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Failure mode analysis of snus production equipment
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School of Engineering |
Master's thesis
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en
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72
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In a fast-moving consumer goods manufacturing sector, reliability of production equipment and efficiency of production system is the key for sustaining profitability and market competition. Reactive maintenance strategies and unplanned stoppages at production lines usually led to loss in productivity, inferior quality products and high operational cost. Within this context, it is essential for manufacturers to adapt a well-structured operational excellence model, combined with digital maintenance management system. This thesis is conducted at a Snus manufacturing unit, in cooperation with University of Trento, Italy and Aalto University, Finland. Aim of this study is to address the failure modes of critical equipment and develop preventive maintenance system, in line with company’s operational framework.
Studied manufacturing unit had a problem of frequent unplanned stoppages at its production lines due to failure of critical equipment, mainly driven by reactive maintenance approaches. This study focused on conducting failure mode analysis of critical equipment, identifying root causes of failures, and translating these insights into preventive actions by developing preventive maintenance plans.
This thesis study follows an operational excellence framework, known as Integrated Work System (IWS) for failure modes analysis and integrates IWS tools and methodologies in the research. In addition, a computerized maintenance management system, SAP PM is utilized for developing and scheduling preventive maintenance plans. This study begins with first developing understanding of Snus manufacturing processes and market dynamics, that subsequently helped in defining critical equipment on production line. In next steps, failure mode analysis is performed by following IWS methodologies and integrating techniques from IWS Focused Improvement pillar in root cause analysis. Also, preventive maintenance plans for critical equipment are developed based on condition-based and time-based maintenance strategies, in-line with IWS Progressive Maintenance pillar.
The study is conducted through personal involvement in entire process, from data collection and failure mode analysis to preparing base data for preventive maintenance, developing and scheduling PM plans. Results of this study show an improvement in uptime of critical equipment, increased OEE across all studied production lines, and a transition in maintenance strategy from reactive maintenance to corrective maintenance approach.