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Question:
A dataset with records of downtime for 8 major machinery in an Industrial Facility for over 2 years is provided. Details of the fields are as follows.
Field
Description
Remarks
Start Time
Start time of interruption
End Time
End time of interruption
Duration(Hours)
Duration of interruption
Machine Centre
APM Anode Preparation Machine
1. There are two Cathode Stripping
APS Anode Preparation Station
Machines, located at East and West End
ASM Anode Scrap (Washing) Machine
of the Electro Refinery Building
ECSM East Cathode Stripping Machine
2. There are two cranes, located at North
WCSM West Cathode Stripping Machine
and South end of the building
HLW 1& 2 High Lift Wagon 1&2
3. The High Lift Wagons 1 & 2 are
N Crane North Crane
considered as one machinery centre
S Crane South Crane
Event Type
Downtime Slowdown
Limit analysis to Event Type Downtime
Reason
Causes of downtime
The causes are machine specific
Time Usage
Category of downtime classification
Limit Analysis to the following
–
Code
Operational Breakdown
Electrical Breakdown
Human Error
Mechanical Breakdown
Power / Water / Air Failure
Test / Check / Adjust
Mechanical Planned
Electrical Planned.
Comment
Detail on downtime cause
This field is manual entry and hence data is not 100% structured.
A1
. Rank the Machine Centres in decreasing order of downtime duration. Trend individual machine
downtime history on a monthly basis for entire duration
A2
. For the top three machine centres (from answer 1), generate two PARETO charts for each
machine.
The PARETO charts shall be
Cause of downtime vs. downtime events
Cause of downtime vs. downtime duration.
A3
. For the most affected machine centre identified in Answer 1, analyse the causes of downtime
from information available in the fields Reason and Comments. Explain your findings.
A4
. Generate two parameter Weibull Model for the three machine centres with highest downtime
duration. Explain relative Reliability performance
Details of sub-systems for a bicycle are given below.
B1
. Use the RCM process to develop an FMEA sheet for the bicycle, rank the criticality using RPN
and develop a list of recommended actions with frequencies. Explain your findings
B2
. Develop Fault Tree for the scenario of bicycle fails to stop upon applying brake
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