ABSTRACT: The concept of advanced maintenance management technique in the field of heavy earthmoving mining machinery is recently developed in India, and has taken pace with the demand of the same, rising continuously over the years. This paper indulges into considering of hydraulic excavators, which is a large machinery that is designed for excavation and demolitions purposes. It spreads to various sizes and functions. The development of the mining industry has been escalated largely due to the introduction of different types of excavators. These excavators are used to satisfy various mining, industrial and construction needs. The mining excavators are mainly of two types that are used in modern era namely backhoe and dragline, other being suction excavator, long reach/long arm, crawlers and compact excavators, power shovel etc. The data collected and analysis has been done keeping in mind the vicinity of the coal capital of India, where hydraulic excavator is mainly used. It is so, that the same gets prime focus in the paper. The increased penetration of service of the high yield machines in the above-mentioned sectors have made them really important. Halting or stoppages are seen as the bottlenecks, which disturbs the productivity. Seeing the large benefits, and associated productivity and profit loss, the maintenance engineer felt the need to have advanced maintenance of the same. The paper deals with different faults of the excavator, and based on the data acquired, takes on further steps towards carrying out the FMEA analysis which incorporates into it by estimating Severity, Occurrence and Detection of the considered parts respectively, and then Risk Priority Number (RPN) is calculated, ranging from 1 to 1000. The quantitative approach helps in deciding the various maintenance strategies for the different parts and subparts. It is based on the above factors that maintenance plans are initiated, designed and implemented.
Studying the Advance Maintenance Practice & Computerised MaintenanceIJERA Editor
Many companieѕ think of maintenance aѕ an inevitable ѕource of coѕt. For theѕe companieѕ maintenance
operationѕ have a corrective function and are only executed in emergency conditionѕ. Today, thiѕ form of
intervention iѕ no longer acceptable becauѕe of certain critical elementѕ ѕuch aѕ product quality, plant ѕafety,
and the increaѕe in maintenance department coѕtѕ which can repreѕent from 15 to 70% of total production coѕtѕ.
The managerѕ have to ѕelect the beѕt maintenance policy for each piece of equipment or ѕyѕtem from a ѕet of
poѕѕible alternativeѕ. For example, corrective, preventive, opportuniѕtic, condition-baѕed and predictive
maintenance policieѕ are conѕidered in thiѕ paper.
Improving maintenance management: Case Study of a Local Textile CompanyIJMREMJournal
The manufacturing sector in Botswana has been rapidly growing in recent times. Maintenance management
system plays a vital role in keeping equipment on condition and also major contributor for overall productivity.
The current study seeks to improve maintenance management of a local textile case study company with its
operations based in Gaborone Botswana. The study sought to assist the organization take advantage of low
labor costs and good export policies to manufacture goods for both local and the international markets through
effective maintenance management. In order to effectively compete, organizations need to produce quality
products and services. In that regard, manufacturers need to reduce redundancy in business processes,
redesign products using prime components and increase availability of products and services through provision
of effective equipment maintenance. The case study company’s current maintenance management system is
simple and not effectively contributing in terms of equipment availability. Through this present work, we were
able to develop, document and implement a maintenance management system for the organization
Bio medical equipment maintenance & managementGm Kanhar
This thesis covers the maintenance and management issues of the medical equipment. The case study briefly describes the maintenance issues of Bio-medical equipments
Studying the Advance Maintenance Practice & Computerised MaintenanceIJERA Editor
Many companieѕ think of maintenance aѕ an inevitable ѕource of coѕt. For theѕe companieѕ maintenance
operationѕ have a corrective function and are only executed in emergency conditionѕ. Today, thiѕ form of
intervention iѕ no longer acceptable becauѕe of certain critical elementѕ ѕuch aѕ product quality, plant ѕafety,
and the increaѕe in maintenance department coѕtѕ which can repreѕent from 15 to 70% of total production coѕtѕ.
The managerѕ have to ѕelect the beѕt maintenance policy for each piece of equipment or ѕyѕtem from a ѕet of
poѕѕible alternativeѕ. For example, corrective, preventive, opportuniѕtic, condition-baѕed and predictive
maintenance policieѕ are conѕidered in thiѕ paper.
Improving maintenance management: Case Study of a Local Textile CompanyIJMREMJournal
The manufacturing sector in Botswana has been rapidly growing in recent times. Maintenance management
system plays a vital role in keeping equipment on condition and also major contributor for overall productivity.
The current study seeks to improve maintenance management of a local textile case study company with its
operations based in Gaborone Botswana. The study sought to assist the organization take advantage of low
labor costs and good export policies to manufacture goods for both local and the international markets through
effective maintenance management. In order to effectively compete, organizations need to produce quality
products and services. In that regard, manufacturers need to reduce redundancy in business processes,
redesign products using prime components and increase availability of products and services through provision
of effective equipment maintenance. The case study company’s current maintenance management system is
simple and not effectively contributing in terms of equipment availability. Through this present work, we were
able to develop, document and implement a maintenance management system for the organization
Bio medical equipment maintenance & managementGm Kanhar
This thesis covers the maintenance and management issues of the medical equipment. The case study briefly describes the maintenance issues of Bio-medical equipments
Development Of An Effective Industrial Maintenance Practice For Plant Optimum...IJERA Editor
Plant optimization is a sound fiscal decision and this is a key attribute of good operational management. The
decision to adhere strictly to the maintenance measurements, controls and efficiencies necessary for optimum
performance not only enhances the plant operations, it quite often produces a safer operating facility and
protects plant asset or investment. Plant operations rely on dependable acquired knowledge, skills, equipment
and maintenance programs for an assured performance whiles strategies are required to be in place for
equipment optimum availability to ensure system operational integrity in order to reduce costs which affect
production. This optimized system would ideally give meaning to effective maintenance practice of plant
equipment and accepted best maintenance management system. This paper presents a comprehensive review of
characteristics of plant equipment and maintenance strategies and proposes sustainable maintenance
management performance criteria. Thereby improving business, safety, equipment efficiency and sustain the
environment. The goal is to achieve optimum availability and optimum operating condition of the equipment
life cycle in a cost optimized approach.
Reliability, availability, maintainability (RAM) study, on reciprocating comp...John Kingsley
What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
.
To know more, on How iFluids can help you operate & maintain Safe and Reliable plant Contact us Today --> info@ifluids.com
For any training enquiries, contact us today --> training@ifluids.com
Studying the Factors Affecting Mainteneance Strategies & Computerised Mainten...IJERA Editor
Manufacturing firmѕ face great preѕѕure to reduce their production coѕtѕ continuouѕly. One of the main
expenditure itemѕ for theѕe firmѕ iѕ maintenance coѕt which can reach 15–70% of production coѕtѕ, varying
according to the type of induѕtry (Bevilacqua and Braglia, 2000). The amount of money ѕpent on maintenance in
a ѕelected group of companieѕ iѕ eѕtimated to be about 600 billion dollarѕ in 1989 (Wireman, 1990, cited by
Chan et al., 2005). On the other hand, maintenance playѕ an important role in keeping availability and reliability
levelѕ, product quality, and ѕafety requirementѕ. Unfortunately, unlike production and manufacturing problemѕ
which have received tremendouѕ intereѕt from reѕearcherѕ and practitionerѕ, maintenance received little
attention in the paѕt. Thiѕ iѕ one of the reaѕonѕ that reѕultѕ in low maintenance efficiency in induѕtry at preѕent.
