OPTIMIZATION OF PRODUCTIVITY IN AGRO INDUSTRIES USING RELIABILITY CENTERED MAINTENANCE

Intenational Jounal of Technology and Engineeing System (IJTES) Vol 6. No.2 Jan-Mach 2014 Pp. 203-208 gopalax Jounals, Singapoe available at : www.ijcns.com ISSN: 0976-1345 OPTIMIZATION OF PRODUCTIVITY IN AGRO INDUSTRIES USING RELIABILITY CENTERED MAINTENANCE S.Anbuselvan 1, S.Aunkuma 2, G.Guhan 3, K.Muuganantham 4, T.Rajesh 5 1,2,3,4 UG Student, 5 Assistant Pofesso M.A.R College of Engineeing and Technology, Vialimalai, India. ABSTRACT India is one of the second lagest poduce of ice in the wold. Nealy 70% of the population depend on agicultue and ago-based industies. The main dawback of this industy is high maintenance cost and low poduction. To ovecome this poblem the Reliability Centeed Maintenance (RCM) method is used. In this method was developed by the aicaft industy only. This is the fist time used in the ago industy. The poposed method is to conside one ago industy and calculate thee months daily analysis. The effectiveness of this poject is to compae with pevious analytical epot and RCM method. Keywods- Reliability centeed Maintenance (RCM), Citicality Analysis (CA), Failue Mode and Effects Analysis (FMEA) etc., I. INTRODUCTION Maintenance is defined as an action o combination of actions caied out in outine o ecuing manne to eplace, epai, modify, sevice the component o goup of components of a plant and machiney fo keeping a paticula machine o system in its nomal opeating condition so that it continues to opeate at a specified availability fo a specified peiod. Maintenance has a numbe of functions as the efficiency and life of man, machine, equipment, building and plant depends on the natue of woking envionment used fo paticula poduction system etc...pope maintenance will educe the deteioation of life of the equipment; help to keep it in good woking condition which will help to achieve the poduction taget. R.Paanthaman, K.Alagusundaam and J.Indhumathi India Institute of Cop Pocessing Technology, Thanjavu, Tamil Nadu, India Poduction of Potease fom Rice Mill Wastes by Aspegillus nige in Solid State Fementation On the light of the obtained esults, it could being the log phase of the gowth of the fungus fo concluded that femented PONNI ice boken fungus Aspegillus nige at 35 C fo 72 h and ph 7.0 ae the most suitable conditions fo potease poduction [1]. Kanlayakit, Wand Maweang, Faculty of Ago- Industy, Kasetsat Univesity, Bangkok, Thailand,2Cente of Excellence on Agicultual Biotechnology Bangkok,Thailand,3Depatment of Ago-Industy, Faculty of Agicultue,Ubon Ratchathani Univesity, Upon Ratchathani,Thailand,Posthavest of paddy and milled ice affected physicochemical popeties using diffeent stoage conditions Stoage of paddy and milled ice at waehouse condition fo ten months evealed the highest change in the gel consistency, elongation atio and RVA pasting popeties. Howeve, the obvious change in the physicochemical popeties was obseved in Kalasinthan, KhawDokMali [2]. Kazuhiko itoh, Shuso Kawamua andyoshinoi ikeuchi Depatment of Agicultual Engineeing, Faculty of Agicultue, Hokkaido Univesity, Sappoo, and Japan Received May 13, 1985 Pocessing And Milling of Paboiled Rice. This study was caied out in ode to obtain fundamental data fo the paboiling pocess and milling of ice [3]. E. Banshai Rath, Pof B.K.Mangaaj and D.Bishnu Pasad Misha Manage (Electical), Idco, Idco Towe, Janpath, Bhubaneswa, Odisha, India, Fuzzy Logic Based Simulation fo Modeling of Sustainable Maketing Policy fo Moden Rice Mills in Odisha Rice mill up- gadation and installation of new moden ice mill in Odisha will poduce ice of national as well Gopalax Publications Page 203

