Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308 Paper received: 2008-07-16, paper accepted: 2012-03-21

DOI:10.5545/sv-jme.2008.076 2012 Journal of Mechanical Engineering. All rights reserved.

*Corr. Authors Address: Tehnical Faculty Mihajlo Pupin, Djure Djakovic bb, 23000 Zrenjanin, Serbia, [email protected] 300
An Evaluation of Formed Maintenance Programme Effcacy
uri, . Josimovi, L. Adamovi, . Radovanovi, L. Jovanov, G.
eljko uri
1
Ljubia Josimovi
2
ivoslav Adamovi
3
Ljiljana Radovanovi
3,*
Goran Jovanov
4
1
Bauxite Corporation Milici, Bosnia and Herzegovina
2
Polytechnical School Pozarevac, Serbia
3
University of Novi Sad, Technical Faculty Mihajlo Pupin in Zrenjanin, Serbia
4
International University of Brcko, Bosnia and Herzegovina
This paper presents the basic ideas for programming the maintenance of complex technical systems, which is a set of rules for determining
the diagnostic mode of the constituent parts of the system in the actual exploitation process and decision making regarding the need for their
replacement or on the extent of the necessary maintenance based on the information of the actual technical condition of the system.
Assuming that the condition based maintenance is, in fact, the management system of the technical state of the system in the
exploitation process, upon choosing the strategy for the condition based maintenance we have performed an analysis of the applicability of
formed variants of the maintenance programme and evaluated their efficiency by comparing them with basic indicators (for corrective and
preventive maintenance). We have pointed out the importance of using the described maintenance programme to increase reliability level and
decrease the stagnation of technical systems, which results in high efficiency, and thus increases the productivity of companies where the
systems have been installed.
Keywords: reliability of technical systems, maintenance programme, technical diagnostics
0 INTRODUCTION
The shortcomings in policies and strategies of
preventive maintenance within large fields of practice
have recently initiated a trend of the maintenance
planning on the basis of the established condition of
the system within the exploitation process (condition
based maintenance) [1].
The main advantages of introducing the condition
based maintenance lie mainly in the reduction of the
maintenance costs (both direct and indirect) as well
as in the decrease of the possibility of bringing to a
production halt, although other positive effects can be
produced, such as the following:
providing the production of required amounts of
proper quality goods,
improving the safety of the working staff
(operators and maintenance workers),
decrease in dissipating both energy and raw
materials necessary for the production and
providing the operation of the constituent parts
and/or the system within the regime of the highest
level of use,
better relationships with buyers of goods because
of immediate deliveries as well as of the adequate
quality of goods,
greater satisfaction among the staff, particularly
within the departments of production and
maintenance etc.
The policy of preventive maintenance based
on the realisation of planned activities at particular
intervals, independently of the technical condition
of the constituent parts and/or the system, does not
provide sufficient operation and connection between
the process of the alteration of the technical condition
and the exploitation process [2].
A closer connection between them, by work
planning and its periodical performance depending on
the technical condition of the constituent parts and/
or the system obtained on the basis of diagnostics, is
provided by maintenance strategies according to the
condition.
Technical systems provide the possibility of
applying a greater number of maintenance strategies
according to the condition.
According to the standard EN 13306: 2001
(Maintenance Terminology) condition based
maintenance is preventive maintenance based on
performance and/or parameter monitoring and the
subsequent actions [1].
The research [2] and [3] have contributed to these
strategies being divided into two groups:
maintenance according to condition with
parameter control, and
maintenance according to condition with
reliability level control.
Maintenance according to condition with
parameter control includes constant or periodic
control and technical parameters measuring all the
systems components and/or the system as a whole.
The maintenance activities are performed when the
values of the control parameters reach the usability
level, or the pre-critical level.
The condition based maintenance with the
control of the reliability level consists of collecting,
processing and analysing the data on the reliability
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
301
of the constituent parts and/or the system and of
elaborating the decisions on the necessary planning
activities of the maintenance concerning replacing or
repairing the constituent parts of the system.
In the general analysis of recent documents [1]
to [8] preventive maintenance processes, proactive
maintenance, maintenance according to the condition,
technical diagnostics and total maintenance are
reviewed.
The authors specify the significance and the role
of the maintenance according to the condition, while in
documents [1], [2], [4] to [6], this kind of maintenance
is defined as a form of preventive maintenance whose
strategy of decision making on maintenance activities
is based on periodic and constant technical control of
the system in the exploitation process, and according
to the results of the diagnostics control the decisions
are made on the necessary deadline and the amount of
planned maintenance activities.
Maintenance according to the condition is
handled with the control of the parameters and the
usage of the endoscopic method [7], so it can be
concluded that the existing model of maintenance
according to the condition reaches the goal of
successful implementation of the diagnostic method
in which planned maintenance activity duration is
determined.
To some extent, the issue of the improvement
of technical systems maintenance process arises,
based on the implementation of different models of
preventive maintenance, on the knowledge of a certain
part of the systems condition, gained from the routine
or constant observation [8].
In their paper Barros, et al. [4] present a new
methodology for optimizing maintenance and
monitoring performance. The performance of the
monitoring device is modelled classically by receiver
operating characteristic (ROC) curves. From a
practical point of view, this approach leads to a very
simple optimization scheme in which the optimal
monitoring technology or structure can be chosen
among a finite set of possible ones, on the basis of
their impact on the maintenance performance and
their own cost. At the same time, the maintenance
parameters are optimally tuned to adapt to the current
monitoring quality level.
Adjallah and Adzakpa [5] give important and
useful results relating to the minimization of the sum
of the flow time and the tardiness of tasks or jobs
with unequal release dates (occurrence date), with
application to maintenance planning and scheduling.
First, the policy of real-time maintenance is defined
for minimizing the cost of tardiness and critical states.
