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عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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أخوانى فى الله أحضرت لكم مشروع تخرج بعنوان Reliability Centered Maintenance For Longitudinal Seaming Station Graduation Project (Practical Case Study) Supervised By: Dr / Islam H. Afefy Submitted By: AJhmaedl Mohamed Basanien Ahmed Mohamed A. El-Rahman Elham Mohammed Alhm Abeer Hassan Moawad Fayoum University Faculty of Engineering Industrial Engineering Dep.
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TABLE OF CONTENTS Chapter 1: Maintenance Over view 1.1 Introduction 2 1.2 Maintenance polices and reliability centered maintenance (rcm) 3 1.3 Maintenance types 5 1.3.1 Reactive maintenance (run-to-failure) 5 1.3.2 Preventive maintenance 7 1.3.2.1 Value of preventive maintenance 7 1.3.2.2 When does Preventive maintenance make sense 8 1.3.2.3 The fallacy of "constant failure rate" and "preventive replacement" 9 1.3.2.4 Determining preventive replacement time 9 1.3.3 Predictive maintenance 11 1.3.3.1 Chemical analysis 12 1.3.3.2 Vibration analysis 15 1.3.3.3 Temperature measurement 19 1.3.4 Proactive maintenance 20 1.3.4.1 Specifications for new/rebuilt equipment 21 1.3.4.2 Failed-part analysis 23 1.3.4.3 Root-cause failure analysis (rcfa) 23 1.3.4.4 Reliability engineering and reliability calculations 24 1.3.4.5 Rebuild certification/verification 27 1.3.4.6 Age exploration 28 1.3.5 Risk based maintenance 29 1.3.5.1 Principles and benefits of “risk based inspection” 29 1.3.5.2 key success factors in implementing risk based maintenance 31 1.3.5.3 Conclusions 36 1.3.6 Reliability centered maintenance 36 1.3.6.1 Reliability centered maintenance features 37 1.3.6.2 Reliability–centered maintenance methodology 38 Chapter 2: Reliability Centered Maintenance(RCM) 2.1 Introduction 41 2.2 Reliability centered maintenance history 42 2.3 Reliability centered maintenance principles 44 2.4 Reliability centered maintenance analysis 48 2.5 Basic steps of applying reliability centered maintenance (rcm) 50 2.5.1 Identify functional failures 51 2.5.2 Identify and evaluate (categorize) the effects of failure 52 2.5.3 Identify the causes of failure (failure modes) 53 2.5.4 Failure modes and effects analysis (fmea) 56 2.5.4.1 When to use the FMEA 57 2.5.4.2 Failure Mode Effect Analysis procedure 57 2.6 Reliability centered maintenance program benefit 60 Chapter 3: Practical Case Study 3.1 Company overview 64 3.1.1 Vision, mission and culture of the company 65 3.1.1.1 Vision 65 3.1.1.2 Mission 65 3.1.2 The heritage of the company 66 3.1.3 History of the company 66 3.1.4 Awards of the company 67 3.1.5 Care for the environment 67 3.1.5.1 Noise reduction 68 3.1.5.2 Low pollutant emissions 69 3.1.6 The exhaust system from about el yazeed 69 3.2 System selection and information collection 70 3.2.1 Company departments description 71 3.2.1.1 Press shop 71 3.2.1.2 Tube forming shop 71 3.2.1.3 Wire forming shop 71 3.2.1.4 Muffler assembly shop 72 3.2.1.5 Exhaust system shop 72 3.2.2 Company production line 72 3.2.3 System selection 74 3.2.4 Information collection 74 3.3 Functional block diagram 75 3.3.1 Block diagram for hydraulic cycle 76 3.3.2 Blocks diagram for longitudinal seaming and flanging m/c 77 3.4 system Boundary 78 3.4.1 Boundary overview 78 3.4.2 Boundary details 80 3.5 System description 83 3.5.1 Programmable logic controller unit (plc) 84 3.5.2 Hydraulic stations 85 3.5.2.1 Electric motor 86 3.5.2.2 Coupling 87 3.5.2.3 Oil pump (gear type) 88 3.5.2.4 Valves 88 3.5.2.5 Oil tank 92 3.5.2.6 Water cooling cycl 93 3.5.2.7 Oil indicator 93 3.5.2.8 Oil filter 94 3.5.3 Longitudinal seaming machine 94 3.5.3.1 Manual loader 95 3.5.3.2 Table 95 3.5.3.3 Mandrel 97 3.5.3.4 Side lock 97 3.5.3.5 Vice 98 3.5.3.6 Accumulator 98 3.5.3.7 Carriage with seaming rolls 99 3.5.3.8 Translator 101 3.5.3.9 flanging Machine 102 3.6 Equipment history 104 3.7 Root cause analysis 105 3.7.1 Effective use of the analysis 106 3.8 Failure mode and effect analysis (fmea 111 3.9 Criticality analysis: 117 3.10 Task selection 123 3.11 Current maintenance plan 129 3.11.1 Labor program 130 3.11.2 Spare parts program 130 3.11.3 Tool program 130 3.11.4 Current preventive maintenance plan 131 3.12 Proposed preventive maintenance plan 133 Chapter 4: Safety Program 4.1 Introduction 145 4.2 Hazards, risks and safety precautions 146 4.2.1 Hazard and near miss definitions 146 4.2.2 Hazard types 146 4.2.2.1 Physical hazards 146 4.2.2.2 Engineering hazards 152
