Developing Autonomous Maintenance through FMEA-RCM Models

to Reduce % Machine Breakdown in Food and Beverages Industry

David Rahmad Iswidibyo, Galih Nugroho, Arif Al Imam, Hari Junianto, Resti Isma Astutik,

Terha Hadi and Karen Puspasari

PT. Nutrifood Indonesia, Jl. Selayar II H7-H8, Jatiwangi, Bekasi, West Java, Indonesia

Keywords: Autonomous Maintenance, % Breakdown, FMEA, RCM, CILT.

Abstract: In order to reduce % of breakdown (9 to 16% in semester 1 of 2018) in filling machine type A, Nutrifood

Cibitung factory implemented Autonomous Maintenance (AM). Which, operator involves in the maintenance

process of the production machine. AM also supports and emphasizes in the proactive-preventive maintenance

in the Engineering department. In this research, autonomous maintenance task was developed using Failure

Mode Effect Analysis (FMEA) and Reliability Centered Maintenance (RCM) on each part of the machine to

determine every failure possibility and the root causes. Autonomous maintenance is developed through an

understanding of existing problems or a history of machine breakdown and minimizing the source of

deteroriation (Sara, 2015). FMEA-RCM is used to determine every failure possibility and the root causes of

the failure. This failure possibility was prevented through the certain task (when, where & how) that is

conducted in autonomous maintenance by operator. Scope of the task is limited to 4 tasks: Cleaning,

Lubrication, Inspection, and Tightening (CILT) in filling machine type A of Nutrifood Cibitung Factory.

Implementation of autonomous maintenance that was developed through FMEA-RCM framework has

reduced 40-60% breakdown level from semester 1 of 2018 in filling machine type A. This maintenance

activity provides initial detection of a failure in the machine which triggers the maintenance team to fix the

problem before getting worse. Autonomous Maintenance also standardizes and increases operator skills in

doing maintenance of their machine.

1 INTRODUCTION

Autonomous maintenance is one of the foundations

of Total Productive Maintenance (TPM), which its

aimed to involve production in maintaining their own

asset. Total Productive Maintenance (TPM) was

developed at Japanese car industy in the 1970s, it was

firstly introduced and successfully being

implemented in Nippon Denso Co., Ltd. Total means

involvement of all employees at all levels of the

organisation, productive means effective utilization

of all resources and maintenance means keeping the

Man-Machine-Material system in optimum condition

(Owen, 2011).

Autonomous maintenance (AM) is confined to 4

major tasks: Cleaning, Lubrication, Inspection, and

Tightening (Mugwindiri, 2013). Autonomous

maintenance provides new habits that are: by clean

machine's part, we start to inspect, this inspection will

lead us to get preliminary detection of deterioration,

which this detection trigger an early correction to the

part of machine before it is getting worse. Which is

carried out by operators in a certain sequence of time.

Development of AM utilised Failure Mode Effect

Analysis (FMEA) model, which is used to determine

the type of failure that can occur in the machine's part.

FMEA was introduced by Ford Motor Company

to the automotive industry for safety and regulatory

consideration in the late 1970s. It also used to

improve production and design. In the 1980s, the

automotive industry began implementing FMEA by

standardizing the structure and methods through the

Automotive Industry Action Group (Carl, 2016). It

continues to be associated by many with reliability

engineering. It analyses potential effects caused by

system elements ceasing to behave as intended (Carl,

2016).

This model requires potential causes, effect

analysis, and also action needed. Focus Group

discussion being held between production and

engineering department to develop FMEA. Every

potential cause in part weather it comes from

operational activity or lifetime is cleaned, inspected,

Developing Autonomous Maintenance through FMEA-RCM Models to Reduce .

DOI: 10.5220/0008434706350639

In Proceedings of the 2nd International Conference on Inclusive Business in the Changing World (ICIB 2019), pages 635-639

ISBN: 978-989-758-408-4

635

lubricated or tightened based on the history of

breakdown and also the possibility of operational

activity interfere with the parts.

Reliability – Centered Maintenance (RCM) was

firstly developed by airlines in 1967 through tree

logic. This tree logic then formed the basis for the

design of the initial matintenance program for the

Boeing 747. In the early '70s, this worked being used

by the Office of the Secretary of Defense, the Naval

Air Systems Command, the Air Force, dan the Army.

