Document Type : Original Article

Authors

Department of Mechanical Engineering, Obafemi Awolowo University, Ile-Ife, Nigeria.

10.22116/jiems.2020.227003.1355

Abstract

Equipment breakdown adds to the cost of production and considerably affect the overall equipment efficiency in automated lines due to unplanned downtime. Preventive maintenance with appropriate actions has been considered to enhance products quality, equipment reliability and minimize the probability of system brake down or failure. To this end, this study conducted a reliability status of nine packaging facilities, from the perspective of existing failure data of production system in the Nigerian multinational bottling plant. Failure data of the production system were stratified and analyzed to achieve the failure interval of each of the facilities and the sub-systems. Stratification of failure data resulted to an established input format that fitted the Pareto chart analysis, Weibull Distributions and Reliability/Failure Time analysis.  The results showed that the facility with minimum value of reliability was filler machine. A standby filler system was therefore recommended in order to prevent unnecessary idleness of the other facilities especially when the production target is high.  The study concluded that, analysis of downtime in a production/manufacturing system assisted in predicting the likely failure interval and hence a preventive maintenance scheduled was proposed.

Keywords

Ab-Samat, H., Jeikumar, L. N., Basri, E. I., Harun, N. A., and Kamaruddin S., (2012). "Effective preventive maintenance scheduling: a case study", In: Proceedings of the 2012 International Conference on Industrial Engineering and Operation Management, Istanbul, Turkey, pp. 1249-1257.
Adik, P., and Bobade, S., (2018). "Analysis of losses due to breakdown of equipment in construction", International Research Journal of Engineering and Technology (IRJET), Vol. 5, No. 6, pp.1831-1836.
Battini D., Manzini, R., Persona, A., and Regattieri, A., (2006). TPM approach and new buffer design paradigm in plant layout, Chicago.
Bose, D., Ghosh, G., Mandal, K., Sau, S.P., and Kunar, S., "Measurement & evaluation of reliability, availability & maintainability of a diesel locomotive engine", International Journal of Scientific and Research Publications, Vol. 3, No. 9.
Dhillon, B. S., and Liu, Y., (2006). "Human error in maintenance", Journal of Quality in Maintenance Engineering, Vol. 12, pp. 21-36.
Dibyojyoti, D., and Thuleswar, N., (2015). "Breakdown and Reliability Analysis in a Process Industry", International Journal of Engineering Trends and Technology (IJETT),Vol. 28, No. 3.
Dodson, B., (1994). Weibull and reliability time analysis,ISBN-10 087389295X. ISBN- 13.978-0873892957.Best Sellers Rank 659410.
Fadeyi, J. A., Oguoma, O. N., and Ogbonnaya, E. A., (2013). "Sanitary towel production plant optimization using reliability model", Nigerian Journal of Technology, Vol. 32, pp. 101-108.
Gupta, Amit K., Garg, R. K., (2012). "OEE improvement by TPM implementation: A case study", International journal of it, Engineering and Applied Sciences Research (IJIEASR), Vol. 1, No.1.
Raju J. B., Govinda, R. M., Govinda, C. H., and Murthy, S. N., (2018). Reliability analysis and failure rate evaluation of load haul dump machines using Weibull distribution, Dept, of Mining Engineering, NITK surathkal 575025, India. 24th June 2018
Senra P., Lopes I., and Oliveira, J. A., (2017). "Supporting maintenance scheduling: a case study", 27th international conference of flexible automation and intelligent manufacturing, FAIM 2017, 27-30 June, 2017, Modena, Italy. Procedia Manufacturing, Vol. 11, pp. 2123-2130.
Shagluf, A., Longstaff, A. P., and Fletcher S., (2014). "Maintenance strategies to reduce downtime due to machine Positional errors", In: Maintenance Performance Measurement and Management Conference Coimbra, Portugal.
Tejas, and Uday (2017). Machine operational availability improvement by implementing effective preventive maintenance strategies, Department of Mechanical Engineering, Walchand College of Engineering, Sangli, Maharashtra, India - 416415.
Lai, C.D., Murthy, and D. Xie, M., (2006). Weibull Distributions and Their Applications. Springer Handbook of Engineering Statistics VL, Chapter 3.
Mirzai, M., Gholami, A., Aminifar, F., (2006). "Failure Analysis and Reliability calculation for power transformers", Journal of Electrical Systems.
Nicolas, and Rosemary (2006). SPSS for Psychologist: A guide to data analysis using SPSS,third edition.
Nwadinobi, C. P., and Ezeaku, I. I., (2018). "Review of maintenance scheduling and optimization models", International Journal of Scientific Research in Mechanical and Material Engineering, Vol. 2, No. 5, pp. 23-35.
Piqueras, R., and Fernandez-Crehuet (2020). "Data analysis for the preventive maintenance of machinery", Studies in Engineering and Technology, Vol. 7, No. 1, pp 1-8.
Prombanpong, S., Kaewyu, J., Thanadulthaveedech, N., andMatwangsang, M., (2013). "A buffer design for mitigationdowntime effect in an automated transfer line", International Journal of Innovation, Management and Technology, Vol. 4, No. 155.
Wakjira, Melesse, W., Singh, A.P., (2012). "Total productive maintenance: A case study in manufacturing industry", Global Journal of Researches in Industrial Engineering,Vol. 12, No. 1.
Yang, Z., Djurdjanovic, D., and Ni, J., (2008). "Maintenance scheduling in manufacturing system based on predicted machine degradation", Journal of Intelligent Manufacturing, Vol. 19, pp. 87-98.