as intenational standad. The slow pocuement and maketing poblems associated with ice will be solved pemanently with incease of ice mills in stategic places with calculated manne. The logistics associated with pocuement of ice mills and paddy can be developed [4]. R. P. Kachu Asst. Diecto Geneal (Pocess Engineeing), Indian Council of Agicultual Reseach, New Delhi, Ago- Pocessing Industies in India Gowth, Status and Pospects minimize poduct losses,add maximum value, achieve high quality standads, keep pocessing cost low,ensue that a fai shae of added value goes to the poduce[5]. K.Laxminaayana Rao, Food and Agicultue Oganization of the United Nations Rome, 2006 Ago-industial paks Expeience fom India. The establishment of dedicated industial estates stated in the southen states of India duing the 1980s. An exclusive industial estate fo phamaceutical industies was established in Tamil Nadu State and included the constuction of sheds, a common effluent plant, and powe plant [6]. Ms. P. Nalini Assistant Pofesso (Senio Gade), Depatment of MBA, Velala College of Engineeing and Technology, Eode, Poblems & Pospects of Rice Mill Entepeneus The Conceptual Famewok, The liteatue suvey depicts the common poblems faced by Entepeneu and individual chaacteistics equied fo entepeneuship and extenal suppots need fom extenal envionment also. And fom above conceptual wok key factos fo the eseach wok is identified petinent to the poblems and pospects of ice mill entepeneus [7]. II. RELIABILITYCENTERED MAINTENANCE When RCM is used fo agicultual the methodology is applied by the ice manufactue. The peventive and pedictive maintenance outcomes ae witten into the mill s opeating and maintenance pocedues that evey ago industies owne is equied by intenational law to adopt and follow. The manuals ae igoously adheed-to by highly skilled, licensed and independently tested technicians. What the Rice manufactue sets down in the Ago industy maintenance schedule the opeato must do at penalty of legal action esulting in goal and fines fo noncompliance. III. CRITICALITY ANALYSIS The Citicality Analysis (CA) povides elative measues of significance of the effects of a failue mode, as well as the significance of an entie piece of equipment o system, on safe, successful opeation and mission equiements. In essence, it is a The RCM outcomes that equie design changes ae the paddy manufactue s esponsibility to do and to then disseminate thoughout the fleet. Evey design change appoved by the egulating machines must be made by the ago industies opeato. Impovements in ago industies equipment and in opeating and maintenance pactices natually esult by the design of the egulated system in-place. In the ago industy thee is no choice of when a scheduled-maintenance task is done, no of what will be done, no of how well it must be done. When an ago machine o ago fame eaches the scheduled the plant must be bought in fo maintenance. Aleady the decision has been made by the manufactue of what pats to eplace duing the outage and what pats to inspect fo condition. If an oncondition inspection finds a poblem the plant cannot etun to sevice until the issue is coected. Thee ae no options to un the plant. A. Types of RCM The RCM analysis may be caied out as a sequence of activities. Some of these activities, o steps, 1. Study opeation 2.System selection and definition 3.Functional failue analysis 4.Citical item selection 5.Data collection and analysis 6.Failue modes, effects and citicality analysis 7.Selection of maintenance actions 