Reliable Center Maintenance (RCM) first use to

describe a process used to determine the optimum

maintenance requirements for aircraft. There are six

concepts that support RCM. 1) an understanding that

the vast majority of failures are not necessarily linked

to the age of the asset. 2) changing from efforts to

predict life expectancies to trying to manage the

process of failure. 3) an understanding of the

difference between the requirements of assets from a

user perspective, and the design reliability of the asset

4) an understanding of the importance of managing

assets on condition (often referred to as condition

monitoring, condition based maintenance and

predictive maintenance). 5) an understanding of four

basic routine maintenance tasks. 6) linking levels of

tolerable risk to maintenance strategy development

(Nowlan, 1978)

In order to reduce breakdown level in our

Sweetener Line, PT Nutrifood Indonesia started to

implementing autonomous maintenance program

trough FMEA-RCM model to minimize potential

deterioration or failure. This project aimed to reduce

% breakdown in Sweetener filling line. Which in

2017, we were facing on average from 4 machines

11% breakdown level in sweetener filling line.

2 THEORITCAL BACKGROUND

In terms of developing autonomous maintenance

tasks, which belongs to Total Productive

Maintenance, PT Nutrifood Indonesia using a tool

that was used in Realibity Centered Maintenance. The

tool was a failure mode effect analysis (FMEA).

2.1 Autonomous Maintenance

Autonomous maintenance is one of the pillars in

Total Productive Maintenance (TPM) (Owen, 2011) :

Figure 1: Pillar of TPM .

Which autonomous maintenance is restricted into 4

major tasks :

a. Cleaning

b. Inspection

c. Lubrication

d. Thightening

The value that was brought by AM was (Day, 2004):

Table 1: Step Process of AM from ANADIGICS.

Step

Activity

Step Zero

Preparation

Step One

Clean to inspect, inspect to detect

Step Two

Detect to correct

Step Three

Correct to perfect

2.2 FMEA

Failure Mode and Effects Analysis is a method

designed to:

a. Identify and fully understand potential failure

modes and their causes, and the effects of

failure on the system or end users, for a given

product or process.

b. Assess the risk associated with the identified

failure modes, effects and causes, and

prioritize issues for corrective action.

c. Identify and carry out corrective actions to

address the most serious concerns.

An FMEA should be the guide to the development

of a complete set of actions that will reduce the risk

associated with the system, subsystem, and

component or manufacturing/assembly process to an

acceptable level (Carl, 2016).

Below is the example of FMEA that is used in this

project :

636

Table 2: FMEA form for analysis.

a. A "Machine/Sub-machine” is the focus item of

the FMEA project

b. A "function" is a standard or minimum

requirement of the machine/submachine is

intended to achieve.

c. A “functional failure” is a failure to reach the

minimum target or standard that has been set.

d. A “failure mode" is a potential failure or

deterioration that causing functional failure.

This can be a single potential failure, or more.

e. An “effect” is the consequence of the failure

on machine/sub-machine.

2.3 RCM

Rather than focusing immediately on subsystems or

equipment and asking, "What preventive

maintenance can be done?", RCM starts from the top

by (Catola, 1983):

a. Partitioning the ships into systems and

subsystems that require analysis;

b. Identifying additional functionally significant

items;

c. Determining the maintenance requirements

(tasks) for each significant item based on

analysis of its functions, both evident and

hidden, and its dominant failure modes;

d. Determining when, how, and by whom each

task will be done;

e. Identifying needs for design change when

safety is threatened by a failure for which there

is no applicable and effective task; and

f. Using information obtained from operations

and appropriate analytical techniques to adjust

these intervals and revise task content.

Which, partitioning the ships into systems and

subsystem is depicted in FMEA by Machine and

Submachine. The function of machine and

submachine was described also in FMEA.

3 METHODS

Development and implementation of autonomous

maintenance were devided into 4 step processes :

a. AM Initial Preparation

- AM team preparation

- AM time frame

- Machine preparation

b. AM Preparation

- Development FMEA-RCM

- Determine autonomous standard

(CILT)

c. Execution Phase

- Initial deep cleaning

- Training for implementation

- Monitoring

d. Evaluation Phase

- Results were gained from AM

The end result was evaluated by comparing

breakdown level in filling machine type A in semester

1 of 2018 with semester 2 of 2018.