The required local optimality rule (flow time and
tardiness rule) is proved, in order to minimize the
sum or the linear combination of the tasks flow time
and tardiness costs. This rule has served to design a
scheduling algorithm, with O (n
3
) complexity when it
is applied to schedule a set of n tasks on one processor.
To evaluate its performance, the results are compared
with a lower bound that is provided in a numerical
case study. Using this algorithm in combination with
the tasks urgency criterion, a real-time algorithm is
developed to schedule the tasks on parallel processors.
This latter algorithm is finally applied to schedule and
assign preventive maintenance tasks to processors
in the case of a distributed system. Its efficiency
enables, as shown in the numerical example, the cost
of preventive maintenance tasks expressed as the sum
of the tasks tardiness and flow time to be minimized.
This corresponds to the costs of critical states and of
tardiness of preventive maintenance.
In this paper we have made an attempt to point out
the influence of formed variants of the maintenance
programme on the increase of the reliability level of
technical systems.
1 FORMING THE MAINTENANCE PROGRAMME
The maintenance programme will here refer to the
set of accepted methods formed on the basis of
documentary materials and the maintenance regime
for the constituent parts and/or systems, which provide
the given management of the technical condition as
well as the reliability within the given condition of the
exploitation process.
The maintenance programme of the constituent
part and/or the system must be aimed at providing the
highest level of efficacy of the constituent part and/or
the system with optimal exploitation costs.
Forming the maintenance programme can be
based on rational combining the condition based
maintenance with traditional preventive maintenance.
Taking into account a great complexity of
technical systems in the industry, this paper deals
with forming the maintenance programme for the
constituent parts of a section (e.g. the convertor
section including the equipment), although this can be
done for the constituent parts (fits) of the system as
well.
The research into forming the maintenance
programme for the constituent parts and/or the system
should, in principle, contains three stages:
forming the maintenance programme variants at
the first level,
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
302 uri, . Josimovi, L. Adamovi, . Radovanovi, L. Jovanov, G.
forming the maintenance variants at the second
level,
evaluating the efficacy and choice of the
maintenance programme variant.
If the failure of the constituent part does not
affect the reliability of the system in operation, then,
when it comes to an increase of the intensity of the
failure, it is the average costs for corrective and
preventive replacement that are compared, and if
those costs are the same, the constituent part of the
system is maintained according to the condition by
controlling the reliability level. If those corrective
maintenance costs are greater than those of preventive
maintenance, then the maintenance with the control of
parameters is applied.
If the failure intensity is approximately constant,
then the condition based maintenance with the control
of the reliability level is applied.
If the failure of the constituent part of the system
affects the reliability of the system in operation, it is
the condition based maintenance that will be used
with the increase of the failure intensity, whereas the
condition based maintenance with the control of the
reliability level will be applied with the non-increase
intensity.
Evaluating the influence of the failure of the
constituent part on the reliability of the system in
operation is performed by comparing the probability
of the occurrence of one of the possible conditions of
the system with corresponding allowable values given
by the equipment manufacturer, where the methods
of mathematical statistics are used and the failure
intensity is analysed. In order to form the diagram of
the failure intensity it is necessary to process statistical
data of the failures of the constituent parts of the
system within the process of technical exploitation
during a period of time that is no longer than 2 to 3
years. The analysis of constant proper functioning of
the constituent parts can be performed according to
the well-known order:
forming the diagram of the failure intensity,
according to the character of the alteration of the
failure intensity, the assumption about the law on
the distribution of the failure occurrence is made,
checking the hypothesis on the law on the failure
distribution according to Pearson etc.
According to the results of modelling the
following can be determined:
the frequency of entering particular conditions of
the exploitation process,
the average amount of the detected failures of
the constituent parts and/or the system within
particular conditions etc.
In this case, some indicators of the maintenance
efficacy can also be calculated, such as the following:
the probability of entering particular exploitation
conditions,
the efficiency coefficient of the constituent part
and/or the system according to the purpose,
specific stops due to maintenance,
average time of the system renewal,
specific maintenance costs of the constituent part
and/or the system etc.
The influence of the characteristics of the
constituent parts referring to the construction and
exploitation on the efficacy of the application of
different maintenance strategies and thus on the
efficacy of the maintenance programme on the whole,
should necessarily be analysed through the alterations
of the reliability indicators and maintenance costs.
The annual economic effect of introducing the
maintenance programme of the constituent parts and/
or the system can arise from:
the reduction of the maintenance exploitation
costs,
the improvement of efficacy of the constituent
parts and/or the system,
the decrease of the amount of the spare parts to be
replaced etc.
2 SPARE PARTS SAVING BY INTRODUCING
THE MAINTENANCE PROGRAMME
The research conducted in steel industry shows
that the probability of continuous operation of
the constituent parts and/or the system, which are
susceptible to accidental failures, can be described
by the exponential and Weibulls distribution for the
working period when the failure intensity is either
constant or on the rise. For failures due to ageing
(gradual failures) the probability of continuous
operation can be described as normal, log-normal by
Erlangs and Weibulls distribution during the working
period when the failure intensity is on the rise.
On the basis of this research it is possible to make
a maintenance programme for a technical system of a
particular type or for more systems combined within
working requirements, and thereby a plan of necessary
spare parts replacements.
The use of the new maintenance programme,
differing from the basic maintenance programme
assumes a significant application of the maintenance
strategies according to the condition, which results in
the reduced use of the amount of spare parts.
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
303
For the amount of the saved constituent parts
of the i-type, which are maintained according to the
condition with the control of parameters Eq. (1) [2].
n T
t mt
i A ef
uri
i
ur
=

