This is one of my assignment from my Monash University studies that I am using to teach on the job how to develop maintenance strategies using RCM.

1. Condition Monitoring of the NewCondition Monitoring of the New
Vibratory Scalping Screen: In-PitVibratory Scalping Screen: In-Pit
Crusher Upgraded Facility, Ok TediCrusher Upgraded Facility, Ok Tedi
MineMine
Gilbert Hamambi
[GEG7054 Assignment 3_Activity 3A_Presentation]

2. ObjectivesObjectives
Demonstrate understanding of how to
apply CM.
Presents the systematic approach in use
at Ok Tedi Mine to select a CM technique
for a given equipment failure mode.
Show use of computer simulation
(RCMCost) in assisting with the selection
of the CM technique.

3. IntroductionIntroduction
 CM should not be applied just because we have
the equipment and skills available.
 Right machines must be selected in order of
priority.
 Tools to assist in prioritizing include RBD,
Pareto Analysis and etc.
 The machines are then assigned the
appropriate CM technique.

4. Selecting the ‘Right’ MachineSelecting the ‘Right’ Machine
0.9 0.9
Series
0.9
0.9
Parallel
Can also be done
using RBD to
identify ‘bottle
necks’ in the
process

5. The Vibratory Scalping Screen (VSS)The Vibratory Scalping Screen (VSS)

6. The VSS: Basic Function, Construction &The VSS: Basic Function, Construction &
Operating PrincipleOperating Principle
 Function:
 physically separates the ROM ore into specific sizes.
 Construction:
1) Grizzly type,
2) Three (3) decks inclined at different angles,
3) Decks positioned parallel to the direction of
travel of ROM ore.
 Operating Principle:
 uses mechanical vibration generated by eccentric drive
shafts.

7. Define the SystemDefine the System
Determine
Limits &
Boundaries
Vibratory Scalping Screen

8. Establish VSS Component HierarchyEstablish VSS Component Hierarchy
Down to the
Maintainable item
level

9. Do Functional Analysis of the VSS ComponentsDo Functional Analysis of the VSS Components
Do Functional
Analysis
Next do
Functional Failure
Analysis
Then Determine
Failure Modes

10. Determining VSS Dominant Failure ModeDetermining VSS Dominant Failure Mode
Drill down and select
Dominant Failure
Modes at the
equipment level. Use
Pareto’s 80/20 rule.
Dominant Failure
Modes will vary for
different criticalities

11. Establishing the Failure Mode EffectsEstablishing the Failure Mode Effects
FMECA is the
HEART of the
RCM Process

12. Classifying the Failure ModeClassifying the Failure Mode
Determining FM
Characteristics
(Behaviour
Prediction)

13. Addressing the FM: UNPLANNEDAddressing the FM: UNPLANNED
RTF Scenario

14. Addressing the FM: PLANNEDAddressing the FM: PLANNED
Correcting the FM:
Planned Scenario

15. Proposed CM TechniqueProposed CM Technique
CM Technique
to Apply

16. Optimizing the CM Technique IntervalOptimizing the CM Technique Interval
Sensitivity
Analysis between
Cost/Safety and
Inspection
Intervals

17. Deciding on the Choice of CM TechniqueDeciding on the Choice of CM Technique
Trading Off
Alternatives by
Weighing out the
Costs & Benefits
Option 1:
Applying CM
Technique
Option 2:
Run-To-Fail
Option Chosen: Apply CM
Technique because of a
Favourable Cost:Benefit
Ratio of
0.0187898

18. Summary of the Failure Modes SelectedSummary of the Failure Modes Selected
These failure modes
were selected using
the same approach

19. SummarySummary
Presented the systematic approach in use
at Ok Tedi Mine to select a CM technique
for a given equipment failure mode.
Showed the use of computer simulation
(RCMCost) in assisting with the selection
of the CM technique.

20. ConclusionConclusion
 The process of choosing which CM techniques
to use follows the RCM Methodology of:
1. Define the System,
2. Establish System Hierarchy,
3. Do Functional Analysis,
4. Do Functional Failure Analysis,
5. Determine Failure Modes,
6. Do FMECA and
7. Determine Maintenance Strategy.
 The appropriate CM technique is selected after
weighing out the costs and benefits (cost-to-
benefit ratio).

21. QuestionsQuestions??