Reliability Centred Maintenance (RCM) started a new chapter in the history of preventive maintenance strategy setting. It was now possible to develop a scientifically based, highly successful maintenance program for complex systems. It developed as a result of the reliability problems and cost of maintenance of aircraft during the late 50’s and early 60’s. The result was a methodology called MSG-1, followed by the improved MSG-2. When MSG-2 was used contractually for the United States Department of Defence, it led to the present definition of RCM. In academic circles there developed a growing dissatisfaction with the technique [Pintelon et al (1999], of which part stems from watering down its scientific basis to make RCM more marketable [Moubray (2000)], while at least part is based on perceived inherent scientific weaknesses in the methodology itself. This thesis, in setting out to solve these limitations, makes several important contributions to the RCM methodology. The first of these is a method of concentrating the RCM analysis effort on the most important failure modes encountered by the organisation. Secondly, it introduces a Quality Improvement task in the RCM task selection tree, based on a limitation identified by Harris (1985). The third contribution is the addition of a formal task packaging methodology, following Gits (1984). The thesisalso combines the use of RCM for the most important failure modes with conventional maintenance tasks for the remaining failure modes, to form a total methodology for the typical industrial concern. It furthermore introduces the application of sound management principles in the implementation of RCM and lastly, blends concepts from different RCM authors, together with the innovations listed above, into one logical whole. In summary, the proposed revised methodology can play a very important part to achieve the goal of World Class manufacturing standards, including ensuring that the organisation’s maintenance effort is as proactive as possible. D13/4/90 / Thesis (PhD (Industrial Engineering))--University of Pretoria, 2002. / Industrial and Systems Engineering / unrestricted

Made available in DSpace on 2015-03-26T14:01:17Z (GMT). No. of bitstreams: 1 texto completo.pdf: 597170 bytes, checksum: b5393c045719ef7bc2a909daf913b77a (MD5) Previous issue date: 2014-06-26 / The pursuit of competitiveness in the current scenario of the pulp industries is a major challenge for companies. Join the efficiency in the process of implementation of forests, silviculture, harvesting, wood logisticsand pulp cellulose logistics results in a complex matrix in industries with high production capacity. The combination of large areas of forests, modern and efficient plants, good capacity for movement of raw materials and the production and relentless pursuit of low operating costs are almost always divergent factors. Fit management teams to conduct detailed each process relating them to the specific characteristics of the regions in which they operate, thus defining the best ways to deal with obstacles studies. Accordingly, this study was undertaken, in order to identify concepts aimed at maintenance efficiency in modern industry, always directed to the new reality of the sector, which is the deployment of high capacity, far from large industrial centers factories. Additionally were raised core services applicable to this type of industry and examined the relationship of efficiency with this new reality. Finally we tried to study various processes considered relevant for new pulp and relate factors focused on maintenance of equipment and facilities, such that focal points can be identified with possible action taken facing the pursuit of efficiency. The analysis of these factors was taken by professionals with experience in manufacturing pulp, beyond the requirements of the search for literature review and empirical evidence for processing of proposals relations. The study confirmed the need for an efficient structure maintenance in factories and allowed us to identify the degree of importance of maintenance planning in maintenance efficiency in pulp mills. / A busca da competitividade no atual cenário das indústrias de celulose é um grande desafio para as empresas do setor. Associar a eficiência nos processos de implantação de florestas, silvicultura, colheita, logística de madeira, produção de celulose e logística de celulose resulta em uma matriz complexa no caso de indústrias com alta capacidade de produção. A combinação de grandes áreas de florestas, fábricas modernas e eficientes, boa capacidade para movimentação de matéria prima e da produção e a busca incansável pelo baixo custo operacional são fatores quase sempre divergentes. Cabe às equipes de gestão a realização de estudos detalhados de cada processo relacionando-os com as características específicas das regiões em que atuam, definindo, assim as melhores formas de tratar os obstáculos encontrados. Nesse sentido, foi conduzido este estudo, com objetivo de identificar conceitos voltados à eficiência da manutenção na indústria moderna, sempre direcionados à nova realidade do setor, que é a implantação de fábricas de alta capacidade, longe dos grandes centros industriais. Associado a isto foram levantados os principais serviços aplicáveis a este tipo de indústria e verificada a relação de eficiência com esta nova realidade. Por fim procurou-se estudar diversos processos considerados relevantes para nova indústria de celulose e relacionar fatores voltados à manutenção dos equipamentos e instalações, de tal forma que possam ser identificados pontos focais com possíveis tomadas de ação voltadas a busca de eficiência. A análise destes fatores foi feita por profissionais com experiência no setor industrial de celulose, além da busca por requisitos da revisão de literatura e de evidências empíricas para tratamento das relações propostas. O estudo confirmou a necessidade de uma estrutura eficiente de manutenção nas fábricas e permitiu identificar o grau de importância do planejamento da manutenção na eficiência da manutenção nas fábricas de celulose.