% Breakdown level itself was calculated trough :

% breakdown =

𝑅𝑒𝑝𝑎𝑖𝑟 𝑡𝑖𝑚𝑒 (𝑚𝑖𝑛𝑢𝑡𝑒)

𝑃𝑙𝑎𝑛𝑛𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒 (𝑚𝑖𝑛𝑢𝑡𝑒)

(1)

4 DISCUSSION

4.1 AM Initial Preparation

In this step process, mapping the program was

conducted. Team selection was delivered by

involving 2 both production and engineering team.

Figure 2: AM Project Team.

The development project involves employees to

the lowest level: operators, technicians were

contributed to completing FMEA. Concerns that been

happened on the floor were brought to the FMEA

scheme. So that FMEA could be generated to capture

all of the possibilities of failure.

The time frame was arranged to finish FMEA and

also develop cleaning, inspection, lubrication and

tightening task in the autonomous task. It is also

covering the time in implementation of autonomous

maintenance in the selected machine.

The pilot plant was choosen from table top of

filling machine that suffering from a breakdown.

Function Failure Effect

Machine/Sub-machine

Functional Failure

Failure Mode

Technician

Operator

Production Team Leader

Project Leader

Engineering Team Leader

Technician

Developing Autonomous Maintenance through FMEA-RCM Models to Reduce

637

Table 3: Top 5 % Breakdwon in Filling Machine.

Machine

% Breakdown

Machine A - 1

16%

Machine A - 3

10%

Machine A - 2

Machine A - 4

Machine B - 5

Machine Type A was choosen to be the pilot project,

and the operators involved in the development of

FMEA was delegated to run this machine type Auring

implementation step.

4.2 AM Preparation

Machine Type A was devided into several

submachines. This submachine is representing the

main function in a group of part machines. Grouping

helps to determine the function of machine

specificaly. Group of the machine led operators and

technician to frame the position of parts and also build

the potential failure in detail.

Cleaning, Inspection, Lubrication and Tightening

were conducted through detail FMEA. CILT was the

preventive action that is assigned to maintain zero

failure or deteroriation. Every part in the sub machine

was discussed and analyzed, through the history of a

breakdown in machine type A and in a similar type of

part in another machine.

Table 4: Autonomous Maintenance Task in Machine Type

The unique code also is used to guide operators

doing the task. The code was provided in the machine

and in AM reporting paper, visualy can help operators

know what they have to do.

Figure 3: Visual Management in Machine Type A.

The code is representing : main tasks (cleaning /

inspection / lubrication / tightening), sequence (daily

/ 3 weeks or every 500 hours of running), Submachine

and the number of tasks.

4.3 AM Execution

At this phase, operators were educated on how to do

cleaning, inspection, lubrication and tightening

properly. This activity was delivered by Engineering

teams. Operators and Technicians also did an initial

deep cleaning to all parts in machine type A.

This initial deep cleaning was aimed to restore the

condition of the machine as it was firstly coming.

Initial deep cleaning help us to determine a

preeliminary judgement on the condition of the

machine, it helped us restore part that had been

broken and replace it with the good one. Then, the

operator just keeps maintaining machine type A as it

has been totaly cleaned.

After the normalized condition of the machine,

operators were monitored daily, 3 weekly to ensure

that all of the items in the task being conducted. It also

helps us to communicate initial finding related to

abnormalities that happened to the machine type A to

the Engineering team.

4.4 AM Evaluation

During the AM process, production could reduce

trapping sachet that happened due to the cleaning

issue. Which dust interrupted the sealing process in a

sachet. AM provide regullar cleaning in all line that

being passed by sachet. Regular cleaning and

lubrication ensure every rotation in bearing, motors

and chain work without problems.

Breakdown level could be decreased by 40 % – 60

% from the previous period (Semester 1 – 2018). We

also reduce non added value activity such as: cleaning

of the funnel at the end of a shift can be lowered after

3 days of usage.

Table 5: % Breakdwon in Filling Machine Type A after.

Machine

% Breakdown

Before

After

Machine A - 1

16%

Machine A - 3

10%

Machine A - 2

Machine A - 4

There is some deviation in each machine, which

machine A has the biggest gap than other machines.

This gap was happened due to the part that was

needed should be delivered from Europe. This

machine took a long period of time to change this

special part.

