An Integrated Methodology for Preventive Maintenance Planning.

摘要

Due to high competition in today's markets, organizations seek to manufacture high quality products with relatively low costs. Increasing equipment's available time reduces manufacturing costs. This can be achieved through preventive maintenance that reduces breakdown of equipment. Well maintained equipment increases a production line's availability and is vital for manufacturing high quality products. This research introduces an integrated methodology for preventive maintenance planning. Product quality and machine behaviors are integrated for development of a preventive maintenance schedule that reduces the breakdown time. The methodology comes in five stages. The first stage is data preparation. The next stage uses this data for failure and repair distribution fitting using Chi-Square and Kolmogorov Smirnov tests and for regression analysis. Regression models have been developed to predict failures due to machine malfunction using product defect times. Simulation model for the current system using Witness software package has been developed, verified, and statistically validated. Failure and repair statistical distributions and regression models are introduced in the simulation model for experimentations. Product defect times and predicted failure times are generated using the simulation model and are used for developing the preventive maintenance schedule. As a case study the methodology has been implemented at a production line that belongs to a local oil and gas company. A preventive maintenance schedule that covers a period of 3 years is proposed. Implementing this schedule reduces breakdowns and increases the production line's availability. Developing the proposed methodology to the component level and an automatic updating routine of machines and products data for updating statistical analysis stage are addressed as future work.