Violation of ethics: DEVELOPMENT OF A MAINTENANCE POLICY FOR A PRODUCTION LINE AT THE HAMMA BOUZIANE CEMENT FACTORY, ALGERIA

Abstract

The object of research is the process of the maintenance used in the HAMMA BOUZIENE cement factory (Algeria), where an attempt was made to devolope a new maintenance policy based on preventive maintenance instead of corrective maintenance. The maintenance of industrial systems has become an essential element for companies seeking to conquer an increasing number of markets.

In this study, we focus on examining the necessary maintenance policy for the production line of the HAMMA BOUZIENE cement plant. The policy used in the HAMMA BOUZIENE cement plant is corrective maintenance which costs 3.9 million euros in year, and creates approximately 5 months of downtime at grinding workshop level. This article describes the evaluation of Reliability, Availaility and Mainenability of various subsystems within the production line. Our system is divided into five subsystems (kk1 grinding mill, kk2 grinding mill, raw mill 1, raw mill 2 and cement kiln). It was proposed a systematic preventive maintenance which reduces the costs of corrective maintenance. to determine the most problematic subsystem, we used Pareto and FMECA methods, The calculation of the reliability of the most critical system was done using the Weibull distribution.

The results of this evaluation showed that the subsystem with a very high failure rate was kk1 grinding mill (with an excessively long downtime…). To reduce this failure rate and increase the reliability and availability of the grinding mill, we conducted an RAM study. The analysis results indicated that the mill's reliability reaches 80% if systematic maintenance is performed every 23 hours. when we use this maintenance policy, the avalabilitty will increase from 87% to 95%.

This work contributes to reducing maintenance costs for the Hamma Bouziane cement company by following the maintenance policy proposed in this research.