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Methods for Availability Improvements of a Scaling Machine System ISSN: 1402-1544 ISBN 978-91-7439-XXX-X Se i listan och fyll i siffror där kryssen är DOCTORAL T H E SI S Department of Civil, Environmental and Natural Resources Engineering Andi Rahadiyan Wijaya Methods for Availability Improvements of a Scaling Improvements Machine System Availability Methods Wijaya for Andi Rahadiyan Division of Operation, Maintenance and Acoustics ISSN: 1402-1544 ISBN 978-91-7439-431-3 Methods for Availability Luleå University of Technology 2012 Improvements of a Scaling Machine System Andi Rahadiyan Wijaya Methods for availability improvements of a scaling machine system Andi Rahadiyan Wijaya Division of Operation and Maintenance Engineering Luleå University of Technology SE – 971 87 Sweden Printed by Universitetstryckeriet, Luleå 2012 ISSN: 1402-1544 ISBN 978-91-7439-431-3 Luleå 2012 www.ltu.se To my family: Ristya – Gita mantra of Devata Krishna – Persona of Nirvana Ziven – Given from Heaven for allowing me to be part of their life and love iii iv Preface The research work presented in this thesis has been carried out during the period 2009 to 2011 at the Division of Operation and Maintenance Engineering at Luleå University of Technology (LTU). The research program was sponsored by Swedish Research Council (SSF), Boliden Mineral AB and Jama Mining Machine AB within the project “Integrated maintenance for improved production and products” (InMaint). First of all, I would like to express my deepest gratitude to my supervisor Professor Jan Lundberg who enriched my knowledge through stimulating discussions and fruitful guidance. You always believed in me and showed a positive attitude. I would like to express my sincere gratitude to Professor Uday Kumar, my co-supervisor and Head of Operation and Maintenance Division, for providing me the opportunity to pursue my research in this division. I would also like to thank him for his invaluable guidance, suggestions and support. I wish to express my sincere gratitude to the Ministry of Education of Republic Indonesia for providing a scholarship which made it possible for me to pursue doctoral work at LTU. I am grateful to all group members in the scaling machine project for their valuable time in meetings, sharing their experiences and suggestions for design improvement. Specific gratitude is extended to Arne Vesterberg, Tommy Öhman, Tommy Strömberg, Christer Andersson, Sören Eriksson, Martin Nilsén and Roger Lindström for sharing their expertise. I would like to thank all my colleagues (present and past) at the Division of Operation and Maintenance Engineering for providing a friendly and open-minded working environment. Special thanks to Rajiv Dandotiya, Ambika Patra and Anna Gustafson for their discussions. Administrative support from Cecilia Glover and Marie Jakobsson is also gratefully acknowledged. I would like to thank my friends and their families in Norrbotten, especially Rupesh Kumar, Fischl Geza, Renu Sinha, Peter Jönsson, Romuald Rwamamara and their families for their hospitality throughout my stay in Luleå. I wish to express my sincere gratitude to my dearest parents, Soetarto and Soekarlina, who have always offered their full support and who taught me the meaning of life. Gratitude is extended to my siblings, parents-in-law and relatives. I am really thankful for all the support given to me. Finally, I would like to express my deepest gratitude to my loving wife, Ristya, and our beloved sons, Krishna and Ziven, for their enormous understanding and endless support during my study. It is not possible to complete this journey without you by my side. Andi Rahadiyan Wijaya v vi Abstract Scaling is the process of cleaning loose material from the roof, face and wall of an underground mine room to make the room safe for the next operation. Due to the nature of the task, scaling incurs a high number of accidents. The use of a scaling machine to replace hand scaling has successfully reduced the number of accidents. However, due to the combination of a hostile environment (such as falling rock, dust, high humidity, etc.), the operation context (e.g. significant vibrations), and reliability and maintainability issues, the scaling machine is identified remains a major contributor to unplanned downtime. The purpose of this research is to develop methods that can be used to identify availability related problems and improving the availability of the scaling machine system in a cost effective way. To this end, it examines the literature, case studies, and simulations studies and includes empirical data from field measurements, document studies, interviews, and observations. For the data analysis, theories and methodologies within reliability, availability and maintainability (RAM), ergonomics and optimisation have been