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Condition-based maintenance: Selection and improvement of a cost-effective vibration-based policy in rolling element bearings
Lunds Universitet. (Systemekonomi)
1997 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Modern machinery is expensive and therefore must run at high availability and effectiveness which cannot be achieved without an effective maintenance policy. Condition monitoring, (CM), techniques can be utilised to reduce or arrest the rate of deterioration of a component so increasing operating life. Successful implementation of condition-based maintenance, (CBM), results from a combined use of  knowledge of CM, failure analysis, design, data acquisition and analysis, and economic optimisation.

The main result reported in this thesis is that the rolling element bearing’s mean effective life could be extended appreciably if an existing vibration-based maintenance policy is used effectively. This result is achieved by a combination of data analysis and logical development. A new maintenance approach was developed to overcome some of the limitations of total productive maintenance (TPM) and reliability-centered maintenance (RCM) and is based upon the Deming managerial feedback cycle (Plan-Do-Check-Act). This method is called Total Quality Maintenance, (TQMain). It is a methodology to sustain and improve continuously the technical and economic effectiveness of the essential manufacturing process elements. It is shown logically that by using vibration-based monitoring (VBM) program in the frame of a common database for a plant IT-system, a pre-requisite of TQMain, the causes behind quality deviations and failures can be identified and eliminated effectively at an early stage and the company’s economics would be improved. The CBM effectiveness and accuracy, i.e. reducing failures and making use of as much as possible of a component’s mean effective life, are usually related to the ability of the CM system to detect failure causes and follow defect development. Criteria to select the most cost-effective VBM system and the most cost-effective vibration-based maintenance policy are developed.

But, in most real cases, CM systems are not utilised effectively and companies are satisfied with the partial savings achieved in maintenance cost. It is shown, by two case studies, that improvements in vibration-based maintenance can be achieved by effective feedback of the results of failures, renewal condition and VBM history analysis. Unfortunately the data coverage and quality in these studies were not sufficient, among other reasons due to the low number of failures and long bearing lives, so the conclusions, although supported by the work results, remain strong qualitative indications, rather than statistical proof. Criteria to measure the effect of improvements to confirm whether it is economically beneficial and to identify the basic reasons why it is not, are developed because it is important for never-ending improvement needed by the company to remain competitive.

The contribution of this thesis is: The development of a sequential method for the selection and improvement of a cost-effective vibration-based maintenance policy. This methodology can be used to justify, on economic criteria, the use of VBM systems to indicate when rolling element bearings should be renewed. It is achieved through;

Tools used in quality and maintenance technology and reliability analysis have either been modified or developed beyond their original concept such as; Maintenance cost equation, Total Time on Test-plots, Overall Equipment Effectiveness. Development of new tools to monitor maintenance effectiveness and accuracy, select the most informative CM parameter(s) and cost-effective vibration-based maintenance policy. A new maintenance approach, (TQMain), and a new envelope alarming method for VBM programs are also developed. Theoretical basis for improvements of the effectiveness of vibration-based maintenance of bearings in paper mill machines and two case studies which tend to confirm the theory are introduced.

Place, publisher, year, edition, pages
Lund: KFS AB, Lund , 1997. , 65 p.
Series
Dissertation series/ Lund University,, ISSN 0280-722X
Keyword [en]
Maintenance Technology, Failure analysis, Vibration monitoring, Spectral analysis, Vibration-based maintenance policy, Maintenance cost-effectiveness, Selection of the most cost-effective maintenance strategy and policy, benchmarking, Total Quality Maintenance (TQMain), Cyclic improvement of maintenance experience
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
URN: urn:nbn:se:lnu:diva-21362ISBN: 91-628-2645-X (print)OAI: oai:DiVA.org:lnu-21362DiVA: diva2:548340
Supervisors
Available from: 2012-09-03 Created: 2012-08-30 Last updated: 2012-09-14Bibliographically approved
List of papers
1. On the selection of condition based maintenance for mechanical systems
Open this publication in new window or tab >>On the selection of condition based maintenance for mechanical systems
1991 (English)In: Operational reliability and systematic maintenance / [ed] Holmberg, K; Folkeson A., London: Elsevier Applied Science , 1991, 153-175 p.Chapter in book (Refereed)
Abstract [en]

