Seminar II – Maintenance and

Reliability in Manufacturing

By Kshitij Shete
Outline slide

• Maintenance in manufacturing industries

• Different Maintenance Strategies
• Reliability
• Importance of Reliability
• Methods to evaluate and improve reliability
• Conclusion
• References

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Maintenance in manufacturing Industries

• Maintenance is the act of maintaining and improving the quality of

the components in a production system by detecting and controlling
the deviations from ideal operating conditions for the given system.
• The Mean Time Between Failure (MTBF) is the arithmetic mean
(average) of the amount of time between the restoration of the
system and immediate system failure of a machine under a given
time of study.
• The Mean Time to Repair (MTTR) is the arithmetic mean (average)
of the amount of time it takes to restore the system (repair of the
system) back to operating state under the time of study.
• MTBF and MTTR data for a system can be used in a number of
ways to improve the reliability of the system.

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Different Maintenance Strategies

• Preventive Maintenance
– Fixed Time or Scheduled maintenance is performed at set
time intervals or duty cycles.

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Different Maintenance Strategies

– Condition-based Maintenance also known as pro-active

maintenance entails the full integration of Inspection, on-line
monitoring is required without ceasing.

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Different Maintenance Strategies

– Routine Asset Care Maintenance is decided if the capacity

drops suddenly again after CBM which will be done at
specific time intervals.

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Different Maintenance Strategies

Run to failure maintenance is often described as part of unplanned

maintenance only performed when the machinery has failed. This might be
true in some cases but run to failure maintenance is not just that, it can also
be a part of planned/predictive maintenance.

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Costs and Benefits of different
Maintenance Strategies

Maintenance Strategy Benefits Costs

Fixed Time/Scheduled Reduced excessive breakdowns Planned with production budget

since issues are known

Condition Based Maintenance done when needed Requires effective use of

information by inspections,
Upfront cost

Routine Asset Care Premature work Minimized due to premature

work
Run to Failure Immediate replacement if Cost Effective since it has been
planned, Part prioritized compared with early
replacement and other forms of
maintenance.

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Reliability

• Reliability engineering is a tool used to define the probability that

a unit component or system will perform its intended function
uninterruptedly, under a specified operational working condition
over a given period of time, (Okpala and Kotingo, 2008).
• The study of the reliability of various units in production industry
will yield a high level of machine performance with consistency,
and it is important to study the variation of reliability with respect
to time, (Deepika and Kuldeep, 2009).
• With a growing competitive market, there is the need to cut down
cost of production, (Khan and Darrab, 2010)

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Importance of Reliability

• Cement manufacturing is a volume-based production process which is

highly machine intensive. The financial cost of downtime can be very
significant, especially in manufacturing industries. The availability of
any plant depends on measures such as reliability and maintainability.
• Reliability assessment for mechanical equipment is important in
condition-based maintenance to lower cost and improve equipment
reliability.
• There are different methods available to assess reliability. Weibull
method is one of the advanced methods to assess the equipment
reliability. Also, Failure mode of effective analysis (FMEA) is
performed to understand the likelihood of the failure of the equipment.

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Methods to evaluate
and improve reliability

• Pareto Analysis
Pareto Chart - Equipment
50%
45%
40%
35%
Downtime hours %

30%
25%
20%
15%
10%
5%
0%
Equipment

Mill motors Mill bearings Mill drivers

Feeders Screw conveyer Kiln coolers

• From the graphs above it can be identified that the Mill motors and Mill bearings are the
Critical equipment for the given system since most amount of downtime is caused by this
two equipment.

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Weibull Method

• It is always useful to determine which distribution best fits any

given set of data, so that the distribution parameters can be
estimated.
• Weibull distribution is one of the most common probability
density functions used in the industry. Weibull distribution can
be applied to large number of situations.
• The main advantage of using this distribution is its ability to
handle small samples of failure data and its flexibility in fitting
different failure modes.
• Small samples are common in reliability testing where tests are
often destructive in nature and require costly resources,

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Failure Mode and Effective Analysis

• Failure Mode and Effective Analysis (FMEA) helps organizations in predicting and
thereby reducing or preventing failure or breakdown problems of many machines.
Failure modes are the ways in which a process can fail and Effects Analysis is done to
identify and reduce these failure modes. FMEA can be performed by following the
steps given below:
1. Reviewing the processes and machines involved.
2. Team members brainstorming for the potential failure modes of machine and effects.
3. Identify possible cause of failure and assign severity, occurrence, and detection
criteria.
4. Evaluating the Risk Priority Number (RPN)
5. Selecting the preventive actions that can counteract the failure modes.
6. Assess RPN after actions
7. Revise preventive maintenance for other equipment.
(Wannawiset and Tangjitsitcharoen, 2019)

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Conclusion and Recommendations

• Throughout this Seminar, it is evident that effective maintenance can help in

reducing the potential unplanned breakdowns.
• Critical Equipment needs to be identified by using tools like Pareto, etc. so that
such problematic machines can be focused upon.
• Data that may be collected for reliability calculations may be in the form of
machine down times, maintenance times, number of failures, etc. for a given time
period. The best method needs to be selected according to the data set given.
• This Data can be utilised to evaluate reliability by methods like the Weibull
Method.
• Methods like FMEA can help in predicting failure modes and identifying effects,
it helps in selecting the corrective actions necessary to avoid machine breakdown.

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References
• Akinyemi, D. T. O. O. O. (2010) ‘Development of Equipment Maintenance Strategy for Critical Equipment’, The Pacific Journal of
Science and Technology, 11(1), pp. 328–342. Available at:
https://www.researchgate.net/profile/Olasunkanmi_Akinyemi/publication/280804155_Development_of_Equipment_Maintenance_Str
ategy_for_Critical_Equipment/links/572342c008ae586b21d87fb8/Development-of-Equipment-Maintenance-Strategy-for-Critical-
Equipment.pdf.
• Idiapho, O. K., Odinikuku, W. E. and Akusu, O. M. (2019) ‘Reliability Assessment of a Cement Industry by Application of Weibull
Method’, Journal of Engineering Research and Reports, (September), pp. 1–11. doi: 10.9734/jerr/2019/v7i216965.
• Mason, T. O. (2018) Cement - Extraction and Processing, Encyclopædia Britannica, Inc. Available at:
https://www.britannica.com/technology/cement-building-material/Extraction-and-processing (Accessed: 16 July 2021).
• Okpala, A. N. and Kotingo, K. (2008) ‘Application of reliablility analysis for predicting failures in glass industry’, Global Journal of
Engineering Research, 6(2), pp. 1–7. doi: 10.4314/gjer.v6i2.18952.
• Wannawiset, S. and Tangjitsitcharoen, S. (2019) ‘Paper Machine Breakdown Reduction by FMEA and Preventive Maintenance
Improvement: A Case Study’, IOP Conference Series: Materials Science and Engineering, 530(1). doi: 10.1088/1757-
899X/530/1/012051.
• Khan, M.R.R. and Darrab, I.A., [2010], Development of analytical relation between maintenance, quality and productivity, Journal of
Quality in Maintenance Engineering, 16.
• Deepika, G. and Kuldeep, K., [2009], Reliability Analysis of Pharmaceutical Plant Using Mat lab-Tool.International Journal of
Electronics Engineering Research Volume 1 Number 2 (2009) pp. 127–133. Research India Publications.
• O’Connor DT, Kleyner A. Practical reliability engineering, John Wiley and Sons,Chichester, UK, 5th edition; 2012.
• Lyonnet P. Tools of Total Quality, An Introduction to statistical Process Control. Chapman and Hall, London; 1991.

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 THANK YOU!

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