Optimization of maintenance strategies for steam boiler system using reliability-centered maintenance (RCM) model – A case study from Indian textile industries

Patil, S. I.; Bewoor, Anand K.

doi:10.1108/ijqrm-07-2021-0216

Cited by 5 publications

(5 citation statements)

References 30 publications

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“…Their study focused on the FMEA application, where the failure effects and consequences were assessed based on the distinctive operational nature of UMS. Patil and Bewoor (2022) proposed a comprehensive RCM framework for a steam boiler in the textile industry. They demonstrated the application of a decision logic to select the optimum maintenance policy.…”

Section: Rcm Applications – An Overviewmentioning

confidence: 99%

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A systematic reliability-centred maintenance framework with fuzzy computational integration – a case study of manufacturing process machinery

Ali Ahmed Qaid,

Ahmad,

Mustafa

et al. 2024

JQME

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PurposeThis study presents a systematic framework for maintenance strategy development of manufacturing process machinery. The framework is developed based on the reliability-centred maintenance (RCM) approach to minimise the high downtime of a production line, thus increasing its reliability and availability. A case study of a production line from the ghee and soap manufacturing industry in Taiz, Yemen, is presented for framework validation purposes. The framework provides a systematic process to identify the critical system(s) and guide further investigation for functional significant items (FSIs) based on quantitative and qualitative analyses before recommending appropriate maintenance strategies and specific tasks.Design/methodology/approachThe proposed framework integrates conventional RCM procedure with the fuzzy computational process to improve FSIs criticality estimation, which is the main part of failure mode effect criticality analysis (FMECA) applications. The framework consists of four main implementation stages: identification of the critical system(s), technical analysis, Fuzzy-FMECA application for FSIs criticality estimation and maintenance strategy selection. Each stage has its objective(s) and related scientific techniques that are applied to systematically guide the framework implementation.FindingsThe proposed framework validation is summarised as follows. The first stage results demonstrate that the seaming system (top and bottom systems) caused 50% of the total production line downtime, indicating it is a critical system that requires further analysis. The outcomes of the second stage provide significant technical information on the subject (seaming system), helping team members to identify and understand the structure and functional complexities of the seaming system. This stage also provides a better understanding of how the seaming system functions and how it can fail. In stage 3, the application of FMECA with the fuzzy computation integration process presents a systematic way to analyse the failure mode, effect and cause of items (components of the seaming system). This stage also includes items’ criticality estimation and ranking assessment. Finally, stage four guides team members in recommending the appropriate countermeasures (maintenance strategies and task selection) based on their priority level.Originality/valueThis paper proposes an original maintenance strategies development framework based on the RCM approach for production system equipment. Specifically, it considers a fuzzy computational process based on the Gaussian function in the third stage of the proposed framework. Adopting the fuzzy computational process improves the risk priority number (RPN) estimation, resulting in better criticality ranking determination. Another significant contribution is introducing an extended item criticality ranking assessment process to provide maximum levels of criticality item ranking. Finally, the proposed RCM framework also provides detailed guidance on maintenance strategy selection based on criticality levels, unique functionality and failure characteristics of each FSI.

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Section: Rcm Applications – An Overviewmentioning

confidence: 99%

“…The second approach is based on the MCDM application. Patil and Bewoor (2022) presented a comprehensive review of the maintenance strategy selection based on MCDM applications.…”

Section: The Proposed Rcm Framework With Fuzzy Computational Processmentioning

confidence: 99%

A systematic reliability-centred maintenance framework with fuzzy computational integration – a case study of manufacturing process machinery

Ali Ahmed Qaid,

Ahmad,

Mustafa

et al. 2024

JQME

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“…The boiler system is a complex system with many critical subsystems defined by Patil et al [36,37] used in the Indian textile industries. Patil et al [38] presented some critical subsystems through failure frequency analysis of the boiler system and reliability analysis [39].…”