combined with the best practices from the related industry. A first result of this study is the development of a method for visualisation of the downtime. This method provides a visualisation of the downtime estimation and the precision and uncertainty of the estimation at a given confidence level, as along with factors influencing the failure. Second, it identifies components that significantly contribute to the downtime and the reason for that downtime (reliability and/or maintainability problems). Based on the failures analysis, it makes suggestions to improve the critical components. Third, it identifies and analyses performance shaping factors (PSFs) that can affect the reliability of scaling machine systems. Fourth, it proposes a methodology that can help the design team select which components of a system require improvement and to what level improvements should be made to optimise the availability of system in a cost effective way. Finally, it proposes a method for a robust-optimum multi-attribute age-based replacement policy. The proposed approach can be used to determine the interval time for preventive replacement that provides a robust and optimum solution for a multi-attribute age-based replacement policy. These results are related to specific industrial challenges, and are expected to improve the availability of the scaling machine system in a cost effective way. The results have been verified through interaction with experienced practitioners from both the manufacturer and the user (i.e. mining company) of the scaling machine. Keywords: Scaling machine, Reliability Availability Maintainability (RAM) analysis, Cost- optimisation, Availability improvement, Multi-attribute optimisation problem (MOP), Age- based replacement policy, Performance shaping factors (PSFs). vii viii Abstract in Swedish (Sammanfattning) Skrotning innebär att löst material rensas bort från tak, front och väggar för att minimera rasrisken vid underjordsbrytning. Syftet med skrotning är att göra gruvrummet säkert för nästkommande arbeten. Skrotning har identifierats som en av källorna till ett stort antal olyckor, vilket beror på de stora riskerna för nedfallande sten. Användandet av skrotare jämfört med manuell skrotning har också minskat antalet skrotningsrelaterade olyckor. På grund av kombinationen av en besvärlig miljö (till exempel fallande sten, damm, hög luftfuktighet etc.), drift faktorer (t.ex. betydande vibrationer), tillförlitlighet och underhållsmässighet är skrotningsmaskinen identifierad som en av de stora bidragsgivarna till oplanerade driftstopp. Syftet med forskningsprojektet är att utveckla metoder som kan användas för att identifiera tillgänglighetsrelaterade problem samt att förbättra tillgängligheten för skrotare på ett kostnadseffektivt sätt. För att uppnå detta syfte har litteraturstudier, fallstudier och en simuleringsstudie genomförts. Empiriska data har samlats in från fältstudier, dokumentstudier, intervjuer och observationer. Data analyser, teorier och metoder inom tillförlitlighet, tillgänglighet och underhållsmässighet (RAM) samt ergonomi och optimering har kombinerats med bästa praxis från industrin. Ett första resultat är utvecklandet av en metod för stilleståndstid vilket ger en visualisering av uppskattning och precision av denna samt osäkerheten i uppskattning vid en viss konfidensnivå. Andra resultat är identifikationen av de komponenter som bidrar väsentligt till stilleståndstid och dess anledningar (tillförlitlighets och/eller underhållsmässighetsproblem). Baserat på felanalyser har också förbättringar av de kritiska komponenterna föreslagits. Ytterligare resultat är identifiering och analys av prestandafaktorer som kan påverka tillförlitligheten i skrotarsystemet. Vidare har en metod utvecklats som kan hjälpa konstruktörna av skrotare att välja vilka komponenter i ett skrotarsystem som behöver förbättras och till vilken nivå detta bör ske för att optimera tillgängligheten av systemet på ett kostnadseffektivt sätt. Slutligen har en metod för att på ett robust sätt föreslå optimala bytesintervaller för ett flertal skrotarkomponenter samtidigt, utvecklats. De nya metoderna är verifierade och relaterade till specifika industriella utmaningar och förväntas förbättra förmåga hos användare och tillverkar, att förbättra tillgängligheten på ett kostnadseffektivt sätt. ix x List of appended papers Paper I Wijaya, A.R., Lundberg, J. and Kumar, U. Down time analysis of scaling machine, accepted for publication in: International Journal of Mining, Reclamation and Environment. Paper II Wijaya, A.R., Lundberg, J. and Kumar, U. Cost optimization of reliability improvement of scaling machine, accepted for publication in: Journal of Quality in Maintenance Engineering. Paper III Wijaya, A.R., Lundberg, J. and Kumar, U. Robust-optimum multi-attribute
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