Maintenance downtime evaluation in a process bottling plant

Abstract

PurposeDowntime is a process parameter that substantially impacts on the operating hours and results in production losses, thus motivating maintenance engineers to control process plants. Notwithstanding, the impacting nature of process equipment failure on the operating hours in bottling plants remains inadequately examined. In this paper, the cause-and-effect analysis was used to establish the root cause of the downtime problem and Pareto analysis employed to justify the greatest opportunities for improvement in reducing downtime and increasing reliability levels. Weibull analysis is then conducted on the industrial setting. Novel aspect ratios are proposed.Design/methodology/approachUsing the Weibull failure function of machines as a principal facilitator to produce failure predictions, the downtime behaviour of a process plant was modelled and tested with practical data from a bottling process plant. This research was conducted in a Nigerian process bottling plant where historical data were examined.FindingsThe analysis of the results shows the following principal outcome: First, the machines with the highest and least downtime values are 2 and 5, respectively, with correspondingly mean values of 22.83 and 4.39 h monthly. Second, the total downtime 92.05 and 142.14 h for the observed and target downtime, with a coefficient of determination of 0.5848 was recorded. Third, as month 1 was taken as the base period (target), all the machines, except M5 had accepted performance, indicating proper preventive maintenance plan execution for the bottling process plant. Availability shows a direct relationship between the failure and uptime of the machines and the downtime impacts on production. Two machines had random failure pattern and five machines exhibited a wear-out failure pattern and probably due to old age and wear of components in the machines.Originality/valueThe major contribution of the paper is the Weibull modelling in a unique application to a bottling plant to avoid current practices that use reliability software that is not easily accessible.

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