Of Shivaji University, Kolhapur - ResearchGate
ADISSERTATION REPORTON“Reliability Analysis and Life Cycle Cost Optimization ofBand Saw Cutting Machine”Submitted in partial fulfillment of the requirement for the post graduate degree ofMaster of EngineeringIn‘Mechanical Engineering (Design Engineering)’OfShivaji University, KolhapurSubmitted byMr. Rajkumar Bhimgonda Patilunder the Guidance ofDr. L. Y. WaghmodeDEPARTMENT OF MECHANICAL ENGINEERINGSant Dnyaneshwar Shikshan Sanstha’sAnnasaheb Dange College of Engineering &Technology, Ashta, Dist. Sangli.June – 20131
Sant Dnyaneshwar Shikshan Sanstha‟sAnnasaheb Dange College of EngineeringAnd Technology, Ashta.CERTIFICATEThis is to certify that the dissertation entitled “Reliability Analysis and LifeCycle Cost Optimization of Band Saw Cutting Machine”, submitted by Mr.Rajkumar Bhimgonda Patil, in partial fulfillment for the award of the post graduatedegree of Master of Engineering in Mechanical Engineering – Design, of ShivajiUniversity, Kolhapur, as a record of his own work carried out by him under mysupervision and guidance during the year 2012-2013.Date – 29/06/2013Place – Ashta.Dr. L. Y. WaghmodeGuideDr. S. S. AhankariHODExternal ExaminerDr. A. M. MullaPrincipal2
ACKNOWLEDGEMENTI am extremely grateful and fortunate enough to have Prof. Dr. L. Y. Waghmodeas my guide without whom present work of my M. E. Dissertation could not have seenthe light of the day. Due to his uncompromising, excellent standards and quest of qualitytowards him for constantly encourage me throughout the year for doing good work andbelieving me. Dr. L. Y. Waghmode has been very helpful to me in many ways frombeginning of my Master of Engineering course at ADCET as my guide, in providinginspiration and encouragement for pulling out of my problems many times.It is indeed an absolute and great privilege for me to work with Mr. AmodKulkarni, Executive, SPM Tools, Ichalkaranji. The examples that Mr. Kulkarni has set byhis personal conducts in professional life was unseen and unheard of to me before I methim. I am very much thankful to him for his suggestions, critical comments and usefuldiscussions on the various aspects of life cycle costing and reliability analysis in regard tothe case study. I wish to express my high regards for him for all that he has done for me.I appreciate greatly the whole team of SPM Tools for their direct and indirect helpand encouragement. In particular I wish to acknowledge the timely help and supportprovided by Mr. Kiran Patil, Mr. P. D. Galgale, Mr. P. R.Yadav, Mr. A. U. Rokade.I am very much thankful to Prof. R. A. Kanai, director, ADCET, Ashta, Dr. A. M.Mulla, Principal, ADCET, Ashta and Dr. S. S. Ahankari, HOD, Mechanical EngineeringDepartment for their help and support. I am also thankful to Prof. S. A. Patil, PGcoordinator of Mechanical Department and all the faculties for their guidance andsuggestions.It would be unreasonable of me not to sufficiently and gratefully acknowledge allthe help and support that Prof. R. S. Powar, HOD, Mechanical, Dr. J. J. Magdum collegeof Engineering, Jaysingpur has provided to me. I would like to express my sincereappreciation towards him for influencing my pattern of thought altogether. It would be anincomplete story without his help and timely encouragement.I deeply feel my gratitude towards my family and friends, without their valuablesupport I would have never seen those days.Mr. RAJKUMAR B.PATIL(M. E. Mechanical Design Engineering)3
INDEXSynopsisiNomenclatureviList of FiguresxList of TablesxiiCHPTER IIntroduction1.CHAPTER ility31.3.1.3.Maintainability41.4.1.4.Life Cycle Cost (LCC)41.5.1.5.Relation between Reliability and LCC Analysis51.6.1.6.Present Theory and Practices51.7.1.7.Requirement of the company111.8.1.8.Outline of the work carried out13Reliability Analysis Methods2.System Reliability Block Diagram161.9.1.2.1.1.Series System161.9.2.2.1.2.Parallel System171.9.3.2.1.3.Combined Series-Parallel System181.10.2.2. Fault Tree Analysis Method181.10.1.2.2.1.Symbols used in FTA201.10.2.2.2.2.Steps involved in Fault Tree Analysis211.10.3.2.2.3.Advantages and Limitations of FTA2426-55Fault Tree Construction3.16-2516Introduction1.9.2.1.CHAPTER III1 to 15Introduction263.1.Design and Construction Details of FCAF-245263.1.1.Design considerations264
