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Problem Identification: Production decreased to low level
Plant Capacity: 450ton/day
Reliability Engineering
1
By Eng. Moh...
Reliability Engineering
2
Problem with
plant production
performance
Transportation of
raw material
problem
Production labor
problem
Others
Breakdown...
Breakdowns issue
Environmental
downtime issue
Electrical issueOther external
factors
Equipments downtime
(unplanned
mainte...
Plant downtime report
Reliability Engineering
5
Equipments
breakdown
issue
Machine 4
Machine 3
Machine #1
Machine #2
Machine 5
Machine 6
Reliability Engineering
6
Equip
code
Critical Equip
description
Total Downtime
hrs (average)
Downtime
frequency
MTTR
(hrs)
Percentage
1 Centrifugal ...
Pareto Analysis A problem solving tool that breaks data down into
manageable groups and identifies the greatest opportunit...
Reliability Engineering
9
Pareto diagram uses bar graphs to sort problems
according to severity, frequency, cost, nature, ...
Motor
Foundation
Bearing FDE Bearing FNDE
Casing
Man Hole
Reliability Engineering
10
Machine 1
failed
Motor electric
failure
Power off
Machine
unplugged
Overloaded
Reliability Engineering
11
Overload
Process problem
Electrical problem
Cleaning problem
Mechanical
Vibration problem
Reliability Engineering
12
Mechanical
vibration
problem
Bent Shaft
Bad maintenance
Bearing failed
Unbalance
Bad
fixation
with the
base
Misalignment
R...
Unbalance
Rotor problem
Bad balancing
Others
Scale
accumulative
Reliability Engineering
14
Reliability Engineering
15
Dust
accumulative
Incorrect
balancing
Cleaning
issue
Design
Problem
Problem in
sandblasting
efficiency
Bad
operation
Proce...
Scale
Reliability Engineering
17
Reliability Engineering
18
System Illustration Diagram
(1) Dryer Drum
(3)
Fan
(4) Bag Filter
(2)
Cyclon
e
Dust settling
Su...
Repair the coating for body of
the cyclone
Repair the pneumatic
system for closing and
opening the gates
Get new discharge...
Reliability Engineering
20
Electric motor
failed
Electric cable
problemPower
off
Machine
unplugged
Motor
overheated
Reliability Engineering
21
Motor
overloade
d
Motor
overheated
121⁰C
Cooling
fan
Motor located in
bad environment
Bad preventive
maintenance
Reliabili...
Motor miss-
installed
Motor
overloaded
Shaft
damage
d
Motor Shaft
Vibration
problem
Machine
problem
Reliability Engineerin...
Shaft damaged
Misalignment
Incorrect fit Incorrect tolerance
Bearing
failed
Reliability Engineering
24
Bearing
failed
Insufficient
lubrication
Excessive
clearance
Mounting
problem
Grease
contamination
Failed motor
bearing
Inc...
Use the proper tools for mounting
and train the maintenance crew
Preventive Action
Reliability Engineering
26
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Root Cause Analysis RCA - Case Study

Root Cause Failure Analysis RCFA & an illustration case study.

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Root Cause Analysis RCA - Case Study

  1. 1. Problem Identification: Production decreased to low level Plant Capacity: 450ton/day Reliability Engineering 1 By Eng. Mohammed Hamed Ahmed Soliman Email: mhamed206@yahoo.com LinkedIn Profile: eg.linkedin.com/in/mohammedhamed
  2. 2. Reliability Engineering 2
  3. 3. Problem with plant production performance Transportation of raw material problem Production labor problem Others Breakdowns Reliability Engineering 3
  4. 4. Breakdowns issue Environmental downtime issue Electrical issueOther external factors Equipments downtime (unplanned maintenance) Reliability Engineering 4
  5. 5. Plant downtime report Reliability Engineering 5
  6. 6. Equipments breakdown issue Machine 4 Machine 3 Machine #1 Machine #2 Machine 5 Machine 6 Reliability Engineering 6
  7. 7. Equip code Critical Equip description Total Downtime hrs (average) Downtime frequency MTTR (hrs) Percentage 1 Centrifugal Fan 16 5 3.2 44.80% 2 Pump station 2 Motor 6 2 3 16.80% 3 Granulator Drum 4 2 2 11% 4 Feed Belt Conveyor 3 2 1.5 8.40% 5 Recycle Belt Conveyor 2.5 1 2.5 7.00% 6 Bag Filter 2.5 1 2.5 7% 7 Burner 1 1 1 2% 8 Belt Conveyor 0.5 1 0.5 1.40% 9 Belt Conveyor 0.2 1 0.2 1.40% 10 Bucket Elevator ---- ---- ---- ---- Priority Identification (Top Failures) Equipments downtime monthly report: Reliability Engineering 7
  8. 8. Pareto Analysis A problem solving tool that breaks data down into manageable groups and identifies the greatest opportunity for return on investment. The analysis is based on the Pareto Principle, also known as the 80:20 Rule. Simply stated, the principle says that 20% of a population will cause 80% of the problems associated with the population 0.00% 5.00% 10.00% 15.00% 20.00% 25.00% 30.00% 35.00% 40.00% 45.00% 50.00% 0 2 4 6 8 10 12 14 16 18 Reliability Engineering 8
  9. 9. Reliability Engineering 9 Pareto diagram uses bar graphs to sort problems according to severity, frequency, cost, nature, or source and displays them in order of size in order of size to show which problem is the most important. Its probably the most often used statistical tool in Toyota.
  10. 10. Motor Foundation Bearing FDE Bearing FNDE Casing Man Hole Reliability Engineering 10
  11. 11. Machine 1 failed Motor electric failure Power off Machine unplugged Overloaded Reliability Engineering 11
  12. 12. Overload Process problem Electrical problem Cleaning problem Mechanical Vibration problem Reliability Engineering 12
  13. 13. Mechanical vibration problem Bent Shaft Bad maintenance Bearing failed Unbalance Bad fixation with the base Misalignment Reliability Engineering 13
  14. 14. Unbalance Rotor problem Bad balancing Others Scale accumulative Reliability Engineering 14
  15. 15. Reliability Engineering 15
  16. 16. Dust accumulative Incorrect balancing Cleaning issue Design Problem Problem in sandblasting efficiency Bad operation Process problem Reliability Engineering 16
  17. 17. Scale Reliability Engineering 17
  18. 18. Reliability Engineering 18 System Illustration Diagram (1) Dryer Drum (3) Fan (4) Bag Filter (2) Cyclon e Dust settling Suction
  19. 19. Repair the coating for body of the cyclone Repair the pneumatic system for closing and opening the gates Get new discharge valve Real Photo Reliability Engineering 19
  20. 20. Reliability Engineering 20
  21. 21. Electric motor failed Electric cable problemPower off Machine unplugged Motor overheated Reliability Engineering 21
  22. 22. Motor overloade d Motor overheated 121⁰C Cooling fan Motor located in bad environment Bad preventive maintenance Reliability Engineering 22
  23. 23. Motor miss- installed Motor overloaded Shaft damage d Motor Shaft Vibration problem Machine problem Reliability Engineering 23
  24. 24. Shaft damaged Misalignment Incorrect fit Incorrect tolerance Bearing failed Reliability Engineering 24
  25. 25. Bearing failed Insufficient lubrication Excessive clearance Mounting problem Grease contamination Failed motor bearing Incorrect bearing type Incorrect lubricant usage Reliability Engineering 25
  26. 26. Use the proper tools for mounting and train the maintenance crew Preventive Action Reliability Engineering 26

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