Aѕ indicated by Mobley (2002), one third of all maintenance coѕtѕ iѕ waѕted aѕ the reѕult of unneceѕѕary or
improper maintenance activitieѕ. Today, reѕearch in thiѕ area iѕ on the riѕe. Moreover, the role of maintenance iѕ
changing from a “neceѕѕary evil” to a “profit contributor” and towardѕ a “partner” of companieѕ to achieve
world-claѕѕ competitiveneѕѕ (Waeyenbergh and Pintelon, 2002). Therefore, reѕearch on maintenance repreѕentѕ
an opportunity for making ѕignificant contribution by academicѕ.
The purpose of this paper is to evaluate the contributions of Total Productive Maintenance (TPM) initiatives in reducing equipment breakdowns, increase equipment reliability and improve productivity. This will result in increased equipment utilization and life, reduced work stoppages and machine slowdowns, closer adherence to production and delivery schedules as well as increased employee morale. The Total Productive Maintenance (TPM) concept addresses these goals. The aim of TPM is to keep the plant and equipment at its highest productive level through the cooperation of all areas of the organization. TPM is a partnership between maintenance and production organization to improve product quality, reduce waste, reduce manufacturing cost and increase equipment availability.
Impact of total productive maintenance methodology on the performanceeSAT Journals
Abstract These days, the organization and companies meet a lot of challenges(internally: to increase the performance, and externally: market share). This work focuses on the internal challenges: such as performance.The most important pillars of the production operations are employees, machines, equipment's, and etc. Maintenance represents the important activity that makes the machines and equipment's operate efficiently. Companies attempt to increase performance and minimize production costs by using a certain approach such as Total productive maintenance (TPM). This work introduces a methodology to improve the performance (operator and equipment) throughproposed model of TPM. Also, it indicates the importance of maintenance which minimizes or eliminates the production problems and increases the organizational productivity. Keywords:Maintenance, Maintenance Management System (MMS), Maintenance Office (MO), Preventive Maintenance (PM), Total productive maintenance (TPM), andOverall Equipment Effectiveness (OEE).
Methods for Risk Management of Mining Excavator through FMEA and FMECAtheijes
Management of maintenance systems in the mining industry is an important condition for their operation. If we recognize the need for risk analysis and management of individual maintenance system, it can generate potential overall efficiency and effectiveness. Special importance for the realization of the objectives of the mining industry belongs to redesign, system harmonization between the various technical structure, standardization, technical diagnostics, analysis of different levels of criticality with variant selection and application of optimal solutions. The potential for the destruction of the complex maintenance systems are a reality in the mining industry and their expression in various applications is a realistic one. For different aspects of the analysis it is possible to decrease risk index range from the threshold to the range of high and low threshold of moderate and acceptable risk. Application of FMEA (Failure Mode and Effect Analysis) and FMECA (Failure Modes, Effects and Criticality Analysis) methods are used to manage risk related to the initial phase of defining the prediction of all possible risks, risk factors and RPN budget priorities. Some risks can be grouped according to the type of errors that occur due to their realization. For effective risk analysis and implement measures to reduce their need is and competent team. No matter what the risks involved, FMECA method can reliably estimate the possibility of their implementation with a satisfactory degree of flexibility and compatibility. In this paper an attempt has been made to develop an effective maintenance methodology of excavator such that the maintenance cost is minimized and technical constraints (such as engine, hydraulic and transmission system, break system, electrical and safety system, suspension and track) are efficiently monitored and maintained. These technical constraints depends upon many factors such as a) Geotechnical parameters, b) Geological parameters, c) Mine parameters, d) Production rate, e) Equipment specification and f) Dig ability assessment etc. Based on the above factors maintenance plans are prepared. This paper discusses a risk management strategy system for Optimal Maintenance Program (OMP) of excavators. The OMP includes functional analysis method of FMEA and FMECA. To develop a successful operation system, it is first necessary to create a risk management program. A prudent management program is one that ensures safety and is environmentally and economically responsible.
ADVANCED FUNCTIONAL MAINTENANCE MANAGEMENT FOR MINING EXCAVATOR IAEME Publication
The concept of advanced maintenance management technique in the field of heavy duty mining machinery /equipment has recently been developed in India. This maintenance concept has the significance of creating a support system for mining equipment functioning. Functional
maintenance is one of the most frequently used methods in maintenance management for mining industries. Management of a custom built maintenance system is the need of the day because of large capital, productivity and risk involved with the mining machinery (excavators) in a high capital intensive industrial scenario with acute sensitivity in the performance of such machines.
Development Of An Effective Industrial Maintenance Practice For Plant Optimum...IJERA Editor
Plant optimization is a sound fiscal decision and this is a key attribute of good operational management. The
decision to adhere strictly to the maintenance measurements, controls and efficiencies necessary for optimum
performance not only enhances the plant operations, it quite often produces a safer operating facility and
protects plant asset or investment. Plant operations rely on dependable acquired knowledge, skills, equipment
and maintenance programs for an assured performance whiles strategies are required to be in place for
equipment optimum availability to ensure system operational integrity in order to reduce costs which affect
production. This optimized system would ideally give meaning to effective maintenance practice of plant
equipment and accepted best maintenance management system. This paper presents a comprehensive review of
characteristics of plant equipment and maintenance strategies and proposes sustainable maintenance
management performance criteria. Thereby improving business, safety, equipment efficiency and sustain the
environment. The goal is to achieve optimum availability and optimum operating condition of the equipment
life cycle in a cost optimized approach.
Reliability, availability, maintainability (RAM) study, on reciprocating comp...John Kingsley
What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
.
To know more, on How iFluids can help you operate & maintain Safe and Reliable plant Contact us Today --> info@ifluids.com
For any training enquiries, contact us today --> training@ifluids.com
Studying the Factors Affecting Mainteneance Strategies & Computerised Mainten...IJERA Editor
Manufacturing firmѕ face great preѕѕure to reduce their production coѕtѕ continuouѕly. One of the main
expenditure itemѕ for theѕe firmѕ iѕ maintenance coѕt which can reach 15–70% of production coѕtѕ, varying
according to the type of induѕtry (Bevilacqua and Braglia, 2000). The amount of money ѕpent on maintenance in
a ѕelected group of companieѕ iѕ eѕtimated to be about 600 billion dollarѕ in 1989 (Wireman, 1990, cited by
Chan et al., 2005). On the other hand, maintenance playѕ an important role in keeping availability and reliability
levelѕ, product quality, and ѕafety requirementѕ. Unfortunately, unlike production and manufacturing problemѕ
which have received tremendouѕ intereѕt from reѕearcherѕ and practitionerѕ, maintenance received little
attention in the paѕt. Thiѕ iѕ one of the reaѕonѕ that reѕultѕ in low maintenance efficiency in induѕtry at preѕent.
