Improving and implementing preventive maintenance systems in a building materials production plant
Koirala, Pratik (2020)
Diplomityö
Koirala, Pratik
2020
School of Energy Systems, Konetekniikka
Kaikki oikeudet pidätetään.
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi-fe2020052839516
https://urn.fi/URN:NBN:fi-fe2020052839516
Tiivistelmä
This master thesis is research about improving and implementing Preventive Maintenance (PM) systems in building material production plant. Finnsementti Oy, a Cement Roadstone Holding (CRH) based company is a building material production plant in Lappeenranta which produce cement. The plant desire to improve its PM plans for the consistency of kiln operation. The research aim is to find the maintenance gaps that has often cause kiln stop. The research aims to suggest necessary maintenance action that will increase the working performance of kiln. The research scope is limited to the kiln area which include Preheating tower, kiln, clinker cooler and clinker conveyer.
It was found that the Finnsementti cement plant is in need of improving their PM. The information gathered throughout this research was used to create and guide Finnsementti in generating PM systems by focusing on some of the mechanical issues that occurred in the last few years. The research focuses on a set few numbers of issues as there are a wide range of problems that can occur during production. The main sources of information used throughout this project were, published literature, internal company data, Finnsementti personal, and the Original Equipment Manufacturer (OEM) of the different equipment used on the site. To represent the gathered data Fault Tree Diagram (FTD), risk analysis charts and surveys were used. The FTDs represents a sequence of events that can occur during different issues encountered. These FTDs highlight the basic need for PM. The risk analysis conducted on the plant equipment used internal company data to find the critical equipment for the kiln area. A survey was circulated within the company to get the opinion of the workforce of the current setup of the maintenance department. A maturity matrix was used to find the current level of maintenance being achieved by the plant. It was found that the majority of the unplanned kiln stops were due to a lack of PM. A list of suggestions was proposed based on the findings of this research.
It was found that the Finnsementti cement plant is in need of improving their PM. The information gathered throughout this research was used to create and guide Finnsementti in generating PM systems by focusing on some of the mechanical issues that occurred in the last few years. The research focuses on a set few numbers of issues as there are a wide range of problems that can occur during production. The main sources of information used throughout this project were, published literature, internal company data, Finnsementti personal, and the Original Equipment Manufacturer (OEM) of the different equipment used on the site. To represent the gathered data Fault Tree Diagram (FTD), risk analysis charts and surveys were used. The FTDs represents a sequence of events that can occur during different issues encountered. These FTDs highlight the basic need for PM. The risk analysis conducted on the plant equipment used internal company data to find the critical equipment for the kiln area. A survey was circulated within the company to get the opinion of the workforce of the current setup of the maintenance department. A maturity matrix was used to find the current level of maintenance being achieved by the plant. It was found that the majority of the unplanned kiln stops were due to a lack of PM. A list of suggestions was proposed based on the findings of this research.