Reliability centered maintenance methodology for product in designimprovement phase : a case study on dough presser

Abstract

Maintenance strategy through the RCM had become increasingly important to the overall operation profit by reducing unnecessary maintenance routine. Maintenance strategy needs have become not just for the maintenance routine but also the design improvement. However, there was no RCM methodology available for the system in design improvement phase. The RCM methodology is not always fits all equipment phase. One of the solutions is using RCM methodology specific for the design improvement phase. The methodology designed to reduce unseen failure risk. The objectives of the research is to validate the methodology through the specific objectives which are to study the effect of the root cause analysis tool change from FMEA to FTA, to examine the finding different between Block diagram and FTA tools and eventually to investigate the benefit of RPN and criticality results integration. The methodology involves four mains phases which are the component classification, root cause analysis, failure risk and criticality analysis and finally the maintenance strategy determination. The change in root cause tool provides the detection towards the relation between the root causes. The qualitative result verification between Block diagram and FTA shows the gap between the tools. Investigation of the RPN and criticality present the situation where the quantitative result has to be integrated. Observed the proposed RCM methodology has provided the opportunity to minimize the risk in design improvement stage