1
2
. (1)
It is possible to achieve the following economic
effect:
C T
t mt
n C
R i ef
ur
i
ur
i
r
i r d
d
1
1 2
1
1
=

=


, (2)
where:

A
is the effciency coeffcient of the constituent part
of the system before introducing the maintenance
programme (with the basic maintenance
programme),

B
is the effciency coeffcient of the constituent part
after introducing the maintenance programme,
T
ef
is the annual number of hours (T
ef
= 8760 h),
r
d
is the amount of the constituent parts of the system
which are maintained according to the condition
with the control of parameters,
t
ur1
is the average time during the work between two
failures for the i-type constituent part [h],
m is the coeffcient of the decrease of the output of
the i-type constituent part of the system when its
parameter reaches the wear out limit,
t
ur2
is the average time while working with the
condition based maintenance [h],

i
is the ratio of the effciency coeffcients of the
constituent part of the system before and after
introducing the maintenance programme (
i
=
B

/
A
),
n
i
is the amount of the spare parts of the i-type
within one system,
C
r/d
is the price of one spare part of the i-type.
The annual economic effect Eq. (3) is produced
for the constituent parts of the system which are
maintained according to the condition with the control
of the reliability level:
C
t t
n C
R A
ur
i
ur
i
n
i r d
P
2
1 2
1
1
=