Cleaning program provides minimum interruption

of dust or polluter enters the part of the machine (for

example: bearing, or heater). Which, could help the

machine perform better. Inspection helped us to find

Kodin g No Proposed Tasks

Interval Alat Ukur/Tools Stan dard Checklist Catatan

1 Pengelapan bearing idle pin Akhir Shift Kanebo kuning T idak ada deposit (debu/produk/oli lumer) & tidak aus/karat

2 Pembersihan locknut adjustment Akhir Shift

Kanebo merah &

Compressed Air

Tidak ada deposit ( debu/produk/oli lumer )

3 Pembersihan jalur rod funnel Akhir Shift Majun dan Penetrate FG Tidak ada deposit (debu/produk) & tidak aus/karat

4 Pembersihan spring rod funnel Akhir Shift Majun dan Penetrate FG Tidak ada deposit (debu/produk) & tidak aus/karat

5 Pembersihan bushing/bearing penggerak rod funnel Akhir Shift Majun dan Penetrate FG Tidak ada deposit (debu/produk) & tidak aus/karat

Pencucian cup doser Akhir Shift Visual check Spring harus dilepas dan dilap

Cleaning

Tasks-Dosing Unit

III. 7 II. 17 I. 6

638

an initial abnomalities in the machine, so that we

could solve the machine's problem faster before it

affected another part (make the breakdown worst).

Regular lubrication keeps the part in machine run

smoothly as the setting of the parameter that has been

set in HMI. Tightening keeps all the mechanical part

stick to the initial places, so as the machine run there

will be no shifting on it.

Autonomous maintenance (CILT) that was

developed through FMEA-RCM processes could be

one of the solutions to boost machine peformance in

the food and beverage industry. FMEA-RCM

processes clearly gave us a deep analysis and helped

us to provide specific and relatively precise action to

be done in autonomous maintenance by operator. It

combined historical data of machine breakdown and

also analysis of failure probability in the parts of the

machine. It is also standardizes how operator

maintains their machine and share the responsibility

to maintain a machine between technician and

operator.

5 COPYRIGHT FORM

This paper has already got an agreement to be

published by the 2

International Conference on

Inclusive Business in the changing world.

6 CONCLUSIONS

Autonomous maintenance provides benefits to our

production line. Which help us to :

a. Reduce breakdown level in filling machine

Type A in average from 11% to 4.2%

b. Reducing non added value activity (cleaning

funnel)

c. Sharing responsibilities in maintaining

machine with Engineering

d. Provide new habits and development to

operator skills : cleaning to inspect, inspect

to detect, detect to correct, correct to perfect

e. FMEA-RCM processes can be a usefull tool

to develop autonomous task in the food and

beverage industry. It combained data of

machine breakdown and also analysis of

failure probability in the parts of the

machine.

This project will be copied to another type of

machines in production. The flow process will be

conducted as it had been proven from this project.

ACKNOWLEDGEMENTS

We realize that AM implementations take a lot of

effort. In addition to developing a good analysis, we

are facing a challenge that is related to changing

operator habit. Making sure that monitoring and

consistency in doing every single task of AM are

conducted also take a lot of time (a lot of task and lot

of machine). Awareness on the top management,

supervisory level, and operators become the key

success to implement AM to reduce machine

breakdown. And continously upgrade AM task

related to the history of the machine after

implementation and eliminating unnecessary tasks.

REFERENCES

Carl S. Carlson, 2016. Understanding and Applying the

Fundamentals of FMEAs. Reliability and

Maintainability Symposium.

Catola, S., G., 1983. Reliability-Centered Maintenance

Handbook. Direction of Commander, Naval Sea

Systems Command.

Chen, C. 2013. A developed autonomous preventive

maintenance programme using RCA and FMEA,

International Journal of Production Research. Taylor

& Francis

Day, J., Troy, D., Heller, D., 2004. The Implementation of

Autonomous Maintenance (Part 1 in a series of the

Total Productive Manufacturing Experience).

CSMANTECH.

Nowlan, F. Stanley, and Howard F. Heap. Reliability-

Centered Maintenance. Report Number AD-A066579.

United States Department of Defense. 1978. Archived

from the original (PDF) on 2013-08-01.

Miranda, S. F., Lopes, I. S. 2015. Development of

Autonomous Maintenance in a Furniture Company.

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Performance Improvement by Using Autonomous

Maintenance - The Case of a Developing Country,

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