Machine Maintenance Scheduling Design Using Reability Centered Maintenance (RCM) method and Maintenance Value Stream Mapping (MVSM) at XYZ

Question

1. What methods are used in this research?

2. What is the purpose of FMEA in machine maintenance?

3. What is Logic Tree Analysis (LTA) used for?

4. What are the types of actions in the action selection stage?

Accepted Answer

The research utilizes reliability centered maintenance (RCM) and maintenance value stream mapping (MVSM) methods. RCM involves data processing techniques such as flowcharts, Pareto diagrams, mean time to failure (MTTF), failure mode and effects analysis (FMEA), and likelihood-to-action (LTA). MVSM is used to analyze the maintenance value stream of the production floor. Both methods are applied to the data obtained from XYZ, which includes information on damage to various machines in 2021. The research aims to understand the relationships between parts and phenomena on the production floor, specifically in the production of white bread, sweet bread, and dry sugar bread at XYZ located in Jl.Plam Griya Indah Desert Lawas, Padang.

Accepted Answer

FMEA, or Failure Mode and Effects Analysis, is a method used to evaluate system design by considering the various failure modes of the system consisting of components and analyzing their effects on the reliability of the system. It aims to identify potential failure modes, their causes, and their effects on the system. By calculating the Risk Priority Number (RPN), which is the mathematical product of the seriousness of the effect (severity), the likelihood that a cause will result in a failure related to the effect (occurrence), and the ability to detect failures before they occur (detection), FMEA helps prioritize components that require corrective action. This ensures that critical components are addressed first, improving the overall reliability and efficiency of the machine maintenance process.

Accepted Answer

Logic Tree Analysis (LTA) is used to prioritize each damage mode in a system. It involves a simple logical question or decision structure categorized into four categories, with each question answered as 'Yes' or 'No'. The important aspects of criticality analysis include evidentness, safety, outage, and categorization. In this section, components are divided into four categories based on these criteria. LTA helps in critically analyzing the possibilities that can occur in the system, ensuring a comprehensive understanding of potential failure modes and their consequences.

Accepted Answer

In the action selection stage, there are three types of actions: Condition Directed (CD), Time Directed (TD), and Finding Failure (FF). Condition Directed actions involve detecting damage through visual inspection, tool inspection, and monitoring existing data. If damage is detected, repair or replacement of components is carried out. Time Directed actions aim to prevent damage based on the component's age or time. Finding Failure actions involve periodic inspections to discover hidden equipment damage. Additionally, the Run to Failure approach involves using a component until it is completely damaged without taking preventive actions. These actions are determined through FMEA and LTA, considering the frequency of damage and economic impact on the company.

Accepted Answer

The Value Stream Mapping (MVSM) method involves the following steps: 1) Identification of other processes and flows: This step involves identifying the bread production process and the flow of the bread-making process, including the oven. 2) Time scale: Calculate the time required for each process and activity in the bread-making process, including the time required for the oven. 3) Identification of wasted time: Identify unproductive bread production time, including time lost due to damage to the oven. 4) Identification of Corrective Actions: Identify actions that can be taken to reduce unproductive time and increase the efficiency of bread production, such as servicing the oven regularly. 5) Implementation and Monitor: Implement corrective actions and monitor results, including monitoring the performance of the oven and ensuring bread production continues to run efficiently and optimally. Additionally, it is recommended to carry out maintenance outside operating hours to reduce wasted time.

Accepted Answer

The RPN value of the oven in the FMEA analysis is 6.25. This value indicates the priority of the oven component, with a higher RPN value representing a higher risk. In the case of the XYZ machine, the oven has a function to bake dough with a safety occurrence rate of 5, an occurrence rate of 25%, and a detection deficiency level of 5. These factors contribute to the oven's low risk, resulting in an RPN value of 6.25. Based on this value, it is evident that the oven requires corrective action, such as replacing spare parts, to ensure the smooth production of XYZ.

Accepted Answer

In LTA analysis, malfunctions are caused by damage to components. The cause of damage can be due to various factors such as wear and tear, improper maintenance, or external factors. The effects of this malfunction include disruptions in the normal functioning of the system, potential safety hazards, and outages that can impact operational plans, product quality, and increase costs. Identifying the specific cause of damage is crucial for implementing effective maintenance actions and preventing future malfunctions.

Accepted Answer

The average operating time between failures for breadline machines is approximately 1460 hours. This data is derived from the reliability analysis (MTTF) of each engine component, considering a total daily use of 8 hours and one year of engine operation time. The analysis indicates that breadline machines experience an average of 1460 hours between 2 failures. This information is crucial for researchers and engineers to understand the reliability and maintenance requirements of breadline machines in industrial settings. By knowing the average operating time between failures, they can plan preventive maintenance schedules, optimize machine performance, and minimize downtime, ultimately improving productivity and efficiency in food processing operations.

Accepted Answer

The average operating time between faults for XYZ Bakery machines varies. The oven has an average operating time of around 584 hours between 5 faults, the breadslicer machine has an average time of around 1460 hours between 2 faults, the proofer machine has an average time of around 1460 hours between 2 failures, breadline machines have an average time of about 1460 hours between 2 failures, vacuum sealer machines have an average time of about 2920 hours between 1 failure, and depositor machines have an average time of 2920 hours between 1 failure. These figures highlight the importance of proper machine maintenance scheduling for optimal performance and reduced downtime.

Machine Maintenance Scheduling Design Using Reability Centered Maintenance (RCM) method and Maintenance Value Stream Mapping (MVSM) at XYZ

Chat with Paper

AI Agents for this Paper

Most frequently asked questions

1. What methods are used in this research?

2. What is the purpose of FMEA in machine maintenance?

3. What is Logic Tree Analysis (LTA) used for?

4. What are the types of actions in the action selection stage?

5. What steps are involved in Value Stream Mapping (MVSM) method?

6. What is the RPN value of the oven in the FMEA analysis?

7. What causes malfunction in LTA analysis?

8. What is the average operating time between failures for breadline machines?

9. What is the average operating time between faults for XYZ Bakery machines?

References

Design of preventive maintenance system at PT. Y with reliability engineering approach

Application of reliability engineering method in machine maintenance

Reliability analysis of systems with discrete event data using association rules

Related Papers (5)

Preventive Maintenance Policies for Equipment Under Condition Monitoring Based on Two Types of Failure Rate

Preventive maintenance policy for life-type equipment

A New Analytic Method of Multistate Single-component System Reliability Model

Optimal Periods of Conducting Preventive Maintenance to Reduce Expected Downtime and Its Impact on Improving Reliability

Control strategy on preventive maintenance of repairable device