operational patterns, and faces challenges in coming up with an effective spare part inventory management regime. This leads to crisis management, thereby increasing the direct cost of maintenance. RCM is used to create a cost-effective preventive maintenance strategy to address the dominant causes of equipment failure. The result is a maintenance programme that focuses scarce economic resources on those items that would cause the most disruption if they were to fail, and thereby increases production.
AFRIKAANSE OPSOMMING: Industrie produktiwiteit word ten nouste bevloed deur uitnemende betroubaarheid en beskikbaarheid van aanlegtoerusting en vervaardigingstelsels. Hierdie navorsing is toegespits op die bestuur van voorkomende instandhouding (VI) met betroubaarheidsgedrewe instandhouding (BGI) by n ferrochroomaanleg. Klem word daarop geldat VI dikwels genoreer word wat daartoe lei dat produkgehalte verswak. Soos produksieonderbrekings toeneem, word vervaardigingsdoelwitte nie bereik nie vir verskeie redes. Die onderneming se instandhoudingsafdeling is gevolglik nie daartoe instaat om instandhouding doelmatig te verrig nie. Instandhoudingskoste neem ook toe.
BGI voorsien n koste-effektiewe instandhoudingstrategie wat fokus op mislukkingsbelangrikheid waar fondse bestee moet word vir optimum aanlegbeskikbaarheid.
CONCLUSIONThe RCM is learned by applying to specific system and during the work several difficulties are discovered. As a solution to these problems there are suggested to use methods such as Concurrent Design and project scheduling. The first achievement of this thesis is using Concurrent Design method to organize RCM analysis process. It has been designed a special session room for RCM analysis process. The session room is organized in such a way to make the analysis process more fast and comfortable. It can be conclude that the Concurrent RCM analysis method can increase effectiveness of RCM application than normal method. Several problems can be solved by carrying it in Concurrent analysis way: 1. Communication between RCM Analysis Members much easer 2. Time can be saved3. Quality of FMECA can be increased4. Great working atmosphere for team work5. Gathering in the same session all relevant engineers or specialistsSecond achievement is using project scheduling methods from Project Management Course to organize maintenance tasks in a such way to reduce delay risk of the tasks. All maintenance tasks are located on Network Diagram and after carefully analysis it can be conclude that using this method to manage maintenance tasks can help to meet required performance standard:1. Equipment with higher criticality can be located in the beginning of the diagram and can be maintained with lower risk of delay.2. Workloads of different maintenance groups can be seen from the diagram and can be early seen how many of workloads has each group3. Slack times can be defined4. Conditional tasks can be scheduled on that slack hours All tasks are locted in the Network Diagram according to their resourse, predecessor and criticality parameters and it can be changed and reanalyzed again and again until get desired maintenance schedule.