8.Detemination of maintenance intevals 9.Peventive maintenance compaison analysis 10.Teatment of non-citical items 11.Implementation 12. In sevice data collection and updating. B. Fomulae 1. Availability= {Available Time-Plant down Time}-{Beak down+ Change ove time} /Available Time-Plant down time 2. Pefomance efficiency = Actual Poduction/Rated Capacity 3. Rate of quality = Actual Poduction-Rejected in Maintenance/Actual Poduction 4. OEE = Availability x Pefomance efficiency x Rate of quality 5. Watts = Actual load in Amps x 415V x 0.92 6. Units/h = Watts/1000 7. Actual KVA = Actual load in Amps x415 V/ 1000 8. Connected KW = Powe in HP x 0.75 9. Powe Facto = Actual KVA/ Connected in KW tool that anks the significance of each potential failue fo each component in the system's design based on a failue ate and a seveity anking. This tool will be used to pioitize and minimize the effects of citical failues ealy in the design. Gopalax Publications Page 204

a) The CA can be pefomed using eithe a quantitative o a qualitative appoach. Figues identify the categoies fo enty into thei espective CA using DA Foms 7611 and 7612, espectively. Availability of pat configuation and failue ate data will detemine the analysis appoach. As a geneal ule, use figue when actual component data is available and use figue when no actual component data o only geneic component data is available. b) Figue is a epesentation of the diffeent levels of data that a facility may have. Depending on the level of data available, the analysts must detemine which appoach they will use fo the CA. The aeas whee thee ae ovelaps between quantitative and qualitative, the analyst will have to assess what the expectations ae fo conducting the analysis to detemine which appoach will be used. IV. FAILURE MODE EFFECT AND CRITICALITY ANALYSIS The FMECA is composed of two sepaate analyses, the Failue Mode and Effects Analysis (FMEA) and the Citicality Analysis (CA). The FMEA analyzes diffeent failue modes and thei effects on the system while the CA classifies o pioitizes thei level of impotance based on failue ate and seveity of the effect of failue. The anking pocess of the CA can be accomplished by utilizing existing failue data o by a subjective anking pocedue conducted by a team of people with an undestanding of the system. Although the analysis can be applied to any type of system, this manual will focus on applying the analysis to a C4ISR facility. The FMECA should be initiated as soon as peliminay design infomation is available. The FMECAis a living document that is not only beneficial when used duing the design phase but also duing system use. As moe infomation on the system is available the analysis should be updated in ode to povide the most benefit. This document will be the baseline fo safety analysis, maintainability, maintenance plan analysis, and fo failue detection and isolation of subsystem design. Although cost should not be the main objective of this analysis, it typically does esult in an oveall eduction in cost to opeate and maintain the facility. 50 40 30 20 10 0 V. MACHINERY REPORT Machi ney Name Po we in HP Act ual load in Am ps Stand ad load in Amps Pow e in Wat ts Unit /h Act ual KV A Conn ected KW Powe facto Boile 1 1.7 2 649. 0.65 0.70 0.75 0.941 06 55 Elevato 1 1.5 2 572. 0.57 0.62 0.75 0.83 7 25 Dye 1 1.5 3.5 572. 0.57 0.62 0.75 0.83 7 25 Dye 9 30 35 1145 11.4 12.4 6.75 1.844 4 5 5 Dye 10 32 35 1221 12.2 13.2 7.5 1.771 7.6 2 8 Paddy 5 6.5 7.5 2481 2.48 2.69 3.75 0.719 cleane.7 75 Shelle 7.5 10 15 3818 3.82 4.15 5.625 0.738 Hulle 25 35 40 1336 13.3 14.5 18.75 0.775 3 6 25 Rice 20 25 30 9545 9.55 10.3 15 0.692 whiten e 75 Blowe 7.5 10 12 3818 3.82 4.15 5.625 0.738 Silky polishe 20 25 30 9545 9.55 10.3 75 Blowe 3 4.3 5 1641.74 De 3 4.2 5 1603 stone.56 Cylind 1 1.5 2 572. ical 7 gade Rice colou sote 10 13 15 4963.4 Powe in HP vs connected KW 1.64 1.78 45 1.60 1.74 3 0.57 0.62 25 4.96 5.39 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Powe Connected 15 0.692 2.25 0.793 2.25 0.775 0.75 0.83 7.5 0.719 Gopalax Publications Page 205

