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INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Maintenance Strategies Selection Using Fuzzy FMEA and Integer Programming
INCAPIE 2015
Pranav SankpalPost-Graduate Student
A. AndrewBHEL PPPU, Thirumayam.
Dr. S. KumananProfessor
Department of Production Engineering
National Institute of Technology, Tiruchirappalli.
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Contents
•Introduction
•Literature Analysis
•Problem Statement
•Objectives
•Proposed Model
•Case study
•Conclusion
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Introduction
Efficient maintenance planning is important for achieving higher productivity levels.
Maintenance cost is one of the significant component of operational expenditure.
Selection of right maintenance strategy is critical because it determines future maintenance related direct and indirect costs.
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Literature Analysis Pariazar et al. (2008) combined factorial analysis and the
analytic hierarchic process (AHP), (improved by means of rough set theory) and first recognized 19 effective criteria in maintenance strategy selection.
Shyjith et al. (2008) proposed the combination of AHP and TOPSIS to select the suitable maintenance policy for a textile spinning mill ring frame unit.
Mousavi et al. (2009) used factorial analysis for clustering many decision making criteria into groups. Then they applied a fuzzy technique for order preference by similarity to ideal solution (TOPSIS) method to help decision makers to select the most appropriate maintenance strategy.
Arunraj and Maiti (2010) presented an approach to maintenance policy selection based on the combined use of AHP and goal programming.
Braglia, M., Castellano, D. and Frosolini, M.(2013) proposed an integer programming approach to maintenance strategies selection to optimally allocate the budget monetary resources and maximise the potential reduction of the RPN
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Problem Statement
Aim is to select most effective combination of maintenance strategies for an industrial equipment.
Currently FMEA is widely used tool for failure mode prioritisation
All the maintenance activities are directed towards critical failure.
Hence criticality evaluation is the most important part of the model
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Limitations of traditional FMEA:
Criticality analysis is not realistic
Selection of maintenance strategies is very qualitative and does not consider costs associated with maintenance strategy and their effectiveness.
First limitation is addressed using fuzzy logic system
Problem of selecting optimum mix of maintenance strategies subject to budget constrain is resolved using integer programming.
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Objectives
To develop fuzzy logic system for realistic estimation of criticality of each failure mode.
To select optimum mix of maintenance strategies taking into account budget constraint and compatibility constraint.
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
INCAPIE 2015
Proposed Model
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Integer Programming Model
RCM prioritises various failure modes based on fuzzy Risk Priority Numbers
Next step is to assign to each failure mode, a suitable maintenance strategy in such a way that reduction in RPN for all failure modes is maximised.
Problem is formulated as mixed-integer linear programming model and solved using GAMS
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
INCAPIE 2015
•
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Case Study
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Continued..
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Continued..
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Optimum mix of maintenance strategies
INCAPIE 2015
INTERNATIONAL CONFERENCE ON ADVANCES IN PRODUCTION AND INDUSTRIAL ENGINEERING
20-21, FEBRUARY 2015
Sponsors
Conclusion
INCAPIE 2015
The application of maintenance strategy can reduce the RPN value of a failure mode.
The proposed model allows to choose a set of maintenance strategies which will maximise total reduction in RPN for all failures.
Also the major difficulty in realistic assessment of RPN value is addressed using fuzzy logic system.
More refinement in cost estimation task is required to enhance the utility of proposed model.
