Abstract:
In modern manufacturing, optimizing maintenance strategies is essential for cost reduction, competitive advantage, and product integrity. This study investigates the integration of Condition-Based Maintenance (CBM) and Reliability-Centered Maintenance (RCM) in vehicle manufacturing, focusing on Ries Engineering. The goal is to enhance system efficiency, minimize downtime, and improve reliability by constructing RCM-based CBM model for predicting equipment conditions.
Following a Risk Priority Number (RPN) assessment, the study emphasizes the critical status of the EcoSport car's transmission system. It integrates oil analysis (viscosity, wear particles, contamination), vibration analysis (vibration levels, frequencies), and temperature analysis (thermal stress, cooling effectiveness). High RPN values identified critical failure modes: shift timing issues, fluid degradation, and solenoid or sensor failures. Each failure mode was analyzed to determine underlying causes and consequences, leading to targeted maintenance strategies.
The results show that combining CBM with RCM will enhances maintenance efficiency, reduces costs, and improves reliability. Shift timing issues were managed through condition-based monitoring, fluid degradation was addressed with regular fluid changes and proactive oil analysis, and solenoid or sensor failures were mitigated with inspections and predictive maintenance. This structured approach significantly boosts operational reliability, extends component lifespan, and optimizes maintenance practices.
Future research should validate these findings in real-world settings, implement continuous monitoring systems, provide targeted training, and conduct cost-benefit analyses. Refining the risk matrix and incorporating expert judgment are recommended to advance predictive maintenance capabilities. This study highlights the potential of integrating CBM and RCM to drive innovation in automotive maintenance and enhance overall operational excellence.
Keyword: Condition-based maintenance; reliability-centered maintenance