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การประชุมวิชาการดานการวิจัยดําเนินงานแหงชาติ ประจําป 2554
วันที่
8-9 กันยายน 2554 ณ โรงแรม เอส ดี อเวนิว กรุงเทพฯ
Applications of Reliability Centered Maintenance for Reducing Downtime in a Paper Plant
Prachuab Klomjit 1 and Pichet Kaewsaithom 2
1, 2
Department of Industrial Engineering and Management, Faculty of Engineering and Industrial Technology,
Silpakorn University, Muang, Nakorn Phathom 73000
Telephone/Fax: 034-219-362, E-mail: 1 prachuab@su.ac.th, 2 pichetkaew@hotmail.com
Abstract
The objectives of this study are to reduce downtime that
cause from machine breakdown during operation and to select the
preventive maintenance task categories based on the Reliability
Centered Maintenance (RCM) for the machine components. The study
starts from identify the critical machine or equipment that impact to the
paper production and then analyze the root cause & failure analysis by
using Failure Mode and Effect Analysis (FMEA). The next step is to
simulate the failure patterns of component parts which are used
statistics data in order to forecast the suitable reliability parameters. The
final phase is to select the preventive maintenance task which is
meeting the reliability parameter of each failure mode. The result of this
study has shown that the downtime is decreasing per machine downtime
rate at 5.68% for machine MC1, 10.04% for MC2 and MC3 is 4.94%.
Moreover the machine availability has been increased, machine MC1
increased 80.20%, MC2 increased 80.02% and MC3 increased 81.00%
accordingly.
Keywords: Reliability Centered Maintenance, Failure Mode and Effect
Analysis, Paper production.
1. Introduction
As many modern maintenance practices, the reliability
centered maintenance (RCM) concept originated within the aircraft
industry. RCM has now been applied with considerable success for
more than 20 years; first within the aircraft industry, and later
within the military forces, the nuclear power industry, the offshore
oil and gas industry, and many other industries. Experiences from
these industries show significant reductions in preventive
maintenance (PM) costs while maintaining, or even improving, the
availability of the systems.
The main objective of RCM is to reduce the maintenance
cost, by focusing on the most important functions of the system, and
avoiding or removing maintenance actions that are not strictly
necessary. If a maintenance program already exists, the result of an
RCM analysis will often be to eliminate inefficient PM tasks [1].
This paper illustrated the operation of paper plant a poor
maintenance tasks and high rate of machine downtime. These problems
root from:
1. Machine has been serviced for a long time with
ineffectively maintenance.
2. Operator; due to high rate of turn over the new person has
no experience to operate the machine.
3. Ineffective management; lack of maintenance standard
and work instruction that is machine manual, maintenance guide etc.
In addition, it may come from the lack of understanding
importance maintenance and there is no data as a reference. From above
reasons lead to machine maintenance unreliability.
Applications of RCM such monitoring, assess, predict and
understand the working of the machine can be helped to reduce machine
breakdown and improve the maintenance plan. More importantly it will
define the appropriate maintenance for each machine such as preventive
Maintenance for machine that have constant failure rate and Predictive
Maintenance or Condition Based Monitoring for machine that critical
process [2].
2. Objectives of this study
2.1 To reduce the production downtime from machine
breakdown.
2.2 To define the appropriate maintenance task based on
RCM to the machine parts per their function and operation for paper
plant.
3. Reliability Centered Maintenance (RCM) approach
RCM is a structured methodology for determining the
maintenance requirement of a physical asset in its operating context.
The asset can be part of a larger system. The primary objective of RCM