Güvenilirlik Merkezli ve Toplam Verimli Bakıma Dayalı Entegre Bakım Konsepti

Abstract

The competitive environment in the industry forces businesses to create the right maintenance plans. Maintenance management is very important, especially for businesses that have high production volumes and use complex and advanced production systems. With correct maintenance planning, the availability of production equipment increases, expected quality standards are achieved, and safety and environmental risks arising from equipment become manageable.

In the presented thesis study, a preventive maintenance plan was created for a selected hydraulic press production line in order to improve the maintenance management processes in a white goods company. While creating the preventive maintenance plan, the most suitable ones for the equipment were selected from different failure management policies with Reliability Centered Maintenance (RCM) analysis and the applicable maintenance periods were decided.

The study started with line efficiency measurement for the purpose of analyzing the current situation of the production line. Line efficiency is calculated based on Overall Equipment Effectiveness (OEE), the key performance indicator of Total Productive Maintenance (TPM).

According to the calculations, the Availability (A) of the line was 83.39%, the Performance (Pr) was 99.19% and the Quality (Q) was 99.51%, and the OEE was obtained as 82.31%. When the values of the OEE parameters were examined, it was seen that the line worked at high performance and had a sufficient quality production amount. In this case, an improvement in the production line will only be possible by increasing the A value. Accordingly, in order to increase the availability (A) of the production line and reduce unplanned downtime losses, the preventive maintenance needs of the line were determined through RCM analysis and a preventive maintenance plan was created for the line.

As a result of the GMB analysis, 16 preventive maintenance tasks were determined for the production line. For 27 failure types, there are 11 scheduled on-condition tasks, 10 of which are to be performed by the operator and one to be performed by the maintenance engineer, for one failure type, one scheduled discard task to be performed by the maintenance personnel, and for six failure types, there are four failure finding tasks one of which is to be performed by the operator and three to be performed by maintenance personnel have been defined.

Maintenance tasks determined by RCM analysis were grouped according to maintenance personnel in order to include autonomous maintenance that is within the scope of TPM. Autonomous maintenance task cards were prepared for defined maintenance tasks to give the operator autonomous maintenance authority, and the approach of supporting the production line with visual aids in the lean production philosophy was also implemented.

As a result of the study, it is aimed for the operator to take ownership of her equipment with the preventive maintenance tasks determined by the RCM analysis and those falling within the scope of autonomous maintenance. With an integrated maintenance concept created with RCM and TPM methods, it is expected that unplanned/unexpected downtimes in the production line will decrease and thus the effective time of the line in production will increase.