=


, (3)
where:
n
p
is the amount of spare parts which are maintained
according to the condition with the control of the
reliability level.
Expressing the average time during work (t
ur1
)
with the parameters of the exponential, normal, log-
normal, Erlangs and Weibulls laws and classifying
them into Eqs. (2) and (3), the total saving of spare
parts is achieved by introducing the maintenance
programme Eq. (4) [3]:
C T
t t
n C
t mt
n
R A ef
ur
i
ur
i r d
i
k
ur
i
ur
i
=

|
\

|
.
|
+

|
\

|
.
|
=

1
1
1 2
1
1 2
CC
t
m
k
n C
t
r d
i
l
ur
i
e
e
i r d
i
f
ur
i
+

|
\

|
.
|
|
|
|
+

|
\
=
=

1
1
1
1
1
1
1

|
.
|
+
|
\

|
.
|

(
(
(
(
(
+

|
\

|
.
=

1
1
1
1
1
1

T
n C
t
i r d
i
p
ur
i i
+

=
=

n C
t
k
n C
t
m
i r d
i
n
ur
i
e
e
i r d
i
e
ur
i
1
1
1
1
1
1
1

|
\

|
.
|
+
|
\

|
.
|

(
(
(
(
(

1
1
1
1
T
n C
i r d
i
q

, (04)
where:
k, l is the amount of the spare parts which are
maintained according to the condition with the
control of the reliability level and control of
the parameters and which have the normal and
log- normal distribution of the probability of
continuous work,
n is the amount of the spare parts which are
maintained according to the condition with the
control of the reliability level and which have the
exponential distribution of the continuous work
with the parameter
i
,
e, f is the amount of the spare parts which are
maintained according to the condition with the
control of the reliability level and the control of
parameters, which have Erlangs distribution
of the probability of continuous work with the
parameters k
e
and
e
,
p, q is the amount of the spare parts which are
maintained according to the condition with the
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
304 uri, . Josimovi, L. Adamovi, . Radovanovi, L. Jovanov, G.
control of the reliability level and the control of
parameters, which have Weibulls distribution
of the probability of continuous work with the
parameters and ,
t
ur2
is the mathematical expectation of the average
time during work for normal and log-normal
distribution,
r is gamma function.
In mathematical modeling, when preparing a
maintenance strategy, equipment utilization rate
and the cost of lost production per tim. should be
considered.
The utilization rate must be considered when
equipment is designed under competitive conditions.
This rate consists of the following factors: the quality
of equipment and its operation and the operational
(demand) situation. As a utilization criterion we took
the utilization function F, which should be optimized
over the planned time T to produce N part, Eq. (5):
F
P C
T
=

, (5)
where P is the sale price of N parts, and C is the cost
of the parts [9].
The paper [10] explains and justifies the necessity
and the importance of using the shift level of the
utilization of capacity as the stochastic variable in
determining the total level of the capacity utilization
in the production process by using the method of
work sampling. The conclusion is that the shift level
of capacity utilization as the stochastic variable in
work sampling is the model that solves the problem of
determining the total level of capacity utilization in a
convenient way with accurate results.
Fig. 1. Typical cash flow diagram illustrating the cost of lost
production
The cost of lost production is a random set of
peaks in the cash flow diagram as shown in Fig. 1. If
treated independently, this cost can appear as a minor
problem, but if aggregated, the result can be quite
startling. Even if it is possible to calculate the cost of
lost production accurately, the frequency and duration
of future break-downs should still be estimated before
making a cash flow statement. Accordingly, it is
important to have good past records if we are to do
any better than just guess a value. If breakdowns are
purely random occurrences, then past records are not
going to be enough to predict precise savings that
could be included in a sound financial case. They may
give an indication of the likely cost when a breakdown
happens [11].
This is a model for calculating the cost of lost
production during maintenance actions in Eq. (6):
C
LP
= N
WP
RC, (6)
where C
LP
is the cost of lost production, N
WP
the
number of days without production, and RC the
replacement cost.
A model for determining the distribution of the
net present value (NPV) characterizing the production
systems is developed in the paper [12]. The model has
significant advantages compared to models based on
the expected value of the losses from failures. The
model developed in this study reveals the variation of
the NPV due to the variation of the number of critical
failures and their times of occurrence during the entire
useful life-cycle of the systems.
At the heart of the NPV-model there is a model
for tracking the losses from failures L
i
. These have
three major components:
cost of lost production C
LP
,
cost of intervention C
I
to initiate repair which
also includes the cost of mobilization of resources
for repair, and
cost of replaced components and cost of repair
C
R
.
As a result, the losses from failures L can be
presented as a sum of these three components, Eq. (7).
The losses from failures L
i
= C
LP,i
+ C
I,i
+ C
R,i
in the
i-th year are a sum of the cost of lost production C
LP,i
,
the cost of intervention C
I,i
and the cost of repair/
replacement C
R,i
in the i
th
year.
L
i
= C
LP,i
+ C
I,i
+ C
R,I
. (7)
The cost of lost production C
LP
is calculated from
Eq. (8):
C
LP
= L
d
V
d
P
V
, (8)
where L
d
is the number of lost production unit-days,
V
d
is the volume of production per day per production
unit and P
V
is the selling price per unit volume
production.
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
305
3 FORMING THE MAINTENANCE PROGRAMME FOR THE
ENGINE-ROOM OF CONVERTORS
The engine-room of convertors (Fig. 2) consists of:
a firth crane, a charging crane, a magnetic crane, the
preparation of non-metal additives, conveyors T1 and
T2, the engine-room of blowers, the installation for
water and oxygen, the delivery of non-metal additives,
a scrubber, an exhaust fan and a convertor.
The reliability of the engine-room of convertors
(R
uk
) can be calculated as in Eq. (9) (the signs are
from Fig. 2):
R R R R R R
uk K K
=
( ) ( )

