STOP YOUR BREAKDOWNS NOW! How RCM (Reliability Centred-Maintenance) helps to improve your machine performance and availability by identifying optimised maintenance strategies.
Monition delivers expert RCM facilitation, training and consulting across numerous types of industries. Most notably is a large scale RCM implementation program at one of the largest food manufacturing sites in Europe.
The three phase, six stage approach for RCM implementation is a tested methodology developed by Monition through 28 years of experience at the leading edge of condition monitoring and plant reliability services. The approach is a spearhead methodology focusing on delivering immediate benefits and long term sustainable results.
The complex food processing system under investigation had faced several problems over a 12 month period resulting in 35% downtime versus a target of only 10%. Through the structured, concise and standardised approach of conducting RCM, Monition have recently reduced the risk of failure from 100% to 20% by identifying 7 key maintenance packages. These packages include an array of advanced technology approaches including vibration analysis, oil analysis, thermal imaging and focused lubrication and asset care activities.
One of the key techniques identified in the RCM was condition monitoring, which is a critical aspect of maintenance that improves the detectability of a failure mode. Through assessing the health of the machine by periodic monitoring and analysis of data obtained during operation; trends can be analysed to identify impending failure modes. The technologies are efficient, non-intrusive to the production process and with the proven potential to save thousands of pounds in secondary damage, lost production and unnecessary maintenance.
Vibration Analysis was selected as a predictive maintenance technique for some of the primary load bearings and main drive gears in the station as four failure modes had occurred previously on these components. A key aspect of preventing accelerated wear and deterioration of the bearings and gears is to ensure that adequate lubrication schedules are implemented at the correct frequency and amount. The RCM process allowed us to identify the most optimum lubrication schedule based on past performance of the machine and to meet risk reduction targets.
Oil Analysis was identified as a key technology due to the nature of the oil sump (1000L) which lubricates more than 30% of the primary components and was prone to contamination which had been identified as a key failure mode. Monition’s ISO accredited laboratory service analyses Oil Chemistry to tell you the condition of your oil and advise you when it needs changing to ensure the ongoing protection of your machinery. In order to prevent the contamination failure mode an asset care strategy was identified and implemented to reduce the possibility of product and dirt contamination.
The Monition RCM process not only provided tangible business results and improved machine performance but also, through the complete journey, resulted in:
- Improved team collaboration,
- Deeper knowledge and understanding of the machine operation,
- Improved confidence of the operators and engineers in delivering a value adding maintenance strategy,
- Allowed management to justify the maintenance packages through quantifiable risk comparisons and,
- Increased stakeholder engagement across the site.
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