VI. ANALYTICAL REPORT Oveall Efficiency epot fo the DAY shift of Januay'14 Date Available Plant Down Beakdown Change Availability Actual Rated PefomancRejected Rate of OEE (a) Time Time(b) (C) ove time(d) Podction Capacity Efficiency in MT Quality 1/1/2014 0 0 0 0 0 0 0 0 0 0 2/1/2014 8 0 1 0 0.875 14 32 0.4375 0 1 0.3828125 3/1/2014 8 0 0 0.5 0.9375 16 32 0.5 0 1 0.46875 4/1/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 5/1/2014 8 0 0 0 1 16 0 0 0 1 0 6/1/2014 8 0 0 1 0.875 15 32 0.46875 0 1 0.4101563 7/1/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 8/1/2014 8 1 0 1 14 32 0.4375 0 0 0 9/1/2014 8 0.5 0.9375 16 32 0.5 0 1 0.46875 10/1/2014 8 2 0.75 12 32 0.375 0 1 0.28125 11/1/2014 8 1 1 14 32 0.4375 0 0 0 12/1/2014 8 1 1.5 0.6875 12 32 0.375 0 1 0.2578125 13/1/2014 8 0 1 0 0.875 15 32 0.46875 0 1 0.4101563 14/1/2014 0 0 0 0 0 0 0 0 0 15/1/2014 0 0 0 0 0 0 0 0 0 16/1/2014 0 0 0 0 0 0 0 0 0 0 0 17/1/2014 0 0 0 0 0 0 0 0 0 0 18/1/2014 8 0 0 1 16 32 0.5 0 1 0.5 19/1/2014 8 1 0 1 14 32 0.4375 0 1 0.4375 20/1/2014 8 1 0 0.875 15 32 0.46875 0 1 0.4101563 21/1/2014 8 0.5 0 0.9375 15.5 32 0.484375 0 1 0.4541016 22/1/2014 0 0 0 0 0 0 0 0 23/1/2014 8 1 0.875 15 32 0.46875 0 1 0.4101563 24/1/2014 8 1 0.875 16 32 0.5 0 1 0.4375 25/1/2014 8 0 1 16 32 0.5 0 1 0.5 26/1/2014 8 0 1 16 32 0.5 0 1 0.5 27/1/2014 8 2.5 0.6875 16 32 0.5 0 1 0.34375 28/1/2014 8 2 0 0.75 12.5 32 0.390625 0 1 0.2929688 29/1/2014 0 0 0 0 0 0 0 0 30/1/2014 8 0 1 16 32 0.5 0 1 0.5 31/1/2014 8 0 1 16 32 0.5 0 1 0.5 Total 192 3 10.5 6 0.9126984 360 736 0.48913 0 1 0.446429 OEE O.446429% 44.64% oveall efficiency effectiveness day shift febuay 2014 Date Available Plant Down Beakdown Change Availability Actual Rated Pefomance Rejected Rate of OEE (a) Time Time(b) (C) ove time(d) Podction Capacity Efficiency in MT Quality 1/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 3/2/2014 8 0 1 0 0.875 14 32 0.4375 0 1 0.382813 5/2/2014 8 0 0 0 1 6 32 0.1875 0 1 0.1875 7/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 9/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 11/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 13/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 15/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 17/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 19/2/2014 8 0 1 0 0.875 14 32 0.4375 0 1 0.382813 21/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 23/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 25/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 27/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 Total 112 0 2 0 0.982142857 210 448 0.46875 0 1 0.460379 oveall efficiency effectiveness day shift ma 2014 Date Available Plant Down Beakdown Change Availability Actual Rated Pefomance Rejected Rate of OEE (a) Time Time(b) (C) ove time(d) Podction Capacity Efficiency in MT Quality 1/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 3/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 5/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 7/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 9/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 