( ) ( )

1 3 4
1 1 1
1 2
' ' '
, (9)

R R R K
R K
R R
uk sk SK
MK MK
N
1
1 1 1
1 1 1
1 1
'
= ( ) ( )

( ) ( )

TT T T
R K
1 2
1 ( ) ( )

,

R R R R R R
R R R R R R
D i ND S V
D i ND S V
3 1 1 1 1 1
4 2 2 2 2 2
'
'
,
,
=
=
where:
R
uk
is the reliability of firth crane,
R
K1
is the reliability of convertor 1,
R
K2
is the reliability of convertor 2,
R
sk
is the reliability of charging crane,
R
MK
is the reliability of magnetic crane,
R
N
is the reliability of engine room of non-metal
additives,
R
T1
is the reliability of conveyor T1,
R
T2
is the reliability of conveyor T2,
R
D1
, R
D2
are the reliability of engine-rooms of
blowers,
R
i1
, R
i2
are the reliability of water and oxygen
armature,
R
ND1
, R
ND2
are the reliability of delivery of non-metal
additives,
R
S1
, R
S2
are the reliability of scrubber,
R
V1
, R
V2
are the reliability of exhaust fan,
K
SK
,

K
MK
,

K
T
are coefficients.
The coefficients K
SK
, K
MK
, K
T
are a measure of
aggravation of total productivity on condition that a
failure occurs on the branch (i) (if they equal 0, the
system does not function on the whole).
The analysis of constant proper functioning of
the constituent parts (subsystems) of the engine-room
of convertors (systems) can be performed on the
basis of the statistical data obtained during the time
of exploitation. The aim of processing the statistical
data is to adopt a law on work distribution until the
failure of all the subsystems. By breaking the above
mentioned subsystems into their constituent parts, it is
also possible to make a proper functioning analysis of
all the constituent parts of the subsystems.
Table 1. The results of the analysis of constant proper functioning and the proposed variants of the maintenance for the constituent parts of
the engine-room of convertors
Position of
const. part
Name of const. part
of the engine-room of convertors
Law on distribution of continuous work
and its parameters
Character of alteration
of failure intensity
Proposed application of
maintenance strategy
1 Firth crane exponential = 204 10
-6
const CBM-CRL
2 Charging crane
Weibull R e
t
=
( ) 6294
1 95 .
increases CBM-CP
3 Magnetic crane
Weibull R e
t
=
( ) 5893
1 68 .
const CBM-CRL; CBM-CP
4 Engine-room of non-metal additives Erlang 2
nd
progression = 2.22 10
-6
increases CBM-CRL
5 Conveyor, T
1
normal m = 9864, = 3869 increases PM
6 Conveyor, T
2
normal m = 8434, = 3904 increases PM
7 Engine-room of blowers exponential = 1.86 10
-6
const CBM-CRL
8 Water&oxygen armature Erlang 2
nd
progression = 4.15 10
-6
increases CBM-CP
9 Delivery of non-metal additives normal m = 7647, = 4098 increases PM
10 Scrubber normal m = 8868, = 3338 increases CBM-CRL
11 Exhaust fan
Weibull R e
t
=
( ) 4682
1 85 .
increases CBM-CP
12 Convertor
Weibull R e
t
=
( ) 4468
2 2 .
increases CBM-CP
PM - preventive maintenance according to constant durability
CBM-CP condition based maintenance with the control of parameters
CBM-CRL condition based maintenance with the control of the reliability level
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
306 uri, . Josimovi, L. Adamovi, . Radovanovi, L. Jovanov, G.
The performed analysis and the choice of
the maintenance strategy for each constituent
part separately enable forming the maintenance
programme (standard).
The evaluation of the efficacy of the formed
programme variants has been made by comparing
them with the basic efficacy indicators (for corrective
and preventive maintenance), whereby the following
results have been obtained:
the operative readiness of the engine-room of
convertors has increased by 6.9 to 8.1%,
the reliability of the engine-room of convertors
has increased by 4 to 8.5%,
specific maintenance costs (direct and indirect)
have decreased by 14 to 21%,
the annual economic effect of the application of
the maintenance programme according to the
condition is (18 to 22)10
6
.
Fig. 2. Schema of the engine-room of convertors
The confirmed hypotheses on the congruence
of the statistical distributions with the theoretical
ones enable determining the distribution parameters
of constant proper functioning, primarily drawing
conclusions on the character of the alteration of the
failure intensity.
When forming the variants of the maintenance
programme for the engine-room of convertors,
the initial point is that the costs of corrective and
preventive maintenance (both direct and indirect)
are always greater than those of the preventive
