Design of a maintenance plan focused on reliability analysis based on root cause to increase the availability of electric motors squirrel cage Alicorp S.A.A

Abstract

This research is based on the design of a maintenance plan reliability-centered methodology it based on root cause analysis "ACR" in order to increase the mechanical availability of the 32 electric motors squirrel cage Alicorp S.A.A which drive critical machines such as rotary dryers, forced draft fans, feedwater pumps, evaporators, fuel pumps, cookers and presses for processes of flour, pasta and balanced food. An assessment of the current conditions of squirrel cage electric motors in 2015 which were obtained 894.20 hours of repair with a total of 663 interventions took place that year. Getting maintenance management indicators in current conditions and availability of 86%, 78% reliability with a mean time between failures of 8.56 hours useful / fail and maintainability of 12% average repair time of 1.35 hours for repair / failure.

The criticality analysis to squirrel cage electric motors to its main elements such as performed: bearings, stator, rotor, fan and motor shaft; based on 5 consequences such as: frequency of failures, operational impact, operational flexibility, maintenance costs and impact safety and the environment, finding such results to the rotor elements, stator, fan and motor shaft. The failure of the critical elements were assessed by developing fact sheets and leaves the FMEA decisions, evaluating 25 functional failure modes. Then through risk priority number, get 19 unacceptable failures, 2 and 4 faults desirable reducible acceptable faults. Finally through Ishikawa diagrams establish the root cause of failures. The maintenance plan focused on reliability based on root cause analysis, improvement in conditions estimated 95% availability, reliability and maintainability 92% to 12%