11/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 13/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 15/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 17/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 19/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 21/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 23/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 25/2/2014 8 0 1 0 0.875 14 32 0.4375 0 1 0.382813 27/2/2014 8 0 0 0 1 16 32 0.5 0 1 0.5 Total 112 0 1 0 0.991071429 222 448 0.495535714 0 1 0.491111 OEE in Day 0.491111 49.1111288 % OEE in Day 0.460379 46.0379464 % Gopalax Publications Page 206

VII. PRODUCTION REPORT Maintenance cost Jan-14 Feb-14 Ma-14 beaings 2000.00 1000.00 1000.00 belt, ubbe 3000.00 2000.00 2000.00 Total 5000.00 3000.00 3000.00 E.B.Consumption Total Units 10875.00 11250.00 10312.50 consumed Units consumption/m.t. 2.175 2.250 2.063 Diesel Consumption in Lts Cost of Poduction in Rs. Packing chages in Rs Labou Cost In Rs Fie Wood in Rs TOTAL MAINTENANCE COST Units consumption/h ou 90.625 93.750 85.938 diesel 7500.00 7500.00 7500.00 Total 7500.00 7500.00 7500.00 Rate of 2.500 3.000 2.143 consent diesel Cost/M.T. in diesel 82.600 99.120 70.800 E.B.Cost 65,250.00 67,500.00 61,875.00 E.B.Cost/M.T 13.050 13.500 12.375. 6000 Backs 90,000.00 90,000.00 90,000.00 TOTAL 90,000.00 90,000.00 90,000.00 BOYS 45000.00 45000.00 45000.00 GIRLS 60000.00 60000.00 60000.00 TOTAL 1,05,000.00 1,05,000.00 1,05,000.00 20 TON 50,000.00 50,000.00 50,000.00 TOTAL 50,000.00 50,000.00 50,000.00 3,22,750.00 3,23,000.00 3,17,375.00 500000 0 total maintenance Jan-14 Feb-14 Ma-14 VIII. CONCLUSION In this poject the RCM technique is used to educe the opeating cost and maintain powe facto in ago industies. The implementation of this poject is to calculate thee months daily analysis epot and the esult is above technique is vey effective because the cost is nominal value and the poduction was inceased. Gopalax Publications Page 207

REFERENCES 1. ALI, N. and PANDYA, A. C.: Basic concept of paboiling of paddy, J. Agi. Reseach, 19: 111-115, 1974 2. BHATTACHARYA, K. R. and RAO, P. V. S.: Pocessing conditions and milling yield in paboiled ice, J. Agi. Food. Chen., 14: 473-475, 1966 3. BHATTACHARYA, K. R.: Beakage of ice duing milling and effect of paboiling, Ceeal Chen., 46: 478-485, 1969 4. HALICK, J. V. and KELLY, V. J.: Gelatinization and pasting chaacteistics of ice vaieties as elated to cooking behavio, Ceeal Chen., 36: 91-98, 1959 5. HALICK, J. V., BEACHELL, H. M., STANSEL, J. W. and KRAMER, H. H.: A note on the detemination of gelatinization tempeatues of ice vaieties, Ceeal Chem., 37: 670-672, 1960 6. Ramesh, M., Bhattachaya, K.R. and Mitchell, J.R. 2000. Developments in undestanding the basis of cooked-ice textue. Citical Reviews in Food Science and Nutition 40 (6): 449-460 7. Siebenmogan, T.J. and Meullenet, J.F. 2004. Roughice stoage. In: Champagne E.T. Rice: Chemisty and Technology. 3d edition. Ameican Association of Ceeal Chemists, Inc. St. Paul, Minnesota, U.S.A. 8. Sodhi, N.S., Singh, N., Aoa, M. and Singh, J. 2003. Changes in physicochemical, themal, cooking and textual popeties of ice duing aging. Jounal of Food Pocessing and Pesevation 27: 387-400. 9. Sowbhagya, C.M. and Bhattachaya, K.R. 2001. Changes in pasting behaviou of ice duing ageing. Jounal of Ceeal Science 34: 115-124. 10. Suksomboon, A. and Naivikul, O. 2006. Effect of dyand wet-milling pocesses on chemical, physicochemical popeties and stach molecula stuctues of ice staches. Kasetsat Jounal (Natual Science) 40 (Supplement issue): Gopalax Publications Page 208