The requirements for increased plant productivity and safety, and reduced maintenance costs, have led to an increasing interest in methods for condition monitoring of mechanical systems.  In the literature on Reliability-Centred Maintenance, RCM, the selection of a maintenance technique is mainly carried out on the level of system failure modes. Also, distinguishing criteria such as the long run average cost per unit time are not modelled see for example, Nowlan et al. (1978). In this study, a summary of three papers, Al-Najjar (1990a, b& c), component failure causes and failure mechanisms are involved in the selection problem, and a long run average cost per unit time is modelled. In chapter 2, the identification of significant components is described. State-changes of a component are discussed in chapter 3. New classifications of failures, monitoring parameters and monitoring techniques are proposed in chapters 2 and 4, respectively. Data sampling and analysis are discussed in chapter 4. The cumulative sum chart is proposed as a technique to reduce the fluctuation in monitoring parameter value.   In chapter 5, the selection of a cost-effective policy is carried out based on economical and non-economical distinguishing criteria. Chapters 1 to 5 summarise Al-Najjar (1990a). Modelling of a condition dependent failure rate function is discussed in chapter 6, which the summary of Al-Najjar (1990b). Chapter 7 is addressed to the problem of selecting a cost-effective monitoring technique based on observational data. To carry out the selection, we suggest the use of a generalization of a method, related to the Total Time on Test, TTT-plot, introduced by Bergman (1977). Also, a graphical method to estimate the threshold level of a monitoring parameter when using a cost-effective technique is proposed, see also Al-Najjar (1990c).

Place, publisher, year, edition, pages
London: Elsevier Applied Science, 1991
Keyword
Maintenance, condition based maintenance, selection of maintenance, micganical systems
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
urn:nbn:se:lnu:diva-21292 (URN)1-85166-612-5 (ISBN)
Available from: 2012-08-27 Created: 2012-08-27 Last updated: 2012-09-04Bibliographically approved
2. Total quality maintenance: An approach for continuous reduction in costs of quality products
Open this publication in new window or tab >>Total quality maintenance: An approach for continuous reduction in costs of quality products
1996 (English)In: Journal of Quality in Maintenance Engineering, ISSN 1355-2511, E-ISSN 1758-7832, Vol. 2, no 3, 4-20 p.Article in journal (Refereed) Published
Abstract [en]

The common thread in achieving and maintaining high Overall Equipment Effectiveness, OEE, is the availability of improved manufacturing processes capable of producing quality products without interruption. Implementing Just In Time, JIT, philosophy demands healthy processes. Any interruption of the line caused by any equipment malfunction or failure will result in a major disruption of output or even line or factory shutdown. Thus, an effective maintenance program should be evolved to provide the required availability of machinery and output quality. A new concept of condition-based maintenance, Total Quality Maintenance, TQMain, is presented. It aims to maintain not only machinery but all the elements constituting a manufacturing process, e.g. production/operation, environmental condition, personnel, methods, material, quality control. TQMain is a result of establishing a common database through integrating the maintenance program with other plant programs to form an overall plant Information Technology, IT-system. Identifying and ‘eliminating’ quality deviations and failure causes at early stages, and extensive use of data feedback are the suggested tools to accomplish continuous improvements and to assure high quality products.

Keyword
Failure causes, Vibration monitoring, Condition control, Total Quality Maintenance, Integration of condition-based maintenance with IT-System, Benchmarking, Cost-effective maintenance strategy
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
urn:nbn:se:lnu:diva-21293 (URN)10.1108/13552519610130413 (DOI)
Available from: 2012-08-29 Created: 2012-08-27 Last updated: 2017-12-07Bibliographically approved
3. On the effectiveness of vibration-based monitoring programs
Open this publication in new window or tab >>On the effectiveness of vibration-based monitoring programs
(English)Manuscript (preprint) (Other academic)
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
urn:nbn:se:lnu:diva-21675 (URN)
Available from: 2012-09-14 Created: 2012-09-14 Last updated: 2012-09-14Bibliographically approved
4. Criteria for the selection of a cost-effective maintenance policy
Open this publication in new window or tab >>Criteria for the selection of a cost-effective maintenance policy
(English)Manuscript (preprint) (Other academic)
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
urn:nbn:se:lnu:diva-21670 (URN)
Available from: 2012-09-14 Created: 2012-09-14 Last updated: 2012-09-14Bibliographically approved
5. Improvement in effectiveness of vibration-based condition monitoring system in paper mills
Open this publication in new window or tab >>Improvement in effectiveness of vibration-based condition monitoring system in paper mills
(English)Manuscript (preprint) (Other academic)
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
urn:nbn:se:lnu:diva-21676 (URN)
Available from: 2012-09-14 Created: 2012-09-14 Last updated: 2012-09-14Bibliographically approved
6. Improvement in effectiveness of vibration-based condition monitoring system in paper mills: two case studies
Open this publication in new window or tab >>Improvement in effectiveness of vibration-based condition monitoring system in paper mills: two case studies
1997 (English)In: 10th International congress and exhibiton on condition monitoring and diagnostic engineering management, 1997, 48-57 p.Conference paper, Published paper (Refereed)
National Category
Engineering and Technology
Research subject
Technology (byts ev till Engineering), Terotechnology
Identifiers
urn:nbn:se:lnu:diva-21671 (URN)
Conference
VTT symposium, COMADEM 97, 10th International congress and exhibiton on condition monitoring and diagnostic engineering management
Available from: 2012-09-14 Created: 2012-09-14 Last updated: 2012-09-14Bibliographically approved

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