Aѕ indicated by Mobley (2002), one third of all maintenance coѕtѕ iѕ waѕted aѕ the reѕult of unneceѕѕary or
improper maintenance activitieѕ. Today, reѕearch in thiѕ area iѕ on the riѕe. Moreover, the role of maintenance iѕ
changing from a “neceѕѕary evil” to a “profit contributor” and towardѕ a “partner” of companieѕ to achieve
world-claѕѕ competitiveneѕѕ (Waeyenbergh and Pintelon, 2002). Therefore, reѕearch on maintenance repreѕentѕ
an opportunity for making ѕignificant contribution by academicѕ.
The purpose of this paper is to evaluate the contributions of Total Productive Maintenance (TPM) initiatives in reducing equipment breakdowns, increase equipment reliability and improve productivity. This will result in increased equipment utilization and life, reduced work stoppages and machine slowdowns, closer adherence to production and delivery schedules as well as increased employee morale. The Total Productive Maintenance (TPM) concept addresses these goals. The aim of TPM is to keep the plant and equipment at its highest productive level through the cooperation of all areas of the organization. TPM is a partnership between maintenance and production organization to improve product quality, reduce waste, reduce manufacturing cost and increase equipment availability.
Impact of total productive maintenance methodology on the performanceeSAT Journals
Abstract These days, the organization and companies meet a lot of challenges(internally: to increase the performance, and externally: market share). This work focuses on the internal challenges: such as performance.The most important pillars of the production operations are employees, machines, equipment's, and etc. Maintenance represents the important activity that makes the machines and equipment's operate efficiently. Companies attempt to increase performance and minimize production costs by using a certain approach such as Total productive maintenance (TPM). This work introduces a methodology to improve the performance (operator and equipment) throughproposed model of TPM. Also, it indicates the importance of maintenance which minimizes or eliminates the production problems and increases the organizational productivity. Keywords:Maintenance, Maintenance Management System (MMS), Maintenance Office (MO), Preventive Maintenance (PM), Total productive maintenance (TPM), andOverall Equipment Effectiveness (OEE).
Methods for Risk Management of Mining Excavator through FMEA and FMECAtheijes
Management of maintenance systems in the mining industry is an important condition for their operation. If we recognize the need for risk analysis and management of individual maintenance system, it can generate potential overall efficiency and effectiveness. Special importance for the realization of the objectives of the mining industry belongs to redesign, system harmonization between the various technical structure, standardization, technical diagnostics, analysis of different levels of criticality with variant selection and application of optimal solutions. The potential for the destruction of the complex maintenance systems are a reality in the mining industry and their expression in various applications is a realistic one. For different aspects of the analysis it is possible to decrease risk index range from the threshold to the range of high and low threshold of moderate and acceptable risk. Application of FMEA (Failure Mode and Effect Analysis) and FMECA (Failure Modes, Effects and Criticality Analysis) methods are used to manage risk related to the initial phase of defining the prediction of all possible risks, risk factors and RPN budget priorities. Some risks can be grouped according to the type of errors that occur due to their realization. For effective risk analysis and implement measures to reduce their need is and competent team. No matter what the risks involved, FMECA method can reliably estimate the possibility of their implementation with a satisfactory degree of flexibility and compatibility. In this paper an attempt has been made to develop an effective maintenance methodology of excavator such that the maintenance cost is minimized and technical constraints (such as engine, hydraulic and transmission system, break system, electrical and safety system, suspension and track) are efficiently monitored and maintained. These technical constraints depends upon many factors such as a) Geotechnical parameters, b) Geological parameters, c) Mine parameters, d) Production rate, e) Equipment specification and f) Dig ability assessment etc. Based on the above factors maintenance plans are prepared. This paper discusses a risk management strategy system for Optimal Maintenance Program (OMP) of excavators. The OMP includes functional analysis method of FMEA and FMECA. To develop a successful operation system, it is first necessary to create a risk management program. A prudent management program is one that ensures safety and is environmentally and economically responsible.
ADVANCED FUNCTIONAL MAINTENANCE MANAGEMENT FOR MINING EXCAVATOR IAEME Publication
The concept of advanced maintenance management technique in the field of heavy duty mining machinery /equipment has recently been developed in India. This maintenance concept has the significance of creating a support system for mining equipment functioning. Functional
maintenance is one of the most frequently used methods in maintenance management for mining industries. Management of a custom built maintenance system is the need of the day because of large capital, productivity and risk involved with the mining machinery (excavators) in a high capital intensive industrial scenario with acute sensitivity in the performance of such machines.
Validation of Maintenance Policy of Steel Plant Machine Shop By Analytic Hier...IJMERJOURNAL
ABSTRACT: In this paper the maintenance activities of the Machine shop of Steel plant have been considered. As maintenance is a routine activity to keep a machine at its normal operating condition so that it can deliver its expected performance without causing any loose of time on account of accidental damage or breakdown and maintenance is a recurring activity. So for reduction of maintenance cost and safety of the operator as well as the residents of nearby area it is better to decide which machines should go for which type of maintenance. For this decision AHP is used and the Expert choice software is used for that calculations and this paper is for the validation of results.
Injection Analysis of Hera And Betano New Power Plants At the Interconnection...IJRESJOURNAL
ABSTRACT: Electricity system in Timor Leste is supplied from small scale Diesel Power Plants (DPP) which are distributed at each district that not interconnected, as the consequences, electric continuity at some districts are disturbed so caused power outage. To overcome the matters, the steps taken by Timor Leste government by establishing 2 units of centered DPP with total capacity of 250 MW at Dili District of 120 MW and at BetanoDistrict of 130 MW. The new power plant will be injected at the electricity system of Timor Leste through transmission line of 150 kV. The new power plant injection will cause the power flow and system stability of Timor Leste entirely. Steady state analysis done including the power flow analysis before and after injection of DPP of Hera and Betano so can be seen the voltage profile change and the decrease of electric power losses. Beside the steady state analysis, also done the power system stability analysis to know whether the system can operate normally after short circuit disturbance of three phases before and after new DPP injection. The steady state analysis showed that the system voltage condition before injection of DPP of Hera and Betano experience decrease of -13% from the sending voltage, and the active power losses of 6.8%. After DPP of Hera and Betano injection the decrease only -6% and active power losses can be minimized become 5.3%. The results of power system stability showed the rotor angle stability, frequency and voltage stability during disturbance occurrence become more stable after injection with recovery time faster if compared with before injection of new power plant.
