This study applies the Reliability-Centered Maintenance framework to enhance kiln maintenance effectiveness in the cement industry. Historical breakdown data indicate that the tyre and support roller are the most critical components, given their significant impact on operational downtime. A descriptive quantitative methodology is employed, incorporating Failure Mode and Effects Analysis for risk assessment. Potential failure modes are rated to determine the Risk Priority Number, while probabilistic distribution modeling is applied to evaluate Time to Repair and Time to Failure. Results indicate that the tyre component follows a normal distribution for Time to Repair and a Weibull distribution for Time to Failure, with a Mean Time to Repair of 260.983 hours and a Mean Time to Failure of 7,548.02 hours. The support roller displays a Weibull distribution for Time to Repair and a lognormal distribution for Time to Failure, with a Mean Time to Repair of 311.391 hours and a Mean Time to Failure of 1,124.33 hours. With the highest Risk Priority Number, the support roller is the top maintenance priority. Reliability-based analysis recommends inspection intervals of 19 days for the tyre and 21 days for the support roller. The study demonstrates that integrating Reliability-Centered Maintenance, Failure Mode and Effects Analysis, and Reliability Analysis provides a strong foundation for developing targeted maintenance strategies that improve operational performance and extend asset lifespan.
Yohan et al. (Thu,) studied this question.
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