Computerised Maintenance Scheme for a Process Industry Using Monte-Carlo Simulation Technique
The management of any enterprise aims at the profitable conduct of the same. This can be achieved by decreasing production time lost due to failure of plant, equipment or services by preventing breakdowns, thus lengthening the useful life of plant and equipment and maintaining it at the level of technical performance needed to produce the quantity and quality of output at the lowest level of overall cost.
In the present study data pertaining to life of bearings is collected from a local small scale process industry over a period of 5 years. The management has been adopting the practice of replacing the bearings only when a Vjreakdown occurs which is resulting in a huge production losses. So, the authors are interested to develop an alternative solution to minimise the total production and other losses.
Keeping in view of the above point an attempt has been made to develop a programme to adopt preventive maintenance which reduces the total costs, maintenance cost and production cost. Uhile developing this program the primary limitation of PrereVentiVe maintance that it is applicable only to a Small class of equipment failures is taken into account. Nonte — Carlo simulation technique is used to obtain preventive maintenance schedules. Besides by considering the fact that a high level of mainitenance results in low production looses due to breakdown and vice-versa, a point at which minimum total cost occurs is calculated.
In the present study it is found that the developed program will reduce the costs to half that of breakdown maintenance. Finally, it is suggested that preventive maintenance is always profitable for small scale industries.
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