Harmonic AnalysisofDistribution System Due to Embedded Generation InjectionIJRESJOURNAL
ABSTRACT:The increased demand for electricity and the depletion of fossil energy sources are a challenge to exploit new and renewable energy sources. Relatively cheap renewable energy sources are Wind Power Plant (WPP) and Photovoltaic System (PV). Currently, many small scale generating plants are being evolved into conventional systems known as Embedded Generation (EG). EG as a source of electricity in the distribution system will affect the flow of system power, system reliability, voltage profile and others. Besides, with the placement of converter technology in WPP and PV system will give contribution of harmonic enhancement to the system. This paper presents the harmonic analysis of WPP and PV designs that are injected into conventional distribution system in one bus at Pujon feeder station Malang, Indonesia. The bus is chosen because in this area the need for electric power in the area is very high and the existing system has a harmonic value of 11%. Hybrid Active Filter (HAF) is designed to lower the voltage harmonics due to EG injection into existing systems without affecting harmonics in other buses. To analyze the harmonics in this study there are 4 scenarios offered: Scenario 1 starts with analysis on existing system, scenario 2 existing in WPP 2 MVA injection, scenario 3, injection1.3 MVA PV, scenario 4 injected EG (WPP and PV). The simulation result using PSCAD 4.5 shows in scenario 4 to generate harmonic voltage of 18.6% and after added with HAF, the harmonic value of the voltage becomes 2.434%
Decision Support System Implementation for Candidate Selection of the Head of...IJRESJOURNAL
ABSTRACT: One of agency under the subdivision of The Indonesian National Army is Bintaldam V Brawijaya, acts as the mental founding agency. The head of affairs position replacement is often occurred in this agency, but the positions currently have a large number of incompetence person in charge. Subjection inthe election process leads to the inaccurate placement, resulting in poor leadership. The process of head of affairs assignment starts from candidates dispatching from each head of administrative section. Those candidates must then meet the three elements of assessment, i.e. the personality element, qualification element, and potential element. The candidates will be selected by head of agency as the top leader in the agency. The head of agency, however, poses difficulties to determine which candidate to put into position, frequently because of no proportional system exists to provide assistance in decision making process. A method is needed tomake more accurate placement for better leadership result.This research utilizegroup technology as the assessment elements hierarchical data structure and decision table as the rule evaluation engine to form a decision support system for making the replacement process of the heads of affairs easier and more accurate.
Yield Forecasting to Sustain the Agricultural Transportation UnderStochastic ...IJRESJOURNAL
ABSTRACT: Agricultural transportation is a major part of the United States’ transportation systems. This system follows a complex multimodal network consisting of highway, railway, and waterways which are mostly based on the yield of the agricultural commodities and their market values. The yield of agricultural commodities is dependent on stochastic environment such as weather conditions, rainfall, soil type and natural disasters. Different techniques such as leaf growth index, Normalized Difference Vegetation Index (NDVI), and regression analysis are used to forecast the yield for the end of harvest season. The yield forecasting techniques are used to predict the agricultural transportation needs and improve the cost minimization. This study provides a model for yield forecasting using NDVI data, Geographical Information System (GIS), and statistical analysis. A case study is presented to demonstrate this model with a novel tool for collecting NDVI data.
Injection Analysis of 5 Mwp Photovoltaic Power Plant on 20 Kv Distribution Ne...IJRESJOURNAL
ABSTRACT : A new 5 MWp PLTS or PV has been built in Oelpuah Village, Kupang Tengah. According to PT. PLN NTT,the amount of injected power to the distribution network cannot reach its maximum capability. At the moment, the average value of injected active power is 2 MWp. In this paper, a solution to achieve maximum injected power will be discussed. As a result of the study, the main problem is absence of energy storage. It cause the output power of the PV strongly affected by the weather. Hence a fluctuation of generated power cannot be avoided. The frequency in the distribution network system can be easily increased or decreased. Sudden drop in frequency due to 5 MWp lost, will cause the frequency to decrease beyond the standard value. The under frequency relay trips because it takes a long time to return to the originalvalue. A 5% of droop setting value is not suitable with those conditions. The droop characteristic setting should be reduced to 1% as a proposed solution. So that the response to frequency changes is more sensitive
Developing A Prediction Model for Tensile Elastic Modulus of Steel Fiber – Ce...IJRESJOURNAL
ABSTRACT: This paper attempts to develop a prediction model that can be used in line with prescribed laboratory experiments for indirect tensile test such that tensile elastic modulus can be predicted for cement stabilized lateritic soil reinforced with steel fiber using measured properties of the material. The results of the tensile elastic modulus obtained from the Derived Prediction Model almost nearly replicates that obtained from calculations from laboratory experimentation. Results obtained revealed that both the predicted values and calculated values have a linear correlation with an R2 of 96.4%. On this basis the Derived Prediction Model can be said to be valid within the limits of the study.
Effect of Liquid Viscosity on Sloshing in A Rectangular TankIJRESJOURNAL
ABSTRACT : Liquid sloshing was investigated for a moving partially filled rectangular tank with/without vertical baffles. A set of experiments was conducted using two types of liquids: water and sunflower oil. For these liquids, the effects of varying the external excitation amplitude and the number of vertical baffles on sloshing are discussed. It was found that the mechanical dissipation due to the liquid viscosity has a remarkable influence on the sloshing characteristics
Design and Implementation Decision Support System using MADM Methode for Bank...IJRESJOURNAL
ABSTRACT: The function of banking process can be broadly defined as an institution functioning as a capital receiver and lender, as well as support for trading and payment transactions. In order to maintain the stability of the economy through lending, Bank Indonesia issued a form letter on March 15, 2012 on the application of risk management for the bank conducting credit. In an effort to minimize these problems, Bank Indonesia recommends the precautionary principle in arranging the loan terms and choose the prospective customer in the credit granting institutions, both banks and cooperatives to take into account the risk on lending. A method is needed to select bank for credit applications to the public, i.e. the customer. This research uses the comparison of MADM (Multiple Attribute Decision Making) between TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) method and ELECTRE (ELimination Et Choix TRaduisant la realitE) method for the loan provisions to the customers. With the hope of getting the quickest and the most accurate solutions, the hesitancy in determining customers for lending can then be minimized.
Investigations on The Effects of Different Heat Transfer Coefficients in The ...IJRESJOURNAL
ABSTRACT: In the metal machining, the cutting fluid has become a tough problem in term of the health of works and environmental protection. The heat transfer coefficients of the water-based fluid, mineral oil and plant oil are distinct. An investigation focused on the effects of different heat transfer coefficients (h) on the cutting thickness compression ratio, chip formation, stress distribution and specific cutting energy is presented and discussed. In this study, three heat transfer coefficients have been simulated by Third WaveAdvantedge in machining AISI 1045 steel during different cutting speeds.It has been shown that the Mises stress and temperature are both affected by the heat transfer coefficient. When the h reaches higher, the Mises stress increases and the temperature shows the opposite trend. Also, the results can be found that the chip compression ratio decreases and shear angle increases when hrises. The relationship between specific cutting energy and heat transfer coefficients can be found in this paper.