3.1.2.3.1.2.Construction and operation273.2.Construction of Fault Tree of FCAF-245313.3.Reliability Analysis of Band Saw Cutting40Machine by Fault Tree Diagram3.4.Time to Failure Data Analysis and Model42SelectionCHAPTER IV3.5.Weibull Distribution443.6.Life Cycle Cost Models49Reliability and Life Cycle Cost Analysis of Band Saw56-70Cutting Machine4.Introduction564.1.System Configuration564.2.Reliability Analysis574.3.Life Cycle Cost .6. Costs654.3.4.Support4.3.7.4.3.8. Costs674.3.5.Net4.3.9.4.3.10.Salvage Value684.3.6.Life4.3.11.4.3.12.Cycle Cost68Life Cycle Cost results694.4.CHAPTER VLife Cycle Cost optimization5.CHAPTER VI71-77Introduction715.1.Reliability Improvement Suggestions715.2.Improved reliability and MTBF735.3.Improved Life Cycle Cost74Summary and cope for future work815
CHAPTER VII Selected References82-84Appendix – I85Appendix – II86-87Appendix – III88-946
SYNOPSIS1. RelevanceIn engineering disciplines reliability, maintainability and product life cycle costoptimization has become the focused area of interest. Reliability aspect is essential indesign of any product or system due to the increased complexity and sophistication ofsystems, awareness of customers, high cost of maintenance etc. Reliability is defined tobe the probability that a component or system will perform a required function for agiven period of time when used under stated operating conditions. In short, it is theprobability of non-failure of a product/system over a time [1, 2].Reliability is estimated by analyzing the failure data. Different reliability modelsare used to determine various measures of reliability such as a mean time betweenfailures (MTBF). MTBF is affected by the known or predicted stresses, environmentalfactors, operating conditions, material properties and part geometries. Reliability modelgives critical modes and parameters of failures. Many failures, however, are much moresignificant in both their economic and safety aspect. The reliability of aero-plane iscrucial for the safety of the passengers and the failure of any machine used in massproduction system is not affordable for any industry. Another important aspect isconsidered in reliability based design is that reliability should not increase too much costof the product or system. Maintenance costs form a significant part of the overalloperating costs. Hence, to reduce the overall contribution of the running or operatingcosts reliability and product life cycle cost analysis is important. It also gives exact ideahow to reduce the overall costs of the product or system throughout its lifecycle [3, 4].Taking into consideration the importance of reliability and life cycle cost, it is decided tocarry out reliability analysis and LCC optimization of a band saw cutting machinemanufactured by SPM Tools, Ichalkaranji.2. Industry RequirementsSPM TOOLS, Ichalkaranji are leading manufacturers of band saw cuttingmachines. These machines are used in small scale as well as large scale industries forcutting of steels as well as non-ferrous materials. They are used not only for massproduction but also for batch production. These machines are fully protected to givemaximum safety and prevent accidents. The Band-Saw has a centralised control paneli
conveniently placed within operator‟s reach and a power driven wire brush for chipremoval. For increasing saleability, durability and compete their competitors, research,redesign and development work is going on. The main objective of this research is toimprove reliability and optimize the total life cycle cost in order to increase availability.Out of all the models, Model FCAF-245 shown in Fig. 1 is most sellable and used formass production. The failure of this model is not economical for vendors. Due to thisreason, this model is selected for reliability analysis and life cycle cost optimization [5].Table 1 depicts the specifications of Model FCAF-245.Figure 1 - Band Saw Cutting Machine (FCAF-245) [5]Table 1 - Specifications of Model FCAF-245ModelFCAF-245235, Φ 260 mmCutting RangeFeed Length Range, Cutting Speed0-600mm, 24-100 m/minDrive Motor2.2KW, 440V, 50Hz, 3PhHydraulic Drive0.75KWSpace Requirement1875X 2900 X 1750 mmNet Weight950KgSaw Blade Size3700 X 27 X 0.9 mmBand TensionHydraulic/ ManualHead Elevation clamping and feed vicesHydraulicSaw Feed ControlHydraulicii
