Risk Based Maintenance Case Study

Application of RBM strategy to enhance the productivity in an induction furnace in a casting industry

BALAMURUGAN.Sa, SUKUMAR.T.Rb aPG Scholar, Industrial Engineering, Department of Mechanical Engineering, Kumaraguru College of Technology,

Coimbatore - 641049, India. 08344136718, [e-mail] bAssociate Professor, Department of Mechanical Engineering, Kumaraguru College of Technology,

Coimbatore - 641049, India. 09487700839, [e-mail]

ABSTRACT:

The unexpected failures, the down time associated with such failures, the loss of production and, the higher maintenance costs are major problems in any process plant. Risk-based maintenance (RBM) approach helps in designing an alternative strategy to minimize the risk

As a methodology, it provides a organized approach to decide the most appropriate asset maintenance plans. Upon implementation of these maintenance plans, the risk of asset failure will be low. The risk-based maintenance framework is applied to each system in a facility. The likely failure modes of the system are first determined. Then, a typical risk-based maintenance framework is applied to each risk. The framework is shown in Fig.1 For each identified risk, data needs to be collected. This includes information about the risk, its general consequences and the general methods used to ease and predict the

The more accurately this is done, the better the risk based maintenance outcomes will be. There is no one standard method for assessing risk. Qualitative, semi-quantitative and quantitative approaches are used to determine the possible risks that exist. To estimate the likelihood of these risks, the methods that are used include deterministic, and probabilistic approaches. 62 different approaches to assessing risk are described in Tixier (2002). The most appropriate approach will depend on the data that is available to evaluate each risk.

B. Risk evaluation

At the risk evaluation stage, both the probability of the risk and the consequence of the risk are quantified in the context of the facility under consideration. With the risk evaluation complete, the probability and consequence are combined to determine the total risk. This total risk is ranked against pre-determined levels of risk. As a result, the risk is either acceptable or unacceptable.

C. Maintenance