24th International Conference on Production Research (ICPR 2017)

ISBN: 978-1-60595-507-0

RELIABILITY CENTERED MAINTENANCE FRAMEWORK FOR MANUFACTURING AND

SERVICE COMPANY: FUNCTIONAL ORIENTED

Gania I.P.1, Fertsch M.K.2, Jayathilaka K.R.K.3

Department of Production Management and Logistics, Faculty of Engineering Management,
Poznan University of Technology, ul. Strzelecka 11,60-965 Poznan, Poland

Abstract
Maintenance methodologies are vary due to complexity of the system. There are many ways to approach final
goal in any philosophy by using processes, paths, methodologies and procedure. Reliability centered
maintenance (RCM) is a method that used to ascertain the maintain requirement of any elemental assets in its
operating context. RCM mainly identifies function of a systems, physical assets and equipment which could be
critically fail in operations and RCM uses to optimize their maintenance strategies. This paper focus to present
RCM II methodologies and framework to introduce for manufacturing and service company in functional
oriented context. Through the proposal, company motivated to increase profit over the production and
availability of system continuously. RCM II enables maintenance actions on the basis of evidence and it
reduces failure rate of equipment and unnecessary involvement of maintenance staff. The company doesn’t
use any maintenance strategies. This paper proposes RCM concept for use in general industry specific in
manufacturing and service. Introduced preventive maintenance strategy supposed to collect data by manual
format, the collected data should be used to evaluate machine health, condition and other relevant
information. Collected data forwarded to decision making upon the maintenance strategy.
This Paper demonstrate how successfully maintained program carried out with customized methodology in
manufacturing industry arena. Successfulness of program supported to deliver company common goal.

Keywords:
Reliability centered maintenance (RCM), Maintenance, Function, Industry, FME/CA, Preventive Maintenance

1 INTRODUCTION based maintenance (Continuous monitoring and Periodic

The chosen company is a one of the main fabric structure inspection). Corrective maintenance categorized in to
and tent manufacturing company in Europe and is active Planned corrective and unplanned corrective (primary
more than 20 countries over the Europe and Arabic failures, Maintenance induced failures) [3].
continent. Company dedicated to deliver integrating RCM concept is quite simple, and might be characterized
engineering, production & installation under one roof, and as organized engineering common sense. These
its contain significant number of technical systems to methodologies have four unique features: [1]
achieve common business goals. Maintenance is one of • Preserve functions
the main subject to achieve these goals. Certainly, proper
• Identify failure modes that can defeat the
maintenance does not only help to keep the life cycle cost
functions.
down; it also contributes positively to the overall
performance of the company. However, maintenance also • Prioritize function need (via the failure modes).
contributes significantly to the total cost, and this often • Select only applicable and effective Preventive
forms the basis of performance improvement of company Maintenance tasks.
[7]. RCM a process used to determine what must be done The RCM process entails asking seven basic questions
to ensure that any physical asset continues to do whatever about the Function, asset or system under review, as
is users want it do in its present operating context. That follows [5]:
approach arose in the late 1960s and early 1970s when
the increasing complexity of systems (and consequent • What are the function and associated
increasing size of the preventive maintenance task) forced performance standards of thee asset in its
a rethink of maintenance policies among manufacturers present operating context?
and operators of large passenger aircraft [3]. Other • In what ways dose it fail to fulfill its functions?
extension of RCM described by Anderson and Neri , Smith • What causes each functional failure?
and Moubray. RCM II concept of Moubray, specially
designed to use in general industry which are Analysis of • What happens when each failure occurs?
gathered information, define primary and secondary • In that way dose each failure matter?
functions, possible functional failure etc. [7]. • What can be done to predict or prevent each
RCM mainly focus on functions of the system and main failure?
objectives of RCM is to minimize maintenance cost and  What should be done if a suitable proactive task
increase reliability and safety of regarded system. A cannot be found?
maintenance concept can be defined as the set of various
maintenance interventions (corrective, preventive, Reliability centered maintenance uses many tools and
condition based, etc.) [7]. Generally, in industry arena methods, such as Failure Mode Effects Analysis (FMEA) is
companies are using preventive maintenance strategies or the most effective low-risk tools to minimize possible
schedule based maintenance strategy. Maintenance can failure and identification of more efficacious solutions.
be divide in to three categories such as Preventive FMECA has technique to identification of failure in each
maintenance, corrective maintenance and First-line component, its causes and consequences on the process
equipment as well as on the whole system. The FMECA
maintenance. Preventive maintenance could be analysis is carried out by studying a survey of the
categorized in to two, Time-based maintenances
(Calendar-based and Operational time-based), Condition

