Decreasing inventory of a cement factory roller mill parts using reliability centered maintenance method

According to data from maintenance planning and control, it was obtained that highest inventory value is non-routine components. Maintenance components are components which procured based on maintenance activities. The problem happens because there is no synchronization between maintenance activities and the components required. Reliability Centered Maintenance method is used to overcome the problem by reevaluating maintenance activities required components. The case chosen is roller mill system because it has the highest unscheduled downtime record. Components required for each maintenance activities will be determined by its failure distribution, so the number of components needed could be predicted. Moreover, those components will be reclassified from routine component to be non-routine component, so the procurement could be carried out regularly. Based on the conducted analysis, failure happens in almost every maintenance task are classified to become scheduled on condition task, scheduled discard task, schedule restoration task and no schedule maintenance. From 87 used components for maintenance activities are evaluated and there 19 components that experience reclassification from non-routine components to routine components. Then the reliability and need of those components were calculated for one-year operation period. Based on this invention, it is suggested to change all of the components in overhaul activity to increase the reliability of roller mill system. Besides, the inventory system should follow maintenance schedule and the number of required components in maintenance activity so the value of procurement will be decreased and the reliability system will increase.