Strategy of Adaptation of Traditional House Architecture Bali AgaIJRESJOURNAL
ABSTRACT : Adaptation is defined as a change to adapt to the environment or change the environment to fit the need to achieve balance. The Bali Aga community in Pengotan village has a tradition of building a house that refers to the concept of Tri Angga based on the Tri Hita Karana philosophy which is an expression of harmony with God, with human beings, and with the natural surroundings. Each element and layout of the building represents the alignment. In line with the development of the era, the pattern of community life changed resulting in traditional buildings are very regular and uniforms individually undergo a process of change without leaving the concept of Tri Angga and the philosophy of Tri Hita Karana.This paper is the result of field research that examines building changes by taking the example of traditional homes that undergo many changes to be able to conclude how traditional value changes occur in the original house.The results indicate that the change occurred partly due to the personal tastes of its inhabitants without the loss of fundamental changes in their philosophical value.Changes are found in non-structural building components and are strongly influenced by the ease of implementation of construction aspects. The building facade is striking with the appearance of ornaments on traditional buildings previously unknown in Pengotan
Design of Universal Measuring Equipment for Bogie FrameIJRESJOURNAL
ABSTRACT: The performance parameters of the bogie which directly affect the quality and safety of train operation should be detected during maintenance, especially the structure parameters of bogie frame after many operation years. Based on the related research of the bogie frame measuring requirement, a universal measuring equipment is designed for metro overhaul. The function, basic principle, structure and software design of the universal measuring equipment for bogie frame parameters are described, and the summary meanwhile prospect are given.
A Design Of Omni-Directional Mobile Robot Based On Mecanum WheelsIJRESJOURNAL
ABSTRACT:As one of the important branch of mobile robotics, wheel mobile robot has long been paid atten tion to by the research people at home and abroad for its high load ability, positioning accuracy, high efficiency, simple control, etc. Mobile robot has close relation to many technologies suc-h as control theory, computer tech nology, sensor technology, etc. Therefore, research on the mobile robot has important significance
An Investigation Into The Prevalence of Code Switching in the Teaching of Nat...IJRESJOURNAL
ABSTRACT: This study examines the functions of code-switching in primary schools by science teachers. In Namibia,English is the official language of instruction for science at primary school. At lower primary, Silozi is the language of instruction. Classroom interaction data was obtained from two science lessons. Analysis of the teachers' code-switching shows that code-switching in the two lessons was vastly different, with little codeswitching in the teacher-facilitated lesson.Evident in other lessons, in which science was taught as a content subjectbut with abstract names that had no corresponding local names in Silozi, there was frequent use of codeswitching for reiteration and message qualification. The direction of the language switch from Silozi to English as well as the proportion of teachersspeaking in English suggests that the official language for teaching is English at upper primary, grade 4 to 7. The science lesson and code-switching is a necessary tool for teachers to achieve teaching goals in content-based lessons involving students who lack proficiency in the instructional language. The study was conducted in five government primary schools in Katima Mulilo, the capital of the Zambezi region in Namibia.The national language is English language, with no exception inscience, mathematics, and language subjects.All Schools are located in a Katima Mulilo-urban. The students are from mixed classes, lower, middle and upper class families with their parents typically working as unemployed single mothers, domestic workers, clerks, nurses, teachers, and accountants. Some of the students could understand English because of their parents‟ educational background or in instances where English is spoken at home.
The Filling Up of Yogyakarta Governor Position in Social Harmony PerspectiveIJRESJOURNAL
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Optimal Maintainability of Hydraulic Excavator Through Fmea/Fmeca
1. International Journal of Research in Engineering and Science (IJRES)
ISSN (Online): 2320-9364, ISSN (Print): 2320-9356
www.ijres.org Volume 5 Issue 5 ǁ May. 2017 ǁ PP. 36-45
www.ijres.org 36 | Page
Optimal Maintainability of Hydraulic Excavator Through
Fmea/Fmeca
*Vivek Kumar, **Prof. Prakash Kumar
* Undergraduate Student, Department Of Production Engineering, B.I.T. Sindri, Dhanbad
** Head Of The Department, Department Of Production Engineering, B.I.T. Sindri, Dhanbad
ABSTRACT: The concept of advanced maintenance management technique in the field of heavy earthmoving
mining machinery is recently developed in India, and has taken pace with the demand of the same, rising
continuously over the years. This paper indulges into considering of hydraulic excavators, which is a large
machinery that is designed for excavation and demolitions purposes. It spreads to various sizes and functions.
The development of the mining industry has been escalated largely due to the introduction of different types of
excavators. These excavators are used to satisfy various mining, industrial and construction needs. The mining
excavators are mainly of two types that are used in modern era namely backhoe and dragline, other being
suction excavator, long reach/long arm, crawlers and compact excavators, power shovel etc. The data collected
and analysis has been done keeping in mind the vicinity of the coal capital of India, where hydraulic excavator
is mainly used. It is so, that the same gets prime focus in the paper. The increased penetration of service of the
high yield machines in the above-mentioned sectors have made them really important. Halting or stoppages are
seen as the bottlenecks, which disturbs the productivity. Seeing the large benefits, and associated productivity
and profit loss, the maintenance engineer felt the need to have advanced maintenance of the same. The paper
deals with different faults of the excavator, and based on the data acquired, takes on further steps towards
carrying out the FMEA analysis which incorporates into it by estimating Severity, Occurrence and Detection of
the considered parts respectively, and then Risk Priority Number (RPN) is calculated, ranging from 1 to 1000.
The quantitative approach helps in deciding the various maintenance strategies for the different parts and sub-
parts. It is based on the above factors that maintenance plans are initiated, designed and implemented.
I. INTRODUCTION
Open cast mining is the most common method of mine production in the world. In this, the required
production is provided by set of various tangible equipment, having variability in types and capacities.
Hydraulic excavator is one of them. Being a mega sized equipment; it generally requires a great deal of
investment. So, it is necessary to have its partwise maintenance and the its maintenance methodology has to be
carefully analysed so that overall maintenance can be carried out to bring to surface the full capacity of the
earthmover.
This paper discusses a maintenance strategy and claims to have criticality analysis of components of
mine excavators through FMEA/FMECA analysis program. Various functional analysis of the hydraulic
excavators and its components has been taken into account so that the maintenance cost be minimized and
technical constraints (such as engine, hydraulic and transmission system, break system, electrical and safety
system, suspension and track) are efficiently monitored and maintained. These technical constraints depend
upon many factors such as
a) Geotechnical parameters,
b) Geological parameters,
c) Mine parameters,
d)Production rate,
e) Equipment specification and
f) Dig ability assessment etc.
Taking into consideration the whole of above factors, maintenance plans are prepared for
predicting/accessing equipment’s and their components’ failure. For carrying out the same which is performed
continuously at regular interval, we can use data base similar to that monitored by protective devices to detect
abnormalities in behaviour, FMEC analysis, FMEA worksheet, Condition based monitoring system. (Kumar
Prakash & Srivastava R. K.)