maintenance.
The results of the analysis of the constant proper
functioning of the constituent parts of the engine-
room of convertors, as well as the suggested variant of
maintenance are given in Table 1.
It can easily be seen in Table 1 that for 9 out of
12 considered constituent parts of the engine-room
of convertors the application of the condition based
maintenance is suggested.
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
307
These results also refer to developed maintenance
programmes for the constituent parts of some
subsystems of the engine-room of convertors.
The influence of the number of the formed
variants of the maintenance programme (% of the
included constituent parts of the system) on the
reliability of the engine-room of convertors is shown
in Fig. 3, whereby a field of a relative alteration of the
reliability which has been reached at the current level
of the chosen maintenance programmes (40% of all
the included technical systems within the engine-room
of convertors) can be noticed. The alteration of the
readiness of the engine-room of convertors in relation
to the time at work is shown in Fig. 4.
Fig. 3. The influence % of forming the variants of the maintenance
programme on the reliability of the engine-room of convertors
In Fig. 3 R
N
is System reliability (of engine-room
of convertors) after choice of maintenance program,
R
L
Basis reliability (before choice of maintenance
program), and R
L
= R
N
R
L
.
Fig. 4. The alteration of readiness of the engine-room of
convertors
The occurrence of the period t
k
(Fig. 4) can
be explained by the following fact: in the past the
replacement of spare parts used to be performed
without a sufficient use of reserves of usability and
the parts were mainly imported. Nowadays, domestic
spare parts are used and their basis (projected)
reliability is a little lower than that of the imported
parts.
By introducing the maintenance programme for
the engine-room of convertors the specific costs of
spare parts and materials have been reduced (Fig. 5).
Some benefits obtained by introducing the
maintenance programme are shown in Fig. 6.
Fig. 5. Specific costs of spare parts and materials depending on
specific costs of maintaining the engine-room of convertors
4 CONCLUSION
Condition monitoring prevents failure modes from
occurring by detecting and avoiding failures. Thus,
a measured trend of increasing temperature and
vibrations in a bearing indicates intensive wear out
and incipient failure, which can be prevented by a
timely replacement of the worn-out bearing. Condition
monitoring of operating components and systems also
provides an early problem diagnosis which helps to
plan and organise the repair in advance. By reducing
the mobilization time and the downtime for repair,
condition monitoring reduces the financial losses
associated with failure. Controlling all processing
parameters in safe ranges is another example of a dual
measure reducing both the likelihood of failures and
the consequences of failure.
By introducing the maintenance programme
it is possible to: improve the efficacy of engine
rooms of convertors, reduce the total maintenance
costs, improve the organisation of production and
maintenance, reduce the consumption of electric
power, reduce the number of complaints about
products, improve the level of co-operation with
partners, improve the level of motivation for work
and improve the level of planned activities concerning
maintenance etc.
The results obtained upon implementation of the
maintenance programme, as well as some other results
not presented in this paper, indicate good congruence
with the hypothesis of the significance of the above
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)5, 300-308
308 uri, . Josimovi, L. Adamovi, . Radovanovi, L. Jovanov, G.
described maintenance programme for the increase of
the reliability level and its contribution to the reducing
the stagnation and high level of utilizing technical
systems and company productivity.
Fig. 6. Benefits obtained by introducing the maintenance
programme in the sections of steelworks; a) maintenance work,
b) price of damaged constituent parts of the system,
c) electric power consumption per day
5 ACKNOWLEDGMENTS
This paper is the result of the research within the
project TR 34028, financially supported by the
Ministry of Science and Technology of Serbia.
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