3. Present Theory and PracticesCranwell [6] presented a survey of reliability considerations. Over 90% of allreliability and quality costs in U.S. are being spend to correct product designinadequacies and defects after they have occurred while less than 10% are being spent tomake products right in the first place. It is also suggested that the equipment purchasedecision should be based on total life cycle costs, reliability and availability. Reliabilityand optimization in design help to reduce 15-20% of total life cycle costs.Waghmode [7] analysed and concluded that the initial prise is not the only criteriaof the procurement. Most of the cost is associated with the hazard rate or failure rate ofthe product during the life cycle of the product. From the case study on reliabilityanalysis of multi-stage centrifugal pump, it is found that initial cost is a fraction of thetotal cost.Frank [8] used Fault Tree Analysis (FTA) method to increase the reliability ofspacecraft mission namely „Mars Micro-Met Mission‟. The analysis included thefunctional block diagram framework useful to structure a supporting fault tree analysis.Reliability analysis at an early stage of mission design was shown to be highly effectivemethod for reducing the predicted risk of mission failure. He also suggested that it isbetter to implement reliability improvement options using analysis early in the designwhen it is least costly to make changes.Venter and Scotti [9] suggested a methodology for including the results ofproof/acceptance tests in the Reliability Based Design Optimization (RBDO) process.The proposed method allows for the simultaneous design of the structural component andthe proof test itself and provides the designer with direct control over the probability offailing the proof test. The results indicate that a significant weight saving is possiblewhen including the proof test results in the design process as compared to equivalentdeterministic or RBDO designs, while maintaining the same probability of failure asobtained from the deterministic design.Barringer [10] emphasized the need of practical reliability details to define lifecycle costs of the product. Life cycle cost comparisons help to decide the lowest longterm cost of ownership driven by a single estimator called net present value. The netpresent values require decisions about when and how much maintenance/ replacementiii
costs will be incurred which is driven by the time and modes for component failuresfound by using reliability technology.4. Proposed WorkIt is proposed to carry out the study of reliability analysis and product life cyclecost optimization of band saw cutting machine. The objective is to increase reliability ofthe machine, reduce maintenance work associated with it and the total life cycle cost. Forthis dissertation work, it is proposed to carry out the work in the following phases.Phase I: - Study of design and manufacturing process of band saw cutting machine inorder to understand the process flow, to draw master logic diagram or event sequencediagram and to understand costs associated with each stage.Phase II: - Study of possible modes of failure, collection of failure data of thecomponents and cost associated with the failures.Phase III: - Estimation of the reliability, MTBF and MTTR of each components and thesystem by using different reliability models. Constructing a Fault Tree diagram andfinding critical parameters.Phase IV: - In last stage, the reliability improvement methods and different ways toreduce the life cycle cost of band saw cutting machine will be suggested.References1] Charles E. Ebling, “Introduction to Reliability and Maintainability Engineering”, TataMc Graw Hill Publishing House, Edition 2000.2] H. Paul Barringer, P. E. Barringer & Associates, “An Overview of ReliabilityEngineering Principles”, Penn Well Conferences, January 29 – February 2, 1996.3] A. J. Mokashi, J. Wang, A. K. Vermar, “A study of Reliability-Centred maintenance inmaritime operations”, Marine Policy 26 (2002) 325-335.4] Patrick D. T. O‟Conner “Practical Reliability Engineering”, Wiley India Pvt Ltd,Fourth Edition.5] SPM TOOLS, Ichalkaranji, spmtools.co.in.6] Robert M. Cranwell, “Ground Vehicle Reliability – Design for Reliability”, 2007 DoDMaintenance Symposium, Orlando, Florida, November 13-16, 2007.iv
7] L. Y. Waghmode, “Some studies on Total life cycle costs of an industrial product or asystem”, Dissertation of ME Design, Shivaji University, Kolhapur.8] Michael E. Frank, “Reliability considerations in the mission of Micro-meteorologyMission to Mars”, Probability Safety Assessment and Management 1996 (PSAM III), P.C. Cacciabue and I. A. Papazogluo, ed., Springer-Verlag, London 1996, pp 1613 to 1618.9] Gerhard Venter (University of Stellenbosch, South Africa), Stephen J. Scotti (NASALangley Research Centre, Hampton, VA 23681-2199), “Accounting for Proof test Data ina Reliability Based Optimization Framework”,.10] H. Paul Barringer, “Why you need practical reliability details to define life cyclecosts for your products and competitors products?” www.barringerl.com.v
