Test and Trial Chemical Production Facility

Project Info

The client is a manufacturer of parts for the automotive industry. One machine on the production line was causing a backlog in production, due to repeat failures. The machine was a single point of failure. A discussion was held with site management to determine a strategy of action which would improve the current situation.

Solution

It was agreed to perform an RCM (Reliability Centred Maintenance) study on the facility in order to recognise the modes of failure and contributors to the unavailability losses.
An improvement team made up of a mechanical, production and process engineer were brought together to perform the study.

The process began with a failure mode and effects analysis (FMEA) that identified the facilities failure modes in a systematic and structured manner. The team then examined each failure mode to determine the optimum maintenance policy to reduce the severity impact of each failure.

The chosen maintenance strategy considered the cost, safety, environmental and operational consequences. The effects of redundancy, spares costs, maintenance crew costs, equipment ageing, and repair times were also considered.

Once the optimal maintenance policies had been identified within the RCM process, the team were then able to see the performance predictions and costs, expected spares requirements and maintenance crew manning levels.

Results

The optimised maintenance strategy was also used to determine several outputs including:

• Strategy Comparison
• Maintenance Budget Prediction
• Availability Prediction

Conclusion

The implementation of the recommended maintenance strategy will reduce business effects by minimising losses to production through unplanned outages and increase plant availability.

With a combination of simple methodologies and practical training delivery, Pro-Reliability Solutions support Asset and Continuous Improvement Managers to proactively manage their assets and ensure their equipment delivers the required level of availability while minimising risks to the business. Whether it is a new project in the design phase or an existing facility that needs improvement,
Pro-Reliability Solutions can help customers realise bottom-line results.

This Reliability Study was performed using Isograph Availability Workbench Software.

Further Information

If you are interested in performing a Reliability Maturity Self-Assessment at your facility or would like to develop a roadmap for your Reliability future, then please get in touch.