Section: Case Study Of Boiler System Used In Textile Process Industriesmentioning

confidence: 99%

A New Approach for Failure Modes, Effects, and Criticality Analysis Using ExJ-PSI Model—A Case Study on Boiler System

et al. 2022

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Failure Modes, Effects, and Criticality Analysis are widely used to assess the failure modes of a system, along with their causes and effects. Several Multi-Criteria Decision-Making approaches have been developed to overcome the limitations of the traditional FMECA. In these approaches, several multiple criteria are considered to determine the criticality values and assign criticality ranks. In these developed approaches, only one expert can involve in criticality analysis. By incorporating several experts from design, manufacturing, and maintenance domains in the criticality analysis accuracy of the results can be improved. This paper proposes a new integrated Expert Judgment-based Preference Section Index (ExJ-PSI) model that combines MCDM approaches and integrates expert opinions. The proposed model is applied to a boiler system used in the textile industry. The results are compared with those obtained from the conventional FMECA and normalized median method. In the present study, the opinions of seven experts from various domains and organizations are discussed. To normalize the collected data, one scale is developed by considering four expert criteria, such as the experience of the expert, the number of boilers he is handling, the number of employees under his supervision, and the proficiency in the field. The proposed model is more effective and flexible in handling and analyzing data of complex configured systems consisting of many subsystems, components, and failure modes. The analysis reveals that the feed water pump, feed water pump motor, supply water temperature sensor, return water temperature sensor, header, and coal feed motor are some of the most critical components of the boiler system.

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“…The petroleum industry is characterized by large resource consumption, a complicated production process and a large amount of environmental pollution (Tong et al ., 2020). The industry’s production process comprises considerably complex systems and equipment, and with the increase in mechanization and complexity in manufacturing facilities (Hassan et al ., 2012), and the fact that most equipment operate beyond their original design life, maintaining equipment reliability and integrity as well as operational safety presents unique safety and business risk challenges for the industry (Khan et al ., 2020; Patil and Bewoor, 2022). Unexpected equipment defects will result in serious economic loss, environmental damage, and health and safety harm to the workers and even residents in the vicinity (Ratnayake, 2014).…”

Section: Introductionmentioning

confidence: 99%

Sustainable maintenance planning in the petroleum industry: an application of system dynamics approach

Hosseinzadeh

Foroushani

Ghayem

et al. 2023

IJQRM

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PurposeWhile the petroleum industry remains to be the main source of energy in the world, it is responsible for a large amount of resource consumption, environmental emission and safety issues. In this industry, most of the refinery equipment are running out of their designed life cycle, leading to many challenges regarding equipment reliability, products quality, organizations’ profitability, human resources safety and job satisfaction, and environmental pollution, which affects not only the human resources of the refinery but also the people who live in the vicinity. This study aims to model and simulate the maintenance system of an oil refinery to reduce the rotating equipment’s downtime while simultaneously considering the three pillars of sustainability.Design/methodology/approachConsidering the complexity of the system and its inherent dynamism, System Dynamics (SD) approach is applied to model and simulate the maintenance system of an oil refinery, aiming at reducing equipment’s downtime considering the three pillars of sustainability simultaneously. As a case study, the maintenance system of rotating equipment in the Abadan oil refinery of Iran is investigated.FindingsIndividual policies are investigated and categorized into three main groups: economic, social and environmental. The dynamic nature of the system demonstrates that applying combinations of the policies would be more effective than performing individual ones or even a combination of all policies at the same time. The findings show that to manage the maintenance and reliability issues in complex industries, only operational level maintenance strategies would not be helpful; rather, a holistic strategic solution counting different suppliers or even the government policies supporting the operational level maintenance decisions would be effective.Originality/valueThis study is the first which brings the perspective of sustainable policy-making in the SD modeling of a complex maintenance system like that of the petroleum industry. The developed model considers economic, environmental and social objectives simultaneously. Besides, it reflects the role of different stakeholders in the system. Furthermore, the policy-making attempt is not limited to the operational level corrective and maintenance solutions; instead, a comprehensive, holistic view is applied.

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Optimization of maintenance strategies for steam boiler system using reliability-centered maintenance (RCM) model – A case study from Indian textile industries

Cited by 5 publications

References 30 publications

A systematic reliability-centred maintenance framework with fuzzy computational integration – a case study of manufacturing process machinery

A systematic reliability-centred maintenance framework with fuzzy computational integration – a case study of manufacturing process machinery

A New Approach for Failure Modes, Effects, and Criticality Analysis Using ExJ-PSI Model—A Case Study on Boiler System

Sustainable maintenance planning in the petroleum industry: an application of system dynamics approach

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