NOMENCLATURER(t)Reliability at Time tλHazard Rate FunctionMTBFMean Time Between FailureMTTRMean Time To RepairMTBMMean Time Between MaintenanceMAMTMean Active Maintenance TimeAiInherent AvailabilityAaAchieved AvailabilityAoOperational AvailabilityCDF, F(t)Cumulative Distribution FunctionPDF, f(t)Probability Density FunctionTRandom Variableσ2VarianceσStandard DeviationCFRConstant Failure rateIFRIncreasing Failure rateDFRDecreasing Failure rateβShape parameterΘScale Parameter or Characteristics LifeLCCLife Cycle CostingNPVNet Present ValueLCMLife Cycle ManagementPVPresent ValueMDTMean Down TimeKpCost Of ProductionKrdCost of Research and DevelopmentKosCost of Operation and SupportKdCost of DisposalC1Present Worth of Salvage ValueC2Present Worth of Cost of Energyvi
C3Present Worth of Cost of InvestmentC4Present Worth of Replacement Cost Type IC5Present Worth of Nonfuel, Yearly Recurring Operation andMaintenance CostsC6Present Worth of Replacement Cost IIK1Cost of Test and IntegrationK2Cost of InstallationK3Cost of AnalysisK4Cost of Code and CheckoutK5Operation and Support CostK6Cost of DesignK7Cost of DocumentationK1 (y)Contractual CostK2 (y)Retirement CostK3 (y)Energy CostK4 (y)Procurement CostK5 (y)Service CostIEffective Discount CostFConstant Annual Inflation RateEAnnual Return on Investment RatePFFuture Amount at the End of Years dPAEqual Annual Amount Observed over d YearsCuUnit Acquisition CostNNumber of Identical Units to be ProcuredFoFixed Cost of OperationgCoAnnual Operating Cost per UnitFsFixed Support CostCsAnnual Support Cost per UnitCfCost Per FailuretoOperating Hours per Unit per YeartdDesign Life in Yearsvii
SUnit Salvage Valueto / MTTFExpected Number of Failures per YearCu (MTBF, MTTR)Unit acquisition CostMProgrammed Number of Operating UnitsSNumber of Spare Units (Stand by Redundency)KNumber of Repair ChannelssiNumber of Spares of Componen IkiNumber of Repair Channela for Component IAsysEffective System AvailabilityFrepInitial Acquisition Cost per Repair ChannelCrepAnnual Cost per Repair ChannelCfFixed Cost per FailureCiUnit Cost of Component ICrep,iAnnual Cost per Repair Channel for component ILLabour RatetopNumber of Operating Hours per Year per UnitSaUnit Salvage ValueRDiscount RateCicInitial Cost, Purchase Price, (Band Saw Cutting MachineFCAF 245, Auxiliary services)CinInstallation and Commissioning Cost (Including Training)CeEnergy Costs (For All the Systems)CoOperation Costs (Labour Cost of System Supervision)CmMaintenance and repair Costs (routine and predictedMaintenance)CsDown Time Costs (loss of Production)CenvEnvironmental CostsCdDe-commissioning / Disposal Costs (including restoration oflocal Environment)CSum of All Relevant Costs, Including Initial and Future Costs,Less Any Positive Cash Flows Occurring in Year, tviii
NNumber of Years in the Study PeriodDDiscount Rate Used to Adjust Cash Flow to Present ValuetdDesign or Economic Life in Operating HoursCfFixed Cost of FailureCvVariable Cost per Hour of Down TimeTiCorrective Maintenance or Repair Time Needed to RepairUnit iTpmMean Preventive Maintenance TimeTmpiElapsed Time for Preventive Maintenance task IFptiFrequency of the Preventive Maintenance task IKNumber of Preventive Maintenance TasksTmedMedian Corrective Maintenance TimeTmcmMaximum Corrective Maintenance TimeMLHaMean Maintenance Labour hours per YearTsNumber of Operating Hours per YearNcMean Number of Persons to Perform Corrective MaintenancetaskNpMean Number of Persons Required to Perform PreventiveMaintenance TaskPA(i,td)Annuity Factorix
LIST OF FIGURESFig. No.ParticularsPage No.1.1.Life cycle costs Vs Life cycle phases61.2.Results of implementation of reliability practices at design6stage on LCC1.3.Life cycle cost analysis71.4.Band saw cutting machine (FCAF-245)122.1.Reliability block diagram for components in series162.2.Reliability block diagram for components in parallel172.3Combined series and parallel system182.4.Fault tree diagram202.5.Steps in fault tree analysis223.1.Application of coolant283.2.Auto length indexing mechanism303.3.Feed force controlling mechanism.303.4.Roller assembly313.5.Events leading to the top event323.6.Failure of cutting blade333.7.Electrical control system failure343.8.Head operation failure343.9.Roller sub-system failure353.10.Improper coolant supply363.11.Coolant pump failure363.12.Improper job clamping373.13.Band drive failure383.14.Adjustable saw guide arm failure393.15.Blade driving system failure393.16.Selection of time to failure model433.17.Possible trends in time between failure of band wheel bearing44(ZNR-6307)x
