Identification of failure modes to apply condition monitoring methods on critical components of a hydraulic stamping press machine Diogo de Figueiredo Tomás Maintenance Engineering, master's level (120 credits) 2020 Luleå University of Technology Department of Civil, Environmental and Natural Resources Engineering ACKNOWLEDGEMENTS The present thesis would not be possible without the extraordinary team that supported me, during this time. A special thank you to Professor Diego Galar, my external supervisor, that gave me the opportunity to work within an area of passion, in the field of Condition Monitoring, and providing me constant encouragement and guidance To my supervisor in Luleå University of Technology, senior lecturer Mattias Holmgren, a deeply thank you to his special availability, and total support, this thesis was considerably improved, due to his relevant comments, suggestions and revisions. To my examiner and program director Maintenance Engineering in Luleå University of Technology, senior lecturer Johan Odelius, I would like to thank for his guidance and support during the master program and thesis. For all people in Luleå University of Technology - Sweden, in special my colleagues from the master programme as Danial, Johnny, Laila, Aron, Alvaro, Jaya and Ignacio, a big thank you all for this extraordinary journey that we did together, with mutual support. For all people in Portugal, in special to Professor José Torres Farinha, a big thank you for all the opportunities, advises and support during all my master programme. At the end, I would thank to my mother Odília, my father António, and my girlfriend Joana, for their encouragement, and continuous support during all this time. I hope you enjoy reading this thesis. In case of suggestions, comments or questions, please feel free to contact [email protected] This is a blank page Abstract This thesis is the result of a four months internship in a company that aims to transform technology into value for industry. The industries face a wide range of engineering challenges. The requirements and competitiveness of the industry demands high dependability of the assets. During operations of hydraulic stamping presses, unexpected failures may happen, affecting the production and the overall equipment effectiveness, and therefore, the objectives of the company. It might have serious repercussions, both monetary and reputational, this last one normally difficult to recover from. That is the reason why it is important to find solutions which can prevent these situations to happen. One of the challenges with hydraulic press stamping machines is that there are multiple failure modes that affect the machine dependability. There is a big variety of sensor technologies available in the market, that can be used to monitor the health condition of the hydraulic stamping press machines, providing decision makers with reliable information to coordinate maintenance activities. However, it is required to the users to know the specific condition monitoring methods for each failure mode. The present thesis has the purpose to identify and propose strategies in order to leverage the dependability of hydraulic stamping press machines, to achieve the performance objectives. It serves also as base for the creation of future maintenance plans. The first step is to understand the system operation under study, and then identify failure modes that might happen in the asset. The next step is to select and suggest condition monitoring methods to monitor the machine’s failure modes. Based on this information, excellence in the planning of maintenance and production can be achieved. The Reliability Centered Maintenance (RCM) method and the Failure Modes, Effect and Criticality Analysis (FMECA) were used in present thesis to assess failure modes, criticality and prioritize maintenance interventions. The thesis work presents condition monitoring methods for the analysed subsystems of the stamping press machine. The failure analysis of the subsystems and the proposed condition monitoring methods were based on the related literature and technical staff recommendation. How proposed condition monitoring methods can be complemented with further analysis is discussed. A qualitative approach was used to rank the selected subsystems and components based on their criticality. As a conclusion, the slide of the guide rail was considered the most critical component. The reason is that all the press operation is based on force and guiding precision. This is a blank page Abstract (Swedish) Denna uppsats är resultatet av en praktik på fyra månader i ett företag som vill omvandla teknik till värde för industrin. Industrin står inför en lång rad tekniska utmaningar. Behoven och konkurrenskraften i branschen kräver att tillgångarna har hög tillförlitlighet. Vid drift av hydrauliska stanspressar kan oväntade fel inträffa som påverkar produktionen och den totala utrustningens effektivitet och därmed företagets mål. Det kan få allvarliga konsekvenser, både ekonomiska och anseendemässiga, som kan vara svåra att återhämta sig från. Därför är det viktigt att hitta lösningar som kan förhindra att sådana situationer uppstår. En av utmaningarna med hydrauliska pressmaskiner är att det finns flera typer av fel som påverkar maskinens driftsäkerhet. Det finns ett stort antal olika sensortekniker på marknaden som kan användas för att övervaka tillståndet hos de hydrauliska pressmaskinerna och förse beslutsfattarna med tillförlitlig information för att samordna underhållsverksamheten. Användarna måste dock känna till vilken övervakningsmetod som är lämplig för varje typ av fel. Syftet med denna uppsats är att identifiera och föreslå strategier som påverkar driftsäkerheten hos hydrauliska pressmaskiner och som kan forma en grund för framtida underhållsplaner. Det första steget är att förstå driftprocessen och sedan identifiera möjliga feltyper som kan inträffa hos enheten. Nästa steg är att välja ut och föreslå tillståndsövervakningsmetoder för att övervaka maskinens feltyper. Med denna information som grund kan planeringen av underhåll och produktion optimeras. Funktionssäkerhetsinriktat underhåll (reliability cantered maintenance, RCM) och feleffektsanalys (Failure Modes, Effect and Criticality Analysis, FMECA) användes i denna uppsats för att utvärdera feltyper, kritikalitet och prioritera underhållsåtgärder.. Uppsatsens presenterar förslag på tillståndsövervakning metoder för de analyserade delsystemen. Felanalysen av utrustningen och de föreslagna metoderna för tillståndsövervakning baserades på befintlig litteratur och rekommendationer från teknisk personal. Hur den föreslagna tillståndsövervakningen kan kompletteras med ytterligare analyser diskuteras också. Ett kvalitativa tillvägagångssätt användes för att rangordna de utvalda komponenterna utifrån dess kritikalitet. Sammanfattningsvis visade kritikalitetsedömningen att gejdrarna är den mest kritiska komponenten hos pressmaskinen. This is a blank page Contents 1. INTRODUCTION ......................................................................................................... 1 1.1. Problem statement .................................................................................................. 1 1.2. Purpose ................................................................................................................... 1 1.3. Objectives ............................................................................................................... 2 1.4. Approach ................................................................................................................ 2 1.5. Delimitations .......................................................................................................... 2 1.6. Scope ...................................................................................................................... 3 2. THEORY FRAMEWORK ............................................................................................ 5 2.1. Maintenance ............................................................................................................ 5 2.2. Maintenance Objectives ......................................................................................... 6 2.3. Maintenance Management ...................................................................................... 6 2.4. Types of Maintenance ............................................................................................ 7 2.4.1. Corrective Maintenance .................................................................................. 8 2.4.2. Preventive maintenance ................................................................................... 9 2.5. Maintenance as an investment .............................................................................. 10 2.6. Dependability........................................................................................................ 11 2.7. Reliability Centered Maintenance ........................................................................ 12 2.8. Failure Modes and Effect Analysis ...................................................................... 13 2.8.1. Criticality Analysis (CA) .............................................................................. 14 2.9. Defining the System Hierarchy ............................................................................ 17 2.10. Hydraulic Stamping Press Machines ................................................................ 18 2.10.1. Mechanical