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functions of each part, failure mode of the part, and its properly and mean while air compression presses the air
effect [6]. in to both outer parts of the PVC roof and it get in to dry
The selected RCM implementation program considered as position.
a functional oriented. it focusses preserve system or 3 OBJECTIVE
equipment functions while analyzing step on the The main objective of this proposal, RCM framework is to
framework where customized according to chosen introduce preventive maintenance strategy in chosen
requirements [6]. RCM II concept is customized company. Currently company does not exist any
maintenance concept based on reliable principle and this maintenance methodologies to prevent the failure of
research paper proposal intend to implement maintenance machine or equipment’s. After introducing maintenance
program effectively in chosen company and concept strategy company motivates to improve their maintenance
drawers are practically involving during the implementation strategy as tune-up utilities. Customized RCM analysis can
process until company get in to success stage. be provided suitable optimum maintenance strategies
where need in proper time to schedule and perform
2 EQUIPMENTS maintenance action before the failure appear.
These methodologies will be providing accurate and
optimum information in order to get correct decision for the
company staff. The company is willing to achieve following
main objectives with introduced proposal.
• Introduce maintenance department in to
organization. (depend of utility
availability of the company)
• Increase availability of Equipment and
function 80% to 100%
(a) Tarpaulin W 1 Machine • Increase productivity up to 50 item per
day
• Reduce maintenance cost up to 50%

4 FRAMEWORK AND METHODOLOGY

The one author used to work on the chosen company and
observed current maintenance procedure and
methodologies what company dose use. The proposal
(b) HF welder Fiab 900 (c) Gerber cutter DCS 3500
methodology has been drawn after qualitative and
Figure 1. Available Machineries in Company. quantitative observation of company profile. The company
uses unstructured, unorganized, undocumented
PVC Tarpaulin is a main part of the fabric structure and methodologies for maintenance activity. The proposal
tent. each structure different from other. Company own model use to approach successful customized RCM
small to large size of structure depend on customer framework included seven steps fruitfully adapted to
requirement. Generally, company renting and selling fabric company profile. The framework developed with
structures, although renting usage is more popular in the information worksheets, decision diagram and decision
industry. PVC tarpaulin, it must be washed properly and worksheets. This methodology addresses the whole
upon, this reason company has made their own machine system, and structure evaluates and examine each
for cleaning for large PVC tarpaulin. the machine is unique machine located in company. Functional failure of primary
and it called Tarpaulin W1(Figure: 1 (a)). Company own and secondary function recorded in to information
different type of machine such as HF welder fiab 900, worksheets. Based on this worksheet failure and effect of
Gerber cutter DSC 350, Electronic saw, drilling machine, failure can be determined. Decision diagram use to
cutting machine, lathe machine, etc. integrate all the decisions and decision process bring in to
PVC tarpaulin wash and reuse is one of the most single strategic framework. These diagrams and
important part of the company production process. once information worksheets data record in decision worksheet.
fabric structure is installed most eye touching part is PVC Ex: what maintenance routing need to be done, how
tarpaulin due to visibility and white color. frequently need to do, who will be doing, which failure
frequently happen etc.
Tarpaulin W1 machine is obtain following characteristics.
Length 6.5m, weight 2.7m, height 4.5m and power Critical equipment can be identity by manual observation
consumption is 380 V and up to 44 A. main component and monitoring. Staff can be collect the data by daily basis
such as 2 water tanks (2.7m *1m). main winding rod, 2 and this method is quite had to do and prediction of failure
roller brushers, 2 inches’ water pumps, one main motor, 4 cannot be determine. Although initiation of proper
air compressed motors, 2 air compressed bars, control maintenance process can be done in the company with
panel, gear wheels and chains, drive wheels, roller tiny steps. Get in to practice new methodology directly
bearing, Plummer block bearings, bolt nuts, frame connected with change management procedure therefore
structure etc. this machine used to wash heavy-duty water initiation of proposal maintenance program will be
proof PVC cloths. First machine is winding up PVC roof in executed step by step in to organizational culture.
to winding rod then it bringing in to center of the machine Proposed maintenance plan:
and flowing down to water tank to get wet, here after main 1: Classification of equipment’s.
motor getting start and winding rod is winding PVC roof in
to up, while coming through the roller brushers and next 2: RCM process framework with seven steps.
level soap water, spraying and PVC roof getting wash 3: RCM strategy.

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 Figure 3. RCM Framework.