4.2.2.2.1 Electrical hazard 152 4.2.2.2.2 Mechanical hazard 157 4.2.2.3 Chemical hazard 159 4.3 system hazard 167 4.4 system near miss 168 4.5 risk matrix analysis 174 4.5.1 Risk 175 4.5.2 Risk analysis 175 4.5.3 Risk control 175 4.5.4 Risk assessment 175 4.5.5 Risk level 175 4.6 Recommendation 176 4.6.1 OSHA 1910.119 process safety management. 176 List of Tables Table (1-2): Seven Basic Types of Chemical Analysis 12 Table (1-1): Maintenance Policies 4 Table (1-3): Particle Techniques 15 Table (1-4): ISO 2372-Vibration Severity Range Limits (Velocity) 18 Table (1-5): Example of a System Component Fails 26 Table (2-1): Reliability Centered Maintenance History 42 Table (1-6): Risk Matrix 36 Table (2-1): Reliability Centered Maintenance History 42 Table (2-3): Example of Failure Mode Identification 54 Table (2-4): Failure Mode and Effect Analysis 60 Table (3-1): Boundary Overview 79 Table (3-3): Equipment History. 104 Table (3-4) Root Cause Analysis (RCA). 107 Table (3-5): Failure Mode and Effect Analysis (FMEA). 112 Table (3-6) Criticality Analysis Form. 119 Table (3-7): Criticality Group. 119 Table (3-8): Criticality Analysis 120 Table (3-9): Task Selection Process 123 Table (3-10): Task selection 124 Table (3-11): Labor Program 130 Table (3-12): Spare Parts Program 130 Table (3-13): Tool Program 130 Table (3-14): Current Preventive Maintenance Plan 131 Table (3-15): Proposed Preventive Maintenance Plan 133 Table (3-16): Condition Based Maintenance Tasks (CBM) 135 Table (3-17): Preventive Maintenance Schedule and Tasks 136 Table (3-18): Weekly maintenance tasks 138 Table (3-19): The Size of Maintenance Labor Force 139 Table (3-20): Proposed Labor Program 139 Table (3-21): Proposed Spare Parts Program 140 Table (3-22): Proposed Tool Program 142 Table (3-23): Weekly Maintenance Follow up Form 143 Table (4-1): Risk Matrix Analysis Sample 176
List of Figures Fig. (1-1): Classification of Maintenance Polices. 3 Fig. (1-2): Cost Versus Time for Maintenance Total Cost 10 Fig. (2-1): Components of RCM Program. 47 Fig. (2-2): Reliability Centered Maintenance Logic Tree 49 Fig. (3 -1): Abou El Yazeed Company. 64 Fig. (3-2): Muffler Components. 68 Fig. (3-3): Product of Abou El Yazeed Company. 70 Fig. (3-4): Company Department 71 Fig. (3-5): Company Production Line 73 Fig. (3-6): System Block Diagram. 75 Fig (3-7): Subsystem Block Diagram (Hydraulic Cycle 76 Fig. (3-8): Subsystem Block Diagram (Longitudinal Seaming Machine). 77 Fig. (3-9): Subsystem Block Diagram (Flanging Machine). 78 Fig. (3-10): The Longitudinal Seaming Station 83 Fig. (3-11): Longitudinal Seaming Station Subsystems 83 Fig. (3-12): Programmable Logic Controller Unit. 85 Fig. (3-13): The Hydraulic Station. 86 Fig. (3-14): The Electric Motor. 86 Fig. (3-15): Rigid Shaft Coupling. 87 Fig. (3-16): The Oil Pump (Gear Type). 88 Fig. (3-17): Rated Fatigue Pressure Valve. 89 Fig. (3-18): The Fourth Rated Fatigue Pressure Valve. 90 Fig. (3-19): Schematic Diagram for the Solenoid Valve. 91 Fig. (3-20): Solenoid Valve (England). 91 Fig. (3-21): Solenoid Valve (Germany). 91 Fig. (3-22): Relief Valve. 92 Fig. (3-23): Water Cooling Cycle. 93 Fig. (3-24): Oil Indicator 93 Fig. (3-25): Oil Filter for the Hydraulic Cycle. 94 Fig. (3-26): The Longitudinal Seaming Machine. 95 Fig. (3-27): Manual Loader 95 Fig. (3-28): Table of the Longitudinal Seaming Machine. 96 Fig. (3-29): Table’s Belts. 96 Fig. (3-30): Ruler of Belt Table 97 Fig. (3-31): Mandrel 97 Fig. (3-32): Side Lock of the Mandrel 98 Fig. (3-33): Vice of Mandrel 98 Fig. (3-34): Accumulator Diagram. 99 Fig. (3-35): Carriage with Seaming Rolls 99 Fig. (3-36): First Station (1, 2, 3,4,5,6, and 7 Rolls) 100 Fig. (3-37): Fourth Station. 101 Fig. (3-38): Translator Diagram 101 Fig. (3-39): Flanging Machine 102 Fig. (3-40): Flanging Die. 102 Fig. (3-41): Upper Jaw. 103 Fig. (3-42): Ejector. 103 Fig. (4-1): Mechanical Hazard and Unsafe Act 168 Fig. (4-2): Mechanically, Physically, And Unsafe Act 168 Fig. (4-3): Mechanical Hazard and Unsafe Act 169 Fig. (4-4): Mechanical Hazard, Unsafe Act and Unsafe Condition. 169 Fig. (4-5): Electrically and Unsafe Act 170 Fig. (4-6): Electrical and Physical Hazard 170 Fig. (4-7): Electrically and Unsafe Act 171 Fig. (4-8): Electrically and Unsafe Act 171 Fig. (4-9): Electrical and Mechanical Hazard 172 Fig. (4-10): Physical Hazard 172 Fig. (4-11): Mechanical, Physical and Electrical Hazard 173 Fig. (4-12): Mechanical and Unsafe Condition 173 Fig. (4-13): Unsafe Act and Physical Hazard 174 Fig. (4-14): Unsafe Act and Ergonomic Hazard 174
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Admin مدير المنتدى
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عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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