Total Quality Maintenance and Trouble Shooting A Case Study

Mahesh Sharma1, Alok Khatri2

1

Department of Mechanical Engineering, Government Engineering College, Ajmer, India.

2
Associate Professor, Department of Mechanical Engineering, Government Engineering
College, Ajmer, India.
International Journal of Research in Mechanical Engineering
Volume 3, Issue 2, March-April, 2015, pp. 13-23
ISSN Online: 2347-5188 Print: 2347-8772, DOA : 27032015
IASTER 2014, www.iaster.com

ABSTRACT
Total quality maintenance plays a wide role in any industry. Preventive cum shutdown maintenance
is very necessary to overcome production loss in any industry. Lead time of maintenance should be
less in any industry. It should be less by visualization of graphs and plots and take reading of
equipment time to time. So maintenance team plays an important role in any organization. Total
quality means quality should be maintain in any overhaul or maintenance. By applying optimization
techniques lead time saving in preventive as well as shutdown maintenance will be 10-15% and
production loss saving will be 15-20% approximately. Finally we conclude that total quality
maintenance and trouble shooting is necessary in term of turnover and production capacity.

Keywords: Cause & Effect Diagram, Total Quality Maintenance, Maintenance Forecasting, Lead Time.
I. INTRODUCTION
Past and current maintenance practices in both the private and government sectors would imply that
maintenance is the actions associated with equipment repair after it is broken. From this point of view
maintenance as follows: the work of keeping something in proper condition; upkeep. This would
imply that maintenance should be actions taken to prevent a device or component from failing or to
repair normal equipment degradation experienced with the operation of the device to keep it in proper
working order. Unfortunately, data obtained in many studies over the past decade indicates that most
private and government facilities do not expend the necessary resources to maintain equipment in
proper working order. Rather, they wait for equipment failure to occur and then take whatever actions
are necessary to repair or replace the equipment. Nothing lasts forever and all equipment has
associated with it some predefined life expectancy or operational life [1].
Total quality maintenance is known as total predictive maintenance. Total predictive maintenance
(TPM) originated in Japan in 1971 as a method for improved machine availability through better
utilization of maintenance and production resources. Whereas in most production settings the operator
is not viewed as a member of the maintenance team, in TPM the machine operator is trained to
perform many of the day-to-day tasks of simple maintenance and fault-finding. Teams are created that
include a technical expert (often an engineer or maintenance technician) as well as operators. In this
setting the operators are enabled to understand the machinery and identify potential problems,
righting them before they can impact production and by so doing, decrease downtime and reduce
costs of production [2].

13

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

II. PROBLEM FORMULATION OF AMMONIA PLANT

Any breakdown or stoppage would lead to huge loss in terms of production and efficiency. So it is
necessary to find problems occur in ammonia plant(Urea Plant) and their cause and effects. In this section
we also studies how we reduce maintenance cost or production loss. First we study problem identification.
II.1 Problem Identification
Basically three types of problem occur in the plant can be classifying according to ABC analysis:
(i) Critical problem: Such types of problem are called A type problem. By this type of problem
complete stoppage of plant occur. So these are called critical problem or shutdown maintenance
problem. These problems occur in multistage compressor. In which co2 compressor
does not
compress the ammonia as required pressure.
(ii) Sub critical problem: Such type of problem occurs in single stage and multistage centrifugal
pumps. These problems are called sub critical problem or preventive maintenance problem. Because
these are standing by pumps in spare. We do not purchase these pumps by OEM (original equipment
manufacturer). Since its cost near about 40000 for impeller of KSB pumps and 10000 by local party
indenigation pumps.
(iii) Non critical problem: Such type of problem occurs in dosing pumps and chemical injection
pumps. This type of problem is called preventive maintenance problem. But if pumps are failed due
to some reason the ph of water in boiler does not less than 7. It remains near about 9. By injection of
hydrazine and phosphate it remains near about 11 ph. So failure of dosing and chemical injection
pumps it does not affect the process of plant and production shut down and production stoppage does
not occur so such type of problem is called non critical problem or C type problem.
Basically total quality maintenance is of three types:
(i) Preventive Maintenance: Preventive maintenance is basically two types: running and standby
maintenance. Running maintenance consume one day for maintenance of multistage compressor and
centrifugal pump. Standby maintenance consume one and two days for maintenance of both
machinery. Preventive maintenance is not optimum maintenance programmed so problem
formulation is not done by preventive maintenance programmed.
(ii) Shut down Maintenance: Shut down maintenance is done for plant equipment service. Shut down
maintenance is done only for effectiveness of plant machinery so it is not use in optimum
maintenance programmed.
(iii) Predictive Maintenance: Predictive maintenance is used for optimize machine operation so we
formulate LPP with the help of table 1 as given below.
Table 1: Maintenance Data for A, B &C Type Failure