O envelhecimento de uma instalação industrial provoca o aumento do número de falhas. A probabilidade de falhar é um indicador do momento em que deve ser feita uma parada para manutenção. É desenvolvido um método estatístico, baseado na teoria não-markoviana, para a determinação da variação da probabilidade de falhar em função do tempo de operação, que resulta num sistema de equações diferenciais parciais de natureza hiperbólica. São apresentadas as soluções por passo-fracionário e Lax-Wendroff com termo fonte. Devido à natureza suave da solução, os dois métodos chegam ao mesmo resultado com erro menor que 10−3. No caso estudado, conclui-se que o colapso do sistema depende principalmente do estado inicial da cadeia de Markov, sendo que os demais estados apresentam pouca influência na probabilidade de falha geral do sistema. / During the useful life of an industrial plant, the failure occurrence follows an exponential distribution. However, the aging process in an industrial plant generates an increase of the failure number. The failure probability is a rating for the maintenance stopping process. In this paper, an statistical method for the assessment of the failure probability as a function of the operational time, based on the non-Markovian theory, is presented. Two maintenance conditions are addressed: In the first one, the old parts are utilized, after the repair this condition being called as good as old; in the second one the old parts are substituted by brand new ones this condition being called as good as new. A non-Markovian system with variable source term is modeled by using hyperbolic partial differential equations. The system of equations is solved using the Lax-Wendroff and fractional-step numerical schemes. The two methods achieve to approximately the same results, due to the smooth behavior of the solution. The main conclusion is that the system collapse depends essentially on the initial state of the Markov chain.

O envelhecimento de uma instalação industrial provoca o aumento do número de falhas. A probabilidade de falhar é um indicador do momento em que deve ser feita uma parada para manutenção. É desenvolvido um método estatístico, baseado na teoria não-markoviana, para a determinação da variação da probabilidade de falhar em função do tempo de operação, que resulta num sistema de equações diferenciais parciais de natureza hiperbólica. São apresentadas as soluções por passo-fracionário e Lax-Wendroff com termo fonte. Devido à natureza suave da solução, os dois métodos chegam ao mesmo resultado com erro menor que 10−3. No caso estudado, conclui-se que o colapso do sistema depende principalmente do estado inicial da cadeia de Markov, sendo que os demais estados apresentam pouca influência na probabilidade de falha geral do sistema. / During the useful life of an industrial plant, the failure occurrence follows an exponential distribution. However, the aging process in an industrial plant generates an increase of the failure number. The failure probability is a rating for the maintenance stopping process. In this paper, an statistical method for the assessment of the failure probability as a function of the operational time, based on the non-Markovian theory, is presented. Two maintenance conditions are addressed: In the first one, the old parts are utilized, after the repair this condition being called as good as old; in the second one the old parts are substituted by brand new ones this condition being called as good as new. A non-Markovian system with variable source term is modeled by using hyperbolic partial differential equations. The system of equations is solved using the Lax-Wendroff and fractional-step numerical schemes. The two methods achieve to approximately the same results, due to the smooth behavior of the solution. The main conclusion is that the system collapse depends essentially on the initial state of the Markov chain.