EG 5220: Assessment 3

A. A dataset with records of downtime for 8 major machinery in an Industrial Facility for over 2 years
is provided. Details of the fields are as follows.
Field Description Remarks
Start Time Start time of interruption
End Time End time of interruption
Duration(Hours) Duration of interruption
Machine Centre APM – Anode Preparation Machine 1. There are two Cathode Stripping
APS – Anode Preparation Station Machines, located at East and West End
ASM – Anode Scrap (Washing) Machine of the Electro Refinery Building
ECSM – East Cathode Stripping Machine 2. There are two cranes, located at North
WCSM – West Cathode Stripping Machine and South end of the building
HLW 1& 2 – High Lift Wagon 1&2 3. The High Lift Wagons 1 & 2 are
N Crane – North Crane considered as one machinery centre
S Crane – South Crane
Event Type Downtime Limit analysis to Event Type – Downtime
Slowdown
Reason Causes of downtime The causes are machine specific
Time Usage Category of downtime classification Limit Analysis to the following -
Code Operational Breakdown
Electrical Breakdown
Human Error
Mechanical Breakdown
Power / Water / Air Failure
Test / Check / Adjust
Mechanical Planned
Electrical Planned.
Comment Detail on downtime cause This field is manual entry and hence data is
not 100% structured.
Notes:
a. Apply limits of analysis on Event Type and Time Usage Code as given in table above
b. Limit word count of explanations (where required) to 250 words

A1. Rank the Machine Centres in decreasing order of downtime duration. Trend individual machine
downtime history on a monthly basis for entire duration (10% + 5%)

Answer:

RANKING THE MACHINE CENTRES IN DECREASING ORDER : -

Sum of Duration Rank in Decreasing

Row Labels (Hours) Order
APM 12060.61 1
ASM 11958.67944 2
S Crane 11572.87028 3
WCSM 11340.26306 4
ECSM 11047.59056 5
HLW 1 & 2 10921.65333 6
N Crane 10827.85139 7
APS 10803.0425 8
 EG 5220: Assessment 3

Downtime Trend of Machine Month Wise. We can see spikes in the month on October.

1600

1400

1200 JAN
FEB
MAR
1000
APR
MAY
800 JUN
JUL
AUG
600 SEP
OCT
NOV
400 DEC

200

0
APM APS ASM ECSM HLW 1 & 2 N Crane S Crane WCSM

A2. For the top three machine centres (from answer 1), generate two PARETO charts for each
machine. (20%)
The PARETO charts shall be
1. Cause of downtime vs. downtime events
2. Cause of downtime vs. downtime duration.
 EG 5220: Assessment 3

2. Cause of downtime vs. downtime duration

A3. For the most affected machine centre identified in Answer 1, analyse the causes of downtime
from information available in the fields “Reason” and “Comments”. Explain your findings. (10% +
5%)

ANSWER: The most affected machine is APM Machine Centre. Upon observation, we find that
manual operation, product misalignment, fallen product etc. are major contributors to downtime
apart from schedule being complete. If machine center focuses on work discipline, i.e. timely
housekeeping, products alignment / store, electric supply etc, the downtime can be drastically
brought down.

A4. Generate two parameter Weibull Model for the three machine centres with highest downtime
 EG 5220: Assessment 3

duration. Explain relative Reliability performance (15% + 5%)

B. Details of sub-systems for a bicycle are given below.

Notes:
a. Limit word count of explanations (where required) to 250 words
b. RPN tables from content of Week 4 may be used

B1. Use the RCM process to develop an FMEA sheet for the bicycle, rank the criticality using
RPN and develop a list of recommended actions with frequencies. Explain your findings (20%).

B2. Develop Fault Tree for the scenario of bicycle fails to stop upon applying brake (10%)

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