Machine

Maintenance Time Per Tonne NH3 (In days)

Machine Operation
Impeller(Casing) Maintenance Leakage Problem

Capacity
(Per day)

A Multistage compressor

12 days

20 hrs(5/6 days)

24 hrs(full day)

B Centrifugal pump

10 days

1 day

24 hrs(full day)

__

__

__

C Dosing pump

14

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

Step -1 For year 2012 ammonia cost is 32400 Rs/Tonne so production loss function as stated below
(according to table 4.1):
Min Z = 32400 x1 + 32400 x2
Where x1 and x2 are amount of ammonia loss due to casing maintenance and leakage problem. C1
&C2 are cost coefficient for year 2012 which is 32400.
Step -2 According to table 4.1 constraints are:
X1/12*420 + 6 X2/ 5* 420 1
X1/10*420 + X2/420 1
Where 420 is ammonia production rate per day.
In a category problem we do regular monitoring of compressors and spare inventory should become
100% or one set.
II.2 Cause and Effect Diagram
In multistage compressor basic maintenance problem occurs due to surging, surging can occur shaft
alignment and excessive vibration occur so diffuser and guide vanes damage. Effects are complete
plant shut down occur so production loss occur and high maintenance cost pay to organization.
Surging in diffuser so
stresses develop in impeller,
Change shaft alignment in
multi stage compressor

Cavitations on impeller,
due to reduced flow
seizure of pump internals
in centrifugal pump
NH3 and urea
supply

Low
productivity

High maintenance
cost

Fig.1: Cause and Effect Diagram of Ammonia Plant Maintenance

In centrifugal pump basic maintenance problem occur due to cavitations on impeller and reduced
flow deflection and shearing of shaft, seizure of pump internals and excessive bearing failure. The
effects are production loss due to change pump which are taken in standby.

III. REMEDIES STEPS USED TO REDUCE MAINTENANCE COST

(i) In multistage compressor highly loaded journal bearing can be unstable at high speed so tilting pad
bearing is used. Each shoe tilts independently to maintain to maintain load carrying hydrodynamic
pressure wedge.
(ii) Engineers should check rotor response curve displacement, relative bearing force curve verses
speed curve time to time for multistage compressor.
(iii) Avoiding recirculation in centrifugal pumps.
(iv) Operating characteristics curve head verses flow rate study properly on computer so minimum
flow rate maintain in centrifugal pump.

15

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ENGINEERS&
OPERATORS

Visualization of Flow
Characteristic curves
& Use Remedies

ISSN

REDUCED
MAINTENACE
COST

(O) 2347-5188
(P) 2347-8772

REDUCED
PRODUCTION
LOSS

Fig.2: Visualization and Remedies Concept of Engineers

IV. REDUCTION OF PRODUCTION LOSS BY L.P.P.

In urea plant we want to do minimum production loss by doing minimum lead time of preventive and
shut down maintenance. So we formulate the L.P.P. of problem and applying optimization technique
we do minimum production loss.
Step-1 Formulate the L.P.P. according to problem formulation data we state the actual problem:
For year 2012: minimum Z =32400 y1 + 32400 y2
Here c1=32400, c2 =32400 are cost coefficient for year 2012.Y1, Y2 are amount of ammonia loss due
to casing and leakage problem.
.
Now we are solving minimum production loss for year 2012.
Step-2 By apply simplex method we solve the L.P.P. :
Optimization function:
Minimum Z =32400 y1 + 32400 y2(i)
Constraint according to problem formulation stated below.
X1/12*420 + 6 X2/ 5* 420 1(ii)
X1/10*420 + X2/420 1(iii)
To solve this L.P.P. we apply simplex method. So L.P.P. is solved as stated below.
Maximum Z= -32400 y1 -32400y2 + 0s1 +0s2
Subjected to
y1/5040+ y2/350+ s1=1
y1/4200+ y2/420+s2=1
Basic feasible solution if y1=y2=0 then s1=1, s2=1
Step-3 iteration-1formulate the table according to basic feasible solution
cj
-32400
-32400
0
0
cB
Basis
y1
y2
s1
s2
0
s1
1/5040
1/350
-1
0
0
s2
1/4200
1/420
0
-1
cj-zj
-32400
-32400
0
0
Step-4 iteration-2 formulate the table towards optimality
cj
-32400
-32400
0
0
CB
Basis
y1
y2
s1
s2
-32400
y2
35/504
1
-350
0
0
s2
154/5040
0
350
-420
cj-zj
-2250
-30150
0
0