5 PREVENTIVE MAINTENANCE INTRODUCTION TO

COMPANY
5.1 Pace I - Classification of equipment
According to company requirements, all the equipment’s
needed to classify in appropriate way. two methods can be
used to classify equipment such as criticality analysis
(Figure 2) and question based selection method. In the
criticality analysis, equipment can be divide in to two which
are critical equipment and no critical equipment. If the
equipment categorized as critical, the maintenance
procedure would be preventive or predictive whether
necessity of company. where non-critical equipment base
on non-critical category, company would select reactive Figure 2. Classification of Equipment.
maintenance program which is equipment run to fail.
Re usable PVC Roof cleaning process is not one of the
important process of the company, also it brings direct
impact in to company. The PVC roof visible quality needed In the process of PVC roof cleaning, the critical component
to be in acceptable standard because its directly eye can be nominated as roller brushes and winding rod in
touching contact feature of the business and it potentially tarpaulin W1 machine. In washing and drying process are
generate repeated sales. Upon these reason tarpaulin W1 go through in between two roller brushers and two air
machine is plays vital roles to full fill all requirement of compressors. Another most important and critical function
finishing process of fabric structure. of tarpaulin W1 is water circulation form in spray mode.
Chemical mixed water spray in to the PVC roof in both
sides and its maximum efficiency of tarpaulin W1. The
chemical mixed water support to remove dirtiness of PVC
roof. Compressed air removes wetness of the PVC roof
and improve quality of materials.

5.2 Pace II -RCM framework program

Reliability centered maintenance program (Figure:3) can
be denoted in to three stages (Decision, Analysis and act),
customized RCM framework seven steps and within these
stages it can ensure RCM program successfully can be
implemented.

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Decision stage:
1) Preparation and selection by analysis.
In this step company dose select component /equipment
and function of the system. Moreover, company can
collect the data related to operation and maintain.
Supplementary project leader can be outline
organizational goals budget and timeline potential
obstacles where can be appear.
2) Define system boundaries.
Identify potential important function is this step mainly
considering, precisely what equipment needed to include
in to program and what equipment not needed to include.
All interface identification and this boundary determine all Figure 6. RCM Decision worksheet. [2]
the input, output and function of the system. Y= Yes, O= operational consequences, N= No, N=Non-
3) Identify important functionality. operational consequences=Failure, H1/S1/O1/N1 =On
Defining equipment’s functionality full of list including all condition Task, FF=Functional failure, H2/S2/O2/N2
data and information’s. History of functions, list of =Scheduled restoration Task, FM= Failure Mode
equipment of functions, interfaces of functions etc. H3/S3/O3/N3 =Discard Task, H=Hidden operational
consequences, H4=Default action, S=safety
consequences, H5= Default action, E=Environmental
Analyzing stage: consequences, S4=Default action.
4) Identification of functional failure
Functional failure is lack of ability of asset or function
doesn’t meet expected structured performance. In this
step function and functional failures are listed in
information worksheet (Figure:4) this modes, causes are
directly linking to the failure mode effect analysis. Failure
can be determined poor performance, over performance,
unnecessary of performance or complete failure.

Figure 5. RCM Decision Diagram[4].

Figure 4. RCM Information worksheet. Action stage:

7) Selection of maintenance Tasks
5) Evolution and identification effects on failures. This selection identity which is the most suitable
The step clarify, what consequence happens when failure maintenance program for the company and its based on
happens. Incident observation and what kind of impact can failure mode information. The company need to select
be occurring in production and safety impact assessment their maintenance methodology based on their suitable
of incident. orientation with dependence on decision diagram.
6) Identify failure mode Proactive task represents preventive and predictive
maintenance technique, it based on calendar or usage
After identifying functional failure and equipment failure. base and it helps to reduce risk of failure. Preventive
That must be consider failure modes. In order to identify maintenance can be identity failure before it begins.
failure mode, that can be used failure modes effects and Reactive maintenance is after failure occur.
critically analysis (FMECA). to achieve this mode, we use
decision diagram (Figure:5) decision diagram can be
integrate all in to one strategic framework. With this both 5.3 Pace III-RCM strategy
information worksheet and decision diagram it can be
record in decision worksheet (Figure:6), what kind of The importance of Tarpaulin W1 machine, unscheduled
routing maintenance need to apply, what time duration breakdown at critical component such as roller brushes
need to concern, who will be the responsible, which failure winding rolls water circulation motors directly effect on
is more serious which section frequently occur, which production and their quality. Any of above critical
cause can effect on failure, etc. component inability of performance may cause poor
quality of the products. Preventive maintenance would be
recommended for some of critical equipment and non-
critical equipment/function would be recommended
reactive maintenance.

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6 CONCLUSION 8 REFERENCES
Customized maintenance concept getting popular day by
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7 ACKNOWLEDGMENTS
The support, valuable guidance and facilitation from the
company management specially from Mr. Pierre des
Cressonnières, towards this research study proposal is
hereby acknowledged.

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