3.18.The effect of β on probability density function453.19.Effect of β parameter on cumulative distribution function463.20.Effect of β parameter on reliability function463.21.Effect of β on hazard rate function473.22.Effect of scale parameter on probability density function483.23.SAE model524.1.Life cycle cost of band saw cutting machine705.1.Cost savings776.1.Percentage cost reduction after analysis796.2.Improved life cycle cost components80xi
LIST OF TABLESTable No.ParticularsPage No.1.1.Specifications of model FCAF-245122.1.Symbols used in FTA214.1.List of components of FCAF-245564.2.Reliability analysis584.3.MTBF and MTTR594.4.System MTTR estimation604.5.Mean preventive maintenance time (Tpm)624.6.Failure cost estimation664.7.Support cost estimation674.8.Life cycle cost of band saw cutting machine705.1.Improved reliability and MTBF735.2.Failure cost estimation755.3.Support cost estimation765.4.Improved LCC and cost savings77xii
CHAPTER IIntroduction1. Introduction:Reliability and life cycle cost analysis have become the need of recent fast growingindustries. Reliability analysis helps to manage the product/system failures while lifecycle cost analysis deals with the cost implications over the operational life of theproduct/system. Reliability analysis is important because unreliability has a number ofunfortunate consequences and therefore for many products and services poor reliability isa serious threat. For
Shivaji University, Kolhapur Submitted by Mr. Rajkumar Bhimgonda Patil . coordinator of Mechanical Department and all the faculties for their guidance and suggestions. It would be unreasonable .
Shivaji University, Kolhapur, Maharashtra, India Hiremath AJ Department of Technology and Food Science and Technology, Shivaji University, Kolhapur, Maharashtra, India which accounts for nearly 14.0% of country’s share in the Sahoo AK Department of Technology and Food Science and Technology, Shivaji University, Kolhapur,
TE (CSE) REVISED SYLLABUS, SHIVAJI UNIVERSITY, KOLHAPUR Shivaji University, Kolhapur REVISED STRUCTURE T.E. Computer Science & Engg. (Semester ² V & VI) W.E.F. 2015 -16. Semester V Sr. Subject L T P Tota l Theory Marks T W POE Oral Total No. Written Online Marks
Scientific Publications of Shivaji University, Kolhapur (1989-2018): a Scientometric Study Dr. Shalini R Lihitkar Professor and Head Department of Library & Information Sciences, Shivaji University Kolhapur, Vidyanagar, Kolhapur (MS) Ravindra S Bankar Research Scholar Department of Library & Information Sciences,
OF SHIVAJI UNIVERSITY CAMPUS, KOLHAPUR (MAHARASHTRA) Supriya Gaikwad* and Meena Dongare Department of Botany, Shivaji University, Kolhapur E-mail: supriya15suk@gmail.com (*Corresponding Author) Abstract: The present work is an attempt to the study of Macrophyte diversity from Shivaji University campus reservoirs.
University, Pune 2014-2015 16. Prof. R.S.Mane Swami Ramanand Tirth Marathwada University, Nanded 2015-2016 17. Prof. Pramod Vasubmekar Dept of Electronis, Shivaji University, Kolhapur 2015-2016 18. Prof. P.S.Patil Deapt.of Physics, Shivaji University, Kolhapur 2015-2016 UGC Sponsored National Seminars organized by the Department:
SHIVAJI UNIVERSITY, KOLHAPUR Faculty of Interdisciplinary studies Structure, Scheme and Syllabus for . B. Voc. Part II Advanced Diploma (Second Year) . Write a news story and a feature story (Either in Marathi or English) by applying the theoretical principals taught in the class. The word count of the story must be 300-500 words and it must
Shivaji University, Kolhapur Department of Electrical Engineering Course plans for B.E. (Semester-VIII) Scheme of Teaching & Examination Semester VIII Sr. No Category Teaching scheme per week Contact Hours Examination(Marks) Course Title L T P Theory T W POE Total 1 ES Law for Engineers 2 2 50 50 2 EE HVDC Systems 4 2 6 100 50 150 .
This manual explains how to use the API (application programming interface) functions, so that you can develop your own programs to collect and analyze data from the oscilloscope. The information in this manual applies to the following oscilloscopes: PicoScope 5242A PicoScope 5243A PicoScope 5244A PicoScope 5442A PicoScope 5443A PicoScope 5444A The A models are high speed portable .