16

b
350
70

b
1
1

b/a
5040
2290.9

b/a
350
420

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

Step-5 iteration-3 formulate the table towards optimality

cj
-32400
-32400
0
CB
Basis
y1
y2
s1
-32400
-32400

y2
y1
cj-zj

0
1
-32400

1
0
-32400

ISSN

0
s2

-1145.45
11454.54
-334014516

(O) 2347-5188
(P) 2347-8772

954.54
-13745.4
-360217670

b/a

190.97
2290.9

This is optimum solution so production loss by casing problem for multistage compressor and
centrifugal pump is 190.97 tones of ammonia and production loss for leakage problem for both
machinery is 2290.9 tones of ammonia.
IV.1 Graphical Reduction of Production Loss by L.P.P.
Optimization function:
Minimum Z =32400 y1 + 32400 y2..(i)
Constraint according to problem formulation stated below.
X1/12*420 + 6 X2/ 5* 420 1(ii)
X1/10*420 + X2/420 1(iii)
When x1=0 then x2 = 5/6* 420= 349.99 350 tonnes say A (0,350)
When x2=0 then x1=12*420=5040 say B (5040, 0)
When x1=0 then x2=420 say c (0,420)
When x2=0 then x1=4200 say D (4200, 0)

450
400
350
300
250
200
150
100
50
0
1000

2000

3000

4000

5000

6000

Fig.3: Graphical Representation of Production Loss Problem

IV.2 Analysis of Problem by MATLAB

Optimization function:
Minimum Z =32400 y1 + 32400 y2(i)
Constraint according to problem formulation stated below.
X1/12*420 + 6 X2/ 5* 420 1(ii)

17

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

X1/10*420 + X2/420 1(iii)

To solve this L.P.P. we apply simplex method. So L.P.P. is solved as stated below.
Maximum Z= -32400 y1 -32400y2 + 0s1 +0s2
Subjected to
y1/5040+ y2/350+ s1=1
y1/4200+ y2/420+s2=1
First, enter the coefficients
f = [-32400; -32400]
a = [1/5040 1/350
1/4200 1/420];
b = [1; 1];
lb = zeros(2,1);
Next, call a linear programming routine.
[x,fval,exitflag,output,lambda] = linprog(f,a,b,[],[],lb);
Entering x, lambda.ineqlin, and lambda.lower gets
x=
190.97
lambda.ineqlin =
0
1.5000
lambda.lower =
1.0000
0
Nonzero elements of the vectors in the fields of lambda indicate active constraints at the solution. In
this case, the second and third inequality constraints (in lambda.ineqlin) and the first lower bound
constraint (in lambda.lower) are active constraints (i.e., the solution is on their constraint boundaries).

V. MULTI STAGE COMPRESSOR MAINTENANCE FORECASTING

Basically multistage compressor forecasting is dividing in two stages:
(a)
(b)

For impeller maintenance

Leakage maintenance

(A) For impeller maintenance: we use simple smoothing forecasting formula as stated below:
Ft+1 = Dt + ( 1- ) Ft
Where Ft+1: Forecast for next period maintenance
Dt : Actual maintenance demand for present period
Ft : Previously determined forecast for present period
: Weighting factor smoothing constant
Total impeller maintenance time for multistage compressor is 12 days. It is predictive maintenance or
emergency maintenance. The maintenance demand for June is 2 days and 4 days for July. We use
forecasting method which takes average method maintenance demand forecast for June is 4 days
(smoothing coefficient 0.7 to weight the recent demand most heavily) and we manipulate the
maintenance demand for august and thus we manipulate for other month also.

