Effect of Preventive Maintenance on Machine Reliability in a Beverage Packaging Plant

Abstract

This paper investigates the effect of preventive maintenance on the reliabilities of devices in a bottling plant. Six months of real-time maintenance data were analyzed quantitatively. Based on the breakdown events obtained for each machine, mean time between failure (MTBF), mean time to repair (MTTR), and failure rate (λ) values for individual equipment are calculated. The bottle packer, empty bottle inspector (EBI), and palletizer are identified as the plant's critical machines. A breakdown analysis (BDA) is then performed on the bottle packer and from the failure mode of all the reoccurring problems affecting this machine as a result of ineffective PM. An autonomous maintenance (AM) team is set up as part of establishing an effective PM program to improve the reliabilities of the critical machines that were continually falling. A significant reduction in machine breakdowns is observed after two months of rolling out the AM program. As a result, the reliability of bottle packer increased from 55.30% to 70.80%, while EBI and palletizer increased from 89.20% and 87.20% to 92% and 90.50%, respectively.

New Chemistries for Degradable Pressure‐Sensitive Adhesive Networks

“…Although many PSAs can be lifted from surfaces through chemical treatment (glass bottle recycling, for example, involves soaking in 2 % aqueous NaOH at 80 °C to clean the glass [33] ), the removed PSA remains a crosslinked, insoluble polymer gel. These so‐called “stickies” remain tacky, adhere to surfaces, and increase the reprocessing and waste disposal costs.…”

The returned product‐process matrix: A decision‐making framework for reverse logistics operations strategic choice

“…This is the basis of the ABC inventory management classification, highlighting the critical relationship between expected results and required efforts (Ravinder & Misra, 2014). The cost of reusing a bottle is more efficient than remanufacturing (Ben et al, 2020). In any case, why should a firm spend money to recover an item that is not damaged?…”

“…According to Ben et al (2020), bottle washing involves three phases: prewashing, washing and rinsing. Prewashing is the initial stage of the washing process, where the refillable returnable glass bottles are turned upside-down so that remnant impurities and residuals liquids (such as microbes, sand, dust, crown corks, cigarette butts, rainwater) clinging to the bottom of the bottle fall out, to a collection pan and removed through a sieve-belt conveyor.…”

Plant Maintenance Performance Measurements Shortfalls

“…Along with the strategies, performance indicators help the organisation to fulfil its mission of offering the highest quality services with good value to its stakeholders, maximising human resource potential, and ensuring the physical and fiscal integrity of the institution [30]. According to Behn [7], leaders can use the measurement to evaluate, control, budget, motivate, promote, celebrate, learn, and improve the organisation. This is a powerful behavioural tool, since it communicates what matters to the stakeholders.…”

“…Ben, Mohamed and Muduli [7] investigated the effect of PM on machine reliability in Heineken's South Pacific Brewery beverage packaging plant in Papua New Guinea, which had a high number of breakdown events. Placing experienced operators at the key machines reduced the total breakdown time.…”