RCM Analysis CTN Mariani

Function Function failure Failure mode/consequences

1) To be able to stack packs at 40
per minute.
1A Infeed conveyor does not
transfer packs to layer formation
area.
1A1 Pack sensor B90 fails.
Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
Maintenance OPL.clean, check security, stability.
1 month

1A2 Sensor B54

Packs would continuously feed up inclined conveyor
Downtime, 30 minutes.
Action.
Maintenance OPL. clean, check security, stability.
1 month

1A3 Motor gearbox drives for incline conveyor. M151

Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
Maintenance OPL.gearbox oil leaks, chain tension/lubricated
and sprocket condition
1 month

1A4 Motor gearbox drives for steel roller conveyor. M156

Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
Maintenance OPL. gearbox oil leaks, chain tension/lubricated
and sprocket condition
1 month

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1A5 Motor gearbox drives for green belt conveyor. M121.
Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
Maintenance OPL. gearbox oil leaks, chain tension/lubricated
and sprocket condition
1 month

1A6 Inclined conveyor rollers fail.

Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
No scheduled maintenance, roller critical spare.

1A7 Incline belt slips.

Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
Maintenance OPL.check tension, alignment and condition of
belt.
3 monthly

1A8 Steel roller conveyor rollers fail.

Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
Maintenance OPL. Check condition and operation.
Critical spare.
3 monthly

1A9 Any of the green belt conveyor rollers fail.

Packs will build back until ZVT stops.
Downtime, 30 minutes.
Action.
No scheduled maintenance, Critical spare.

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2B layers not formed correctly or
transferred to bomb bay doors.
2B1 Motor gearbox drives fails for infeed. M122.
Alarm for infeed overflow.
Downtime, 2 hours
Action.
Maintenance OPL. . gearbox oil leaks, chain tension/lubricated
and sprocket condition.
1 month
2B2 Sensor B321, B322, B323 fails.
Alarm for infeed overflow.
Downtime, 30 minutes.
Action
Maintenance OPL. clean, check security, stability.
1 month
2B3 Sensor B351 fails. Stop automatic loading conveyor
photocell
Alarm for infeed overflow.
Downtime, 30 minutes.
Action.
Maintenance OPL. clean, check security, stability.
1 month
2B4 Infeed conveyor roller assemblies fail.
Alarm for infeed overflow.
Downtime, 2 hours
Action
Maintenance OPL Check vee belts condition/tension and track
wear. Roller inspection.
3 monthly
2B5 Pack shifter fails to operate. M146
Alarm for infeed overflow.
Downtime, 1 hour.
Action.
Shire task, yearly.
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2B6 Stop plate fails. C160
Misplaced pack alarm.
Downtime, 1 hour.
Action
Shire task, yearly.

2B7 Stop cylinder fails. C