18

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

For July Ft+1 = 0.7 * 2 +(1- 0.7) * 4 = 1.4 + 1.2 = 2.6 days
For August Ft+1 = 0.7* 4 + ( 1- 0.7) *4 = 2.8 + 1.2 = 4 days and so on.
(B)
Leakage maintenance: Similarly leakage maintenance time for multistage compressor is 20
hrs. It is preventive maintenance. The maintenance demand for June is 1 hrs and 2 hrs for july. We
use forecasting method which takes average method maintenance demand forecast for june is 2 hrs (
smoothing coefficient 0.8 to weight the recent demand most heavily) and we manipulate the
maintenance demand for august and thus we manipulate for other month also.
For July Ft+1 = 0.8 * 1 + ( 1- 0.8) * 2 = 0.8 + 0.4 =1.2 hrs
For August Ft+1 = 0.8* 2 + ( 1- 0.8) *2 = 1.6 + 0.4 = 2.0 hrs
V.1 Centrifugal Pump Maintenance Forecasting
(A)
(B)

Impeller maintenance
Leakage maintenance

(A)

Impeller maintenance forecasting

Total maintenance time for centrifugal pump is 10 days. It is predictive maintenance or emergency
maintenance. Maintenance demand for June is 1 day and 3 days for July. We use forecasting method
which takes average method maintenance demand forecast for June is 3 days (smoothing coefficient
0.7 to weight the recent demand most heavily) and we manipulate the maintenance demand for august
and thus we manipulate for other month also.
For July Ft+1 = 0.7 *1 + ( 1- 0.7) * 3 = 0.7 +0.9= 1.6 days
For August Ft+1 = 0.7 * 3 + (1- 0.7 ) *3 = 2.1 +0.9 =3 days
(B)
Leakage maintenance forecasting: Similarly leakage maintenance time for centrifugal pump
is 1 day. It is preventive maintenance. The maintenance demand for june is 3 hrs and 4 hrs for July.
We use forecasting method which takes average method maintenance demand forecast for June is 4
hrs ( average smoothing coefficient 0.8 to weight the recent demand most heavily) and we manipulate
the maintenance demand for august and thus we manipulate for other month also.
For July Ft+1 = 0.8 *3 + (1-0.8) *4=2.4+0.8=3.2 hrs
For August Ft+1 =0.8 *4+(1-0.8)*4 =3.2+0.8 = 4 hrs
Now we draw operation chats for June, July and august month and we alert for august month
according to previous trends for predictive and preventive maintenance.

VI. OPERATION CURVES FOR FIND OUT CERTAIN PRIOR MAINTENANCE

Operation curves mainly divided in to three basic categories:

(1)
(2)
(3)

Rotor response curves

Efficiency curves
Surge curves

19

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

VI.1 Rotor Response Curves

Modern process compressors are built in API specification. One important item of specification is
natural frequency of rotor. This natural frequency must not occur in variable speed range of
compressor. The dynamics of rotor can be studied with the help of computer and the effect of rotor of
operative unbalance due to built up misalignment can be evaluated. The rotor unbalance will load the
bearing. Computer analysis allows the engineer to predict these bearing loading and to design a
dependable maintenance free machine.

Fig.4: Eight Stage Rotor Response Curve

Fig. 4 shows calculated and measured response curve for eight stage rotor compressor. The measured
values were obtained first during the mechanical test of compressor. Although the vibration level was
less than 0.7 mils and the bearing forces were below the designed dynamic load limit, the steepness of
vibration curve near the maximum operating speed was understandably cause for concern. The rotor
was modified and rested.

Fig.5: Eight Stage Rotor for Modified Response Curve

20

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

These results are shown in Fig.5. The shop test shows quite low vibration amplitudes and low bearing
loading. The compressor, once in actual service, will become unbalanced due to built-up on rotor. The
difference between the calculated and measured response curves shows that this compressor will be
tolerant to considerable rotor deposits before it will have to be cleaned. Lightly loaded journal bearings,
such as those used in compressor, can be unstable at high speeds, and a number of solutions of this
problem have been used. A tilting pad journal bearing is widely used in compressor. Each shoes tilt
independently to maintain its load carrying hydrodynamic pressure wedge.
By observation it is observed that in month of July and august curve is deflected more so prior
maintenance should be done and save the production loss 15-20% respectively.
VI.2 Efficiency Curve

Fig.6: Compressor Performance Curve

Compressor performance curves consist primarily of a plot showing the variation of compressor head
or pressure ratio and efficiency at various constant rpm conditions at different mass flow rates such as
shown in figure 6. It can be seen from figure 6 that increase in rotor speed increases the compressor
flow rate. At a particular rotor speeds an increase in compressor pressure ratio can be obtained by
reducing the mass flow rate. This is to be expected because an increase in pressure at compressor
delivery can only be expected if there is resistance to flow, otherwise, compressor would behave more
like a fan or a blower. In a similar fashion, an increase in flow rate at constant rpm can be obtained by a
reduction in the resistance at the compressor exit. An enhancement of compressor flow rate at constant
delivery pressure is also possible. This requirement however can be met by not only changing exit
throttle, but also increasing the compressor rpm. Minimum and maximum flow rates at constant rpm are
termed surge line. Similarly, locus of operating points of compressor at various rpm is termed operating
line. The compressor rotor should be designed such that constant rpm, its efficiency peaks close to surge
line, as indicated in figure 6 that is when compressor ratio is maximum.
By observation it is observed that in month of July and august curve is deflected more so prior
maintenance should be done and save the production loss 15-20% respectively.

21

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

VI.3 Surge Curve

Fig.7: Performance Map with System Curves and Surge Cycle

A typical centrifugal multi stage compressor performance map used in process industry is shown in
figure 7. The family of fixed pressure drop, or pressure control in the particular system external to
compressor through which the flow is being pumped. However, it should be noted that, to follow any
of these system curves, speed must be changed. This, in turn, changes the flow. With system 2 and 3,
the head is also changed. These statements are valid only if no changes within system itself occur.
Changing setting of control valve, adding another piping loop, or changing catalyst level in a reactor
which would modify the system curve.
To a large extent, the frequency of surge cycle varies inversely with in volume of system. For
example, if the piping contains a check valve located near the compressor discharge nozzle, the
frequency will be correspondingly much higher than that of system with a large volume in the
discharge upstream of a check valve. The frequency can be as low as few cycles per minute or as high
as 20 or more cycles per second. Generally speaking, if the frequency is higher, the intensity of surge
is lower. The intensity or violence of surge tends to increase with increase gas density, which is
directly related to higher molecular weights and pressures and lower temperatures. Higher differential
pressure generally increases the intensity.
By observation it is observed that in month of July and august curve is deflected more so prior
maintenance should be done and save the production loss 15-20% respectively.

VII. EXPECTATION OUTCOME

The basic problem occur in multistage compressor (A type problem), centrifugal pump(B type
problem) and injection pump (c type problem).

22

International Journal of Research in Mechanical Engineering

Volume-3, Issue-2, March-April, 2015, www.iaster.com

ISSN

(O) 2347-5188
(P) 2347-8772

In A type problem company shut down the plant. But I analysis by optimization techniques, the lead
time may be reduced for preventive maintenance by daily monitoring and daily preventive
maintenance policy. Reduce by daily monitoring and daily preventive maintenance policy.
In B type Problem Company put the centrifugal pump in spare and replaces the pump whenever
required. But I also reduced lead time by optimization techniques for preventive maintenance by daily
monitoring and daily preventive maintenance policy.
C type problem is not affected the production. So injection pump may be change over on the monthly
repairing shut down time.
By applying optimization techniques lead time saving in preventive as well as shutdown maintenance
will be 10-15% and production loss saving will be 15-20% approximately.

VIII. CONCLUSION
MORA (2002), states that implementing total quality maintenance is not a difficult task. However, it
requires some customized training in order to succeed. The results of implementing an effective
programmed in terms of increased plant efficiency and productivity are outstanding [3]. According to
Kennedy (2005), it should be acknowledged that a TQM implementation is not a short-term fix
programmed. It is a continuous journey based on changing the work-area then the equipment so as to
achieve a clean, neat, safe workplace through a "pull" as opposed to a "push" culture [4].
Significant improvement can be evident within six months. However, full implementation can take
many years to allow for the full benefits of the new culture created by TQM. At this crucial point of
global competition the implementation of TQM not a matter of liking it or following the fashion.
While TQM in the 60's was just an innovative thing, today it has turned into a survival strategy. TQM
is capable of bringing a machine back to original condition and even better. The cost of postponing a
decision of implementing TQM that has to make sooner or later can be excessive. It is convincing that
the losses for each day of delay are out of imagination.
Successful TQM implementation can achieve better and lasting results as compared to other isolated
programmers because there is an ultimate change in people (knowledge, skills, and behavior) during
the progress. It gives a summary of why companies should consider implementing TQM in their
organization, including the motivating factors as well as the resulting benefits.

REFERENCES
[1] Hopp W. and Wu S., Machine maintenance with multiple maintenance actions, IIE Trans., Vol.
22(3), pp. 226-233, Sep.2002.
[2] http:// www.techeduhry.nic.in/syllabus/computer%20engg/6comp.pdf
[3] Mora S., Implementing total Quality Maintenance is not a difficult task, IIE Trans., Vol. 23(4),
pp. 330-340, Sep.2002.
[4] Kennedy P., TQM implementation is not a short-term fix programmed, IIE Trans., Vol. 26(4),
pp. 231-235, 2005.

23