SUNConferences, Southern African Institute for Industrial Engineering 2014

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Development of a Condition Based Maintenance system for a sugar producing company
Brian Chindondondo, Lungile Nyanga, Andre Francois Van der Merwe, Tapiwa Mupinga

Last modified: 2014-06-24


With globalisation taking centre stage in almost every market; traditionally monopolistic manufacturing companies in Zimbabwe are struggling to compete with international companies whose operations are optimised. This paper focuses on maintenance practises of a Zimbabwean sugar manufacturer with an aim to improve the company’s asset care plans. The company’s current maintenance philosophy and its shortcomings on certain equipment in the plant were identified together with the associated annual maintenance costs. A pareto analysis on the equipment’s breakdown history was used to determine the conditions that can be monitored using Condition Based Maintenance (CBM) and experiments to establish the feasibility of monitoring these conditions were done. A cost benefit analysis of the company’s customary time based and corrective maintenance to a proposed CBM system on the subject equipment was used to show a probable significant reduction in annual maintenance costs should the CBM be implemented. The paper concludes by recommending an implementation matrix for the proposed CBM system with its three main elements of data acquisition, data processing and maintenance decision to introduce an optimised maintenance system that will reduce overall production cost thus bringing an opportunity to compete globally for the local sugar manufacturer.

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