Abstract:
Reliability centered maintenance (RCM) is a new strategic framework for evaluating system
maintenance requirements in its operating conditions. Some industries employ predictive maintenance
strategies in addition to preventive maintenance (PM) strategies, which increase production
costs. As the breakdown maintenance (BDM) technique is used, the maintenance cost increases.
The RCM approach is a mixture of these maintenance strategies that can be used to optimize the
maintenance costs and to ensure the availability of the system. The RCM method was applied to the
steam boiler system used in the textile industries for the research work reported in this paper. The
RCM methodology stated in the literature cannot be implemented, as it is in Indian textile industries
due to the lack of knowledge of RCM principles, a labor-oriented nature, the use of partially
computerized information systems, an inadequate maintenance database, and information about
maintenance costs and production loss. To resolve these issues, a modified RCM approach involving
a large number of experts is developed. To apply this RCM methodology, critical components
are identified through reliability and failure mode effect and criticality analysis (FMECA). Finally,
scheduled maintenance strategies and their intervals are recommended to ensure that the system
continues to operate properly. According to this study, implementing the RCM technique effectively
will increase boiler system reliability and availability by 28.15 percent and 0.16 percent, respectively.
Additionally, up to 20.32 percent of the maintenance cost can be saved annually by applying these
scheduled maintenance programs.