II. LITERATURE REVIEW
Maintenance means the work of keeping equipment or anything in proper condition. It includes
activities like service, lubrication, repair and replacement of different parts of the equipment. It is the work done
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to preserve an asset so that it can perform its function properly. Maintenance keeps the equipment in operable
form so that it can be used effectively and efficiently till at least the design life of the equipment. Maintenance
activities are performed either after the failure of the equipment to restore it to the working condition or before
any kind of failure to avoid the equipment or a part from any kind of failure. Maintenance contributes around
15-40 % of the total production costs. Maintenance strategy can be defined as the identification, researching and
execution of repair, replace, inspect or servicing decisions or in short, the maintenance orders. Reactive
Maintenance is one of the most common and widely used maintenance strategies. Reactive Maintenance focuses
to restore the equipment to its normal operating conditions by repairing or replacing the faulty components and
parts. Preventive Maintenance consists of periodic maintenance. Preventive Maintenance is carried after a
specific operating hour, at calendar intervals or after a certain specified number of operating cycles. The
intervals are based on the operating industry experience and the manufacturers’ recommendations given in the
manuals. It mitigates the degradation of the component or the equipment to sustain its life or even extending it.
Total Productive Maintenance (TPM) is a maintenance philosophy that requires not only the employee’s
involvement but also the corporate management. It is a maintenance system, which is driven by the histories of
the equipment and the statistics. The equipment histories are thoroughly analysed and room for improvements is
found as equipment histories can lead to proactive maintenance approach. “5S” approach is the basis of total
productive maintenance system.
Condition Based Maintenance (CBM) also called predictive maintenance, is a strategy in which
maintenance work is performed when the condition of the equipment warrants10. In such a maintenance
strategy or philosophy, the replace or repair work is performed before obvious problem occurs. It avoids
unnecessary replacement of parts or components because it is purely based on the actual condition of the
equipment. It needs periodic lubrication, testing and observing trends of the equipment failure or unhealthy
events. Industrial Internet is the latest of all maintenance philosophies. Industrial Internet uses data analytics,
data visualization, and mobile collaboration devices with user interfaces. It enables preventive maintenance
based on the actual condition of the equipment or plant thus resulting in a zero-unplanned downtime. It can be
dealt as the advance form of condition based maintenance. Pareto analysis helps in identify the vital
breakdowns. It is based on 80-20 rule which states that eighty percent of the problems are caused by twenty
percent of the factors. It highlights the major factors behind the problems that tend to focus factors. “Five Why”
is another approach used for exploring root causes. It is a questioning method for analysis of the major problem.
It focuses on the major forces behind the occurrences of the failure and to devise a plan or prevention method
for the respective problems. It is a powerful tool used by professionals to find out the root cause of the failure.
Once the root cause of the failure is found then the elimination can be planned.
III. FMEA ANALYSIS
Mining technology development has led to the development of complex technical systems that can
hardly be seen without a systematic approach to analytical and methodological terms. Complex technical
systems in the mining industry are the result of the growing interest in and need for resource potential. Analysis
and risk management in the mining industry is a key factor in the quality and reliability management. One of the
main problems present in the technical systems in the mining industry is to effectively analyse and manage risk?
Until now, risk management did not give adequate importance. However, there is a real need and obligation for
an urgent change in the situation. One of several possible alternatives in the context of risk analysis and the
implementation of a system (FMECA and FMEA method) is to identify errors prior to their occurrence, which
could position the real potential benefits in mining.
FMEA & FMECA, known as Failure Mode and Effects Analysis and Failure Mode Effects and
Criticality Analysis, respectively, are a way for systems to be decomposed on a functional level. The loss of
particular component function is considered to be a failure mode of the component. To use these methods, a
system or component must be functionally decomposed. (Kumar Prakash & Srivastava R. K.)
FMECA is the most prominent and more widely used than FMEA, but is essentially the same method
but yields a criticality instead of risk priority number for a metric. These methods consider a failure mode, its
likelihood of occurrence, the severity of occurrence, and the likelihood of detection of the failure mode
(observe-ability). The problem with the methods comes with the calculation of the severity or Risk Priority
Number (RPN), which is essentially the likelihood (or number) of occurrences times the severity times the
likelihood (or number) of detections. Failure modes with the highest RPNs are to be evaluated first. Although it
is arguable that a more observable failure due to the ability to detect it may be prevented or mitigated more
easily, RPNs are by no means a solid metric for weighing failures. There is no sane agreement from
mathematically equating a highly unlikely, severe event with a highly probable, less severe event.
FMEA/FMECA is generally beneficial at smaller levels of granularity- the micro scale, such as failure modes
within components, rather than at the system level. These methods can also be beneficial in bottom-up
(Inductive) FT generation, although FT’s Department are typically generated from a top-down or deductive
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approach, which does not require the use of a supporting FMECA analysis. (Kumar Prakash & Srivastava R. K.)
Application Of Fmea
In the knowledge engineering phase: If we take the case of load haul dumper, however everybody is
very much familiar with this. The knowledge engineering phase of this research involved the identification of
the different main components and corresponding failure modes for LHD. These systems have some equipment
associated with the sub-system. Through extensive research, relevant data were collected of all the possible
failure modes. Such data were recorded on reliability centred maintenance analysis FMEA (Failure Mode and
Effect Analysis) sheets.
(Sahoo T.K, Sarkar A.K., Sarkar P.K.)
IV. TECHNICAL ASPECT OF RISK ASSESSMENT
Research in fundamental process mining functionality of shows, reliability and safety of technical
systems can hardly be achieved without the identification of all aspects of risk, or at least more, expert-level
analysis, processing, and generate more solutions at the level of qualitative relations professional eligibility
ceilings. Conducted research has focused technical aspects of risk analysis. Knowledge of state and behaviour of
technical systems (excavator for surface mining and related equipment) is the main goal of diagnosis and an
important reason for his constant monitoring online positioned critical areas. This approach allows the routing
information from different fields in order to work with less parameters determine the real behaviour of the
system, or whether his behaviour under load in real operating conditions in accordance with the prediction of the
designer. (Kumar Prakash & Srivastava R. K.) The next step is to develop strategies reaction/response to the
destruction in the context of recovery from the effects. Basic reasons why the relevant research and realized risk
in the mining industry is: (1- complexity of technical systems in the exploitation of mining resources with
critical and high-risk situation in a cancellation), (2- destruction/damage and large Multi-faceted technical
SEVERITY
Duration of service
interruption(hours)
Criterion of severity Value
>8 Very catastrophic 8
7 Catastrophic 7
6 Very serious 6
5 Serious 5
4 Medium 4
3 Significant 3
2 Minor 2
1 Very minor 1
0.5 Small 0.6
<0.5 Very small 0.2
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damage in mining, made in real time and space), and (3 - the potential criticality of the system due to the
technical parts - cracks, crevices, vibration, wear and tear, hidden pipe cavities in castings, etc.).
Risk analysis, minimization and monitoring, manufacturing mining recognize the need for:
1. Development of methodology for systemic risk analysis of technical systems;
2. Developing a methodology for assessing the impact of all identified aspects of the destructive potential of
technical systems in operation;
3. System analysis, needs assessment for partial or complete redesign and modernization;
4. Defining requirements and choice of technical risk management systems;
5. Configuration management process technical risks in mining;
6. Provide competent human resources for multidisciplinary work on risk management.
(Kumar Prakash & Srivastava R. K.)
V. RISK ANALYSIS USING FMECA METHOD
Analysis of the types, effects and critical failure (Failure modes, Effects and criticality analysis-
FMECA) is a method of assessing risk based on consideration of their consequences for the work product. It is a
systematic process that allows the definition of activities aimed at minimizing risk. The basic approach is to
identify and describe each type of potential failure, which may jeopardize the purpose of the product. The
analysis consists in the tabulation or graphical presentation of certain types of dismissal, in accordance with
their consequences and causes, control measures (control and diagnostics), corrective measures (measure of
compensation), the degree of criticism and other data relating to the design, manufacturing process, maintenance
etc. Based on the results obtained using methods FMECA, corrective and preventive measures can be improved
by designing determining ways of eliminating or lowering the probability of critical type of failure phenomena.
However, the method of FMECA can be used as an effective tool not only in design but also for improving the
production process and planning of preventive maintenance.
The essence of methods of FMECA is to identify and prevent known and potential problems with the
products before they reach the user. To do this you need to make some assumptions, such as the problems that
have different priorities. So, setting priorities is important for the breakthrough in the application of FMECA
methods. There are three components that help define priorities related to the dismissals of products:
Failure to appear;
Weight and failure;
Detection of failures.
The frequency of occurrence of a failure.
Weight is the severity (seriousness of the consequences) of cancellation. Describing the ability of
diagnostic failure before it reaches users. Based on the FMECA method it is possible to systematically identify
and document the potential impact of individual failures on the successful functioning of the products, operator
safety, results such as reliability, maintainability and performance products. Specificity FMECA method
consists in the possibility grade products in various stages of its life cycle (design, manufacturing process,use
maitntenance) in terms of ways in which problems (failures, errors. Conflicts,) can happen. (Kumar Prakash &
Srivastava R. K.)
Calculation Of Risk Priority Number
Assessment of the degree of criticism (Risk Priority Number - RPN) for each pair of "possible type of
failure-possible cause of failure types, can be deduced by the expression:
RPN = PF× FDV× PFR
Substrates PF, FDV and PFR are usually measured by grades 1 to 10 (can be used and other intervals).
Thus estimated value of the degree of critical RPN is compared with previously determined values allowed RPN
allowed. The solution is evaluated as satisfactory, if the RPN < RPN allowed, and if not, then the appropriate
corrective measures provides the target. (SAHOO T, SARKAR P. K., SARKAR A.K.)
Criticality Analysis and Maintenance Strategy
Parameters of criticality analysis
Maintenance strategy selection problem is based on criticality analysis. It casts its shadow on
numerous parameters for the criticality analysis. To name, they are Safety, Machine importance for the
process, Cost of maintenance, frequency of failure, Total downtime length, Operating conditions, Availability
of the spare parts/machines, Difficulty in accessing, propagation effect and Production loss cost. Moving onto
the best of them, six parameters have been made the scanner for the subsequent analysis purposes of the
failure components. The analysis is an extension of FMECA technique.
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Following six parameters of criticality analysis being:
Safety
Machine importance for the process
Cost of maintenance
Frequency of failure
Total downtime length
Operative conditions
Weight values are required to assign to the relevant parameters considered in FMECA. The six
parameters presented above derived from an accurate pre analysis of the 12 criteria to select of all relevant
parameters that can contribute to the machine criticality. It is also maneuvered to restrict the complexity
associated with the analysis to be performed, number of parameters is reduced for evaluation by grouping
together similar factors. Because, as the number of parameter increases, complexity also increases tremendously
but that does not guarantee a higher degree of accurate analysis, as anticipated beforehand. Besides, the
quantitative evaluation of factors described is complex and subject to risk of incorrect estimates.
The following clusters were created. The “spare machine availability” mainly affects the duration
which are generally uninterrupted production process and can therefore be linked to the “importance of
machine for some particular processes” which includes the “lost production cost”. In terms of spare parts, the
“maintenance cost” can include the type of machine maintenance and manpower contribution which can be
clustered with the “total downtime length” specifically. “Safety system”, “frequency of failure” “access
difficulty” and “operating conditions” are considered to be standalone factors by maintenance staff.
(Kumar Prakash & Srivastava R. K.)
Criticality Analysis of Equipment:
Weight values assigned to the relevant parameters considered in FMECA analysis
Weight of parameter
Safety – 1.5
Machine importance for the process – 3
Maintenance costs – 2
Failure frequency – 1.5
Downtime length – 1
Access and difficulty & operating condition – 1
Criticality Index: - The factors taken into account are grouped together in following criticality index (C.I),
C.I = (S x Weight Value of Safety) + (IP x Weight value of machine importance) + (MC x Weight value of
maintenance costs) + ( FF X Weight value of failure frequency) + (DL x Weight Value of downtime
length) + (AD x Weight Value of access difficulty).
Where S = safety, IP = importance of machine for the process, MC = maintenance costs, FF = failure
frequency, DL = downtime length, AD = machine access difficulty.
Table : Probability of Occurrence Criteria for Ranking Failure Modes
Probability Unlikely Remote Infrequent Occasional Likely
Failure is
Failure
Failure
could probable in Failure is
Failure under Highly
occur under response to Almost
Description
These Improbable
rare and intermittent, inevitable and
Circumstances due to lack of
Extreme extreme but Possibly
is unlikely Relevant Circumstanc
e foreseeable Frequent
circumstances events
Frequency of
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occurrence in
0 0-1 1-2 2-4 Annually
the 19 year
mine-life
Table : Consequence Criteria for Ranking Failure Modes
Consequence Negligible Minor Modest Critical Catastrophic
Measurable effect on
Measurable effect
on
Overwhelming
effect on
Minor effect on
environment or human
environment or
human environment and
health resulting in health resulting in
human health
resulting
Defined
No
significant
environment,
human
intermittent or
continued
operational in shutdown and
Affect health, or project
temporary operational changes with
financial
consequence
Viability
changes with modest significant financial affecting project
financial consequence consequence viability
Transient, minor
upset
Impact which can be
Impact which can
be Impact requiring
majorrequiring
operational addressed through
Environment
al risk
No
environment
al readily addressed
facility redesign
orresponse, no
design or long term design or
Risk through minor design rebuild, requiring
treatment response
significant
treatment
or treatment action prolonged effort
Required action
Human
health risk
No human
health
No injuries Possible minor injuries Injury, no fatality
Injuries with
fatalities
Risk
Prolonged delay in
Short term loss of
facility operations Complete loss of
requiring major function requiring
Resulting
change in
facility in operation
No changes
Maintenance
action reconstruction, may
facility
replacement or
requiring minoroperations Required Only result in agency loss of project
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reconstructions; other
viability,
initiated temporary
suspension of
mine
resources available
suspension of Permits
operations
Failures Associated With Excavator
It is based on the criticality analysis and the parameters considered in it, that has produced 16 failure
modes, and accounted for necessary and required productivity loss. Subsequently, Pareto analysis has been
conducted and the results of the same has a lot more to say on the most critical causes and frequency of failures
as well. Different failures, which has been culminated are listed below: -
Injector failure
Chain adjuster seals failure
Hydraulic filter failure
Ground engaging tool wear and tear
Chain nut and bolt rundown
Cartridge (hydraulic pump) failure
Oil pump failure
Transmission pump failure
Nozzle run down
Transmission filter failure
Chain sprocket failure
Injector failure
Air filter failure
Water pump failure
Plunger failure
Final drive seals failure
(Ullah Anwar, Islam Sabir, Khattak Sikandar Bilal, Rehman Safi Ur, Maqsood Shahid, Ullah Misbah, Akhtar
Rehman, Nawaj Rashid)
8. Optimal Maintainability of Hydraulic Excavator Through Fmea/Fmeca
www.ijres.org 43 | Page
The above table shows unmitigated components criticality as well as mitigated positive outcomes. One
thing that is very obvious to note here is that there are some proposed solutions to guide through the problems
and mitigate the unmitigated severe problems.
These proposed solutions, if implemented properly, can give better outcomes in terms of proper
functioning as well as better full capacity utilisation of the hydraulic excavator. The advanced maintenance
management strategy proposed after calculation of the Risk Priority Number is also a very important analysis.
Definitely it is impossible to protect the degradation of the equipment or machinery, and that too in the case of
mining machinery which are way too heavy to cost the functioning of the excavator components at faster rate. It
becomes essential for the maintenance engineer to suggest some strategy or technique to slow down the
depreciation of the same, and in this way we can reserve the life of the machine. If the proposed maintenance
strategy is carried out as planned, it will be more easier to utilise the same to its full capacity.
FAILURE
MODES CAUSES
PROBAB
ILITY
CONSEQ
UENCE PROPOSED
SOLUTION
REVISED
PROBAB
ILITY
Revised
Consequence
UNMITIGATED MITIGATED
O-Ring
Failure
1.High
Pressure
2. Weak
Metallurgical
Property
3.Larger
Clearance
Condition
Frequent Catastrophi
c
1. Back Up Devices
Into Action.
2. Temperature
Exposed Is To Be
Kept Minimum.
3. Low Set O-Ring
Material To Be Used.
Remote Critical
Hydraulic
Jack Seals
1. Filthy
Condition
2. Open To
External
Surroundings
Frequent Very
Critical
1.Proper Lubrication
And Cleaning Action,
2. Proactive
Inspection Prior To
Use.
3.Piston And Rod
Retracted When Not
In Use.
Unlikely Modest
Air Filter
Failure
1. Filthy
Condition
Frequent Critical 1. Replacement Of
Air Filter Periodically
2. Air Filter Should
Be Cleaned Prior To
Use.
3. Protection From
Contaminant Liquid.
Unlikely Critical
Hydraulic
Filter
1. Mixing Of
Water And
Oil
2. Oil
Contaminati
on Due To
Particulates
Remote Critical 1. Periodic Inspection.
2. Replacement Of
Filter At Regular
Interval.
Likely Modest
Final Drive
Seals
Failure
1. Oil
Contaminati
on
2.Changing
Filters
Irregularly
3.Sillicon
And Water
Remote Critical 1. Oil Filters To Be
Changed Regularly.
2. Oil Use Efficiently
And Properly.
Unlikely Minor
Cartridge
Failure
1.Hydraulic
Fluids
Adulteration,
2.
Contaminati
on Of Solid
Particles
Remote Modest 1. Replacement Of
Complete Fluid When
Contaminated.
2.Hydraulic Filter To
Be Changed At
Periodic Intervals.
Unlikely Modest
Transmissio
n Filter
Failure
1. Clogging
Fluids.
2. Low Fluid
Levels.
3.Transmissi
on Slip
Infrequent Catastrophi
c
1.Filter Change When
Problem Surfaced.
2. Fluid Inspection.
Likely Catastrophic
9. Optimal Maintainability of Hydraulic Excavator Through Fmea/Fmeca
www.ijres.org 44 | Page
Calculation Of Rpn And Decision On Maintenance Strategy
Sl.
No.
Name Severity Occurrence Detectibility Risk
Priority
Number
Maintenance
Strategy
1.O-Ring 6 8 7 336 Predictive
Maintenance
2.Hydraulic
Jack Seals
4 7 5 140 Corrective
Maintenance
3.Oil Filter 5 7 5 175 Corrective
Maintenance
4.Transmission
Filter
8 6 6 288 Preventive
Maintenance
5.Hydraulic
Filter
6 7 6 252 Preventive
Maintenance
6.Chain
Sprocket
3 5 6 90 Corrective
Maintenance
7.Cartridge
Failure
5 4 5 100 Corrective
Maintenance
8.Oil Pump 4 4 6 96 Corrective
Maintenance
9.Air Filter 6 8 4 192 Corrective
Maintenance
10.Nozzle Run
Down
3 2 3 18 Corrective
Maintenance
As mentioned in the previous pages, 17 modes of failures have been categorised. They have been put
down to the testimony under the Pareto analysis so as to be aware of the frequency of the failures associated.
Afterwards, only 7 highly critical components have been sorted out for FMEA/FMECA analysis. The failures
modes along with causes, unmitigated & mitigated probability and consequences with probable solutions have
been proposed in the analysis. Only those components have been investigated whose downtime length or Failure
rates or both are quite significant in context of desired performance of excavator. O-rings fail frequency is large
followed by jack seals and has been proposed for the predictive and corrective maintenance respectively.
VI. Conclusions
An advanced system for maintenance strategy for mining excavators has been developed. These mining
excavators are increasingly being used in open cast mining. The monitoring and control system has equipment
database obtained from manufacturers and mine specific data are entered into the system. (Adhammar Et.al,
Kumar Prakash, Srivastava R.K.) The paper has FMEA/FMECA analysis of components failure detection and
system related failures and accordingly databases are formed by the FMEA and FMECA which predict fault or
deterioration in excavator components. The main aim is to select the best maintenance strategy to reduce the
maintenance related cost as well as to reduce the unit production cost in mining sector. In the paper, related data
have been collected and then based on the criticality analysis several failure modes have been shortlisted, and
then Pareto analysis conducted shows various failure frequency. Post Pareto results, FMEA/FMECA analysis of
most critical components (8 components) have been carried out, which culminates with unmitigated and
mitigated criticality status along with the proposed solutions to redress the problems. This same helps in
lowering down the failure rate or frequency of the components. The calculation of Risk Priority Number (RPN)
and the suggested maintenance strategy aids in lowering the downtime length of the failure. Therefore, the paper
deals with both the major concerns i.e. failure frequency as well downtime length/durations. The analysis was
used to identify and then propose the mitigation to more typical mine planning in order to enhance the
productivity in mining manoeuvers. The analysis documents the incorporation of these mitigations consistently
and significantly reduces the risk of failure. The same shows the selection of improved process, and
incorporation of improved changes in construction and design methods.
References
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