Reliability Centered Maintenance Practices in Food Industry

ScienceDirect ScienceDirect Procedia Computer Science 00 (2019) 000–000

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Available online at www.sciencedirect.com Procedia Computer Science 00 (2019) 000–000

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www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Computer Science 158 (2019) 227–234

3rd World Conference on Technology, Innovation and Entrepreneurship (WOCTINE) 3rd World Conference on Technology, Innovation and Entrepreneurship (WOCTINE)

Reliability Centered Maintenance Practices in Food Industry Reliability Centered Maintenance Practices in Food Industry Oğuzhan Yavuz1, 2, *, Ersin Doğan1, 2, Ergün Carus1, 3, Ahmet Görgülü1, 4 1, 2 Inc, Eskisehir 26004, Turkey Industry and Trade Oğuzhan Yavuz1, 2,ETI*,Food Ersin Doğan , Ergün Carus1, 3, Ahmet Görgülü1, 4 1

2

Central Maintenance Department, Eskisehir 26004, Turkey 3 Technology Department, 26004, Turkey ETI Food Industry and Trade Eskisehir Inc, Eskisehir 26004, Turkey 4 2 Technology and Product Development Department, 26004, Turkey Central Maintenance Department, EskisehirEskisehir 26004, Turkey 3 Technology Department, Eskisehir 26004, Turkey 4 Technology and Product Development Department, Eskisehir 26004, Turkey 1

Abstract

Abstract The discipline of maintenance in industries has changed more than other management disciplines. This change due to the increase in the number and variety of physical assets, the development of technology, the emergence of new maintenance techniques, and The discipline of perspective maintenanceofinmaintenance. industries has changed more thaninother management disciplines. This changemethods due to the increase the change in the Maintenance teams the enterprise generally apply time-based to maintain in variety of physical assets, the development technology, emergence of new maintenance techniques, and of the number physicaland assets. However, maintenance practices do notofalways providethethe overall equipment efficiency (OEE) expected the in the perspective of maintenance. Maintenance teams in the enterprise apply time-based methods to maintain fromchange the equipment. Reliability centered maintenance (RCM) is an approach thatgenerally determines what the equipment is able to fully of the physical maintenance not alwaysofprovide the overall (OEE) expected perform its tasksassets. in theHowever, present process. In thispractices study, thedoapplication RCM approach onequipment packaging efficiency machines and its effect on from the explained. equipment. Reliability centered maintenance (RCM) is an approach that determines what the equipment is able to fully OEE are perform its tasks in the present process. In this study, the application of RCM approach on packaging machines and its effect on OEE are explained. © 2019 The Author(s). Published by Elsevier B.V. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 3rd World Conference on Technology, Innovation and Peer-review under responsibility of the scientific committee of the 3rd World Conference on Technology, Innovation and © 2019 The Author(s). Published by Elsevier B.V. Entrepreneurship Entrepreneurship Peer-review under responsibility of the scientific committee of the 3rd World Conference on Technology, Innovation and Entrepreneurship Keywords: Reliability; Sustainability; RCM; Equipment function; Process Keywords: Reliability; Sustainability; RCM; Equipment function; Process

1. Introduction 1. Introduction In today’s rapidly growing production facilities, production can be maintained in accordance with the programs, and equipment and facilities depend on the operation without interruption. Maintenance activities are implemented to In today’s rapidly growingand production production be These maintained in accordance withare thenot programs, ensure that these equipment facilitiesfacilities, operate in an activecan state. maintenance activities only as and equipment and facilities depend on the operation without interruption. Maintenance activities are implemented to immediate breakdown intervention, but also as routine inspection, periodic maintenance, preventive maintenance, ensure that these equipment and facilities operate in an active state. These maintenance activities are not only as renewal and condition monitoring tasks [1]. immediate breakdown intervention, but also as routine inspection, periodic maintenance, preventive maintenance, Maintenance is an activity that should be executed in parallel with the production function in facilities. In the renewal and condition monitoring tasks [1]. maintenance application, the equipment and the manufactured product relationship should not be ignored. Otherwise Maintenance is an activity that should be executed in parallel with the production function in facilities. In the maintenance equipment and the manufactured product relationship should not be ignored. Otherwise * Correspondingapplication, author. E-mail the address: [email protected] * Corresponding author. E-mail address: [email protected] 1877-0509 © 2019 The Author(s). Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 3rd World Conference on Technology, Innovation and Entrepreneurship 1877-0509 © 2019 The Author(s). Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 3rd World Conference on Technology, Innovation and Entrepreneurship

1877-0509 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 3rd World Conference on Technology, Innovation and Entrepreneurship 10.1016/j.procs.2019.09.046

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the applied maintenance activity does not provide the expected contribution to OEE, but also the effect of increasing maintenance costs. Factors that adversely affect OEE are down time, speed loses and quality loses in the manufactured product. The maintenance activities should be implemented in a way that allows the equipment to produce the desired speed and quality of the product by fulfilling the expected function within a specific time and certain limits. In the RCM, the production team that operates the equipment will perform timely tasks at checkpoint knowing how to use the equipment for the manufactured product. At the same time, the information about the equipment function of the production team will be provided with the correct data transmission to the maintenance teams. In this way, the maintenance team will perform timely interventions for the sustainability of the equipment function. With timely and accurate interventions of the teams that use and operate the equipment, the OEE will increase and the production program with reliable equipment shall be executed. As a result of the maintenance activities carried out in this way, it is aimed to reach the understanding autonomous maintenance management which is also the philosophy of the total productive maintenance (TPM).

2. RCM RCM a process used to determine what must be done to ensure that any physical asset continues to do what its users want it to do its present operating context [2]. It creates standards for the continuity of the function in the equipment’s manufacturing process and the performance expected from the equipment. This process examines function losses, failure modes, failure modes frequencies and the effects of these failure modes. It also sets job plans to prevent losses and failure modes before they happen, and sets responsible teams. The decision-making process in RCM enhances the maintenance management system by defining the job steps to be done in equipment maintenance, determining job steps periods and spare parts to be used. However it allows to decision determine whether the equipment convenient for the process, and determines the design changes in the equipment needs for new investment and processing convenience. While developing all these standards, it prioritizes environmental impacts and work safety. 3. Execution of the RCM in Packaging Machine Before starting the application of the RCM process, physical assets must be in the operating system and the equipment used in the production process should be active [2]. Based on this requirement, the equipment used in our operation was examined and criticality analysis was performed. After the criticality analysis, equipment for RCM study was determined. In our study, the execution of RCM process will be explained in the packaging machine that performs the tablet chocolate packaging. Figure 1 gives the important steps of the execution of RCM process.

Fig. 1. Execution of the RCM Process



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3.1. Determination of Critical Equipment The key performance indicator (KPI) of the packaging machine that is actively used in our business has been examined for the past years. Breakdown rate, mean time between failure (MTBF), mean time to repair (MTTR), product quality, OEE, planned maintenance labors and breakdown labors are examined within the KPI. It was observed that the packaging machine had periodic planned maintenance but failed to prevent some loss of failure modes. 3.2. Establishment of the RCM Team RCM is an approach that should be implemented in teamwork. For this reason, the RCM team consisting of the process engineer, operators, quality teams, breakdown maintenance teams, planned maintenance teams and maintenance engineer of the identified line of critical equipment was established. Product development teams were also included in the operation during the association of the product to the equipment. 3.3. Present Condition Analysis of the Packaging Machine With the RCM team, the equipment’s faults, quality and performance problems are evaluated and present situation of the equipment is examined during production. After that the equipment’s function in the process and its relationship with product are examined. First step to create maintenance job steps, improvement and maintenance activities have been identified. 3.4. Condition Based Maintenance (CBM) Execution and Monitoring to the Packaging Machine Before the RCM job steps, the necessary CBM is carried out to bring the packaging machine to the first day’s working performance. Part design and material properties have been changed in folding systems by improving the product specifications to eliminate the specified function losses. As a result of this CBM execution, the maintenance job steps are passed to determination phase. 3.5. Composing Maintenance Job Steps 3.5.1. Identification of Equipment Function and RCM Information Form We can define as a function to fulfill the task we want from a subgroup of equipment or equipment in the specified standards and time period. Considering the main function of the equipment in which we perform this work, we can express the packaging process in the desired capacity in accordance with the quality specs. However, in complex systems it is more accurate to do this function description by dividing the equipment into subgroups. We may consider the groups mentioned as subgroups in the packaging machines to pass through various processes by passing through different stations. In this way, we can examine the function losses and failure modes as more details. The inability to perform the function expected from the equipment or subgroup of the equipment is defined as a loss of function. The cause of the function loss is determined by a failure mode. This is why the function is not fulfilled from failure mode. We describe the effect of failure mode on the equipment as a failure effect. The function of the equipment is revealed with the experience of the equipment manufacturer and the operator who is using the equipment, maintenance technician and maintenance engineer. Then a list of function losses, failure modes and failure effects is generated. This list is called the RCM information form [2]. We may consider this form an error finding map for teams that use the equipment and are responsible for operation of the equipment. Thanks to this form, the function of the equipment in the process is defined and the decision is made to determine what should be done to avoid the loss of function. Figure 2 gives the information form is prepared for the packaging machine in which we applied the RCM execution.

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Fig. 2. RCM Information Form

After the RCM information form is prepared, the decision is made using the decision making diagram to fill the decision form. 3.5.2. Decision Making Diagram and Decision Form In the decision making step, the pre-seen activities are determined to prevent the failure modes that cause function losses. Determining the pre-seen activities using decision making diagram, environmental impacts, occupational health and safety, design change, feasibility, planned maintenance activities, breakdown maintenance activities, predictive maintenance activities and new equipment investments are assessed. This diagram allows to determining the correct job step by asking the method determining questions about the function losses specified in the RCM information form [2]. Figure 3 gives information about the making decision diagram.

Fig. 3. RCM Decision Diagram



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The decision form is filled by following the steps in the decision making diagram. The job step that needs to be done is specified under the preliminary activity and assigned to the responsible part of the teams to do this job. All these data are filled on the decision form and the required job steps and job step periods are determined so that the equipment can continue to function in the production process [2]. The packaging machine which we carry out the RCM operation, packages the product in different sizes and specifications. For this reason, we have determined the function losses that we have identified on the packaging machine for products of different properties. In the next stage, we used to the decision diagram to determine the job steps that should be made to avoid the loss of function. As a result of the evaluation in the decision diagram, we have stated the need to be done in the preliminary activity to avoid these function losses. We have specified teams that will fulfill these activities. We have completed the job steps that prevent the function losses in the process according to the packaged product properties for the packaging machine. Figure 4 gives the decision form is prepared for the packaging machine in which we applied the RCM operation.

Fig. 4. RCM Decision Form

The parameter settings for the job steps to be applied and instructions describing how to do them are composed. 3.5.3. Parameter Settings and Instructions for Different Types of Product After completing the job steps for the packaging machine, the teams who will perform these job steps are required to learn the settings and how to do them according to the product. Otherwise, a job step that will be applied with the wrong method may cause other errors.

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Mechanical cam mechanisms are used in the packaging machine in which we have carried out the RCM operation. These mechanisms are connected to a single shaft and perform a different task at each station. The correct adjustment of the cam mechanisms on a shaft driven by a single electrical motor is mandatory for the different stations in the packaging machine to working synchronously. The operator using the packaging machine should know the mechanical parameter of the machine according to the dimensions and specifications of the product it packs and apply the correct methods when modifying these parameter settings. In the same way, for maintenance teams that maintain the operational continuity of the equipment, it is important to implement the correct procedures for maintenance interventions. This parameter settings and instructions are prepared and how to apply the job steps in the right way and on time. Figure 5 gives sample of about mechanical cam parameters.

Fig. 5. Mechanical Cam Parameters

Figure 6 gives instruction sample how to set the parameter values given in the Figure 5.



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Fig. 6. Instruction Sample

4. RCM Effect on Packaging Machine OEE As a result of the application, equipment availability increased and problems experienced due to quality have been eliminated. Due to timely interventions with the right methods, a rapid increase in OEE has been seen. More effective work was carried out with the team who knew the equipment characteristics of the product and its equipment. We evaluated the OEE data of this pilot study within six months period from the first intervention date. Figure 7 gives the increased OEE data as a result of the intervention in the packaging machine.

Fig. 7. OEE Data

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5. Conclusion With the RCM operation applied in the packaging machine, the actual function of the equipment in the process and its relationship with the product are understood for teams that use the equipment and provide the sustainability of the equipment. A positive increase in equipment OEE has been seen with the elimination of function losses by teamwork. Unplanned breakdown is avoided and error caused by product quality is prevented. It was contributed to the creation of a self-contained autonomous maintenance management system that one of the objectives of the TPM. This study, which took place with the participation of all teams, led to the challenges of using equipment and teams responsible for the operation of the equipment. References [1] Prof .Dr. Mustafa Köksal (2015) “Bakım Planlaması” Seçkin Yayınları 2.Baskı s.15. [2] J. Moubray (1997) ”Reliability-centered Maintenance” Published by Elseiver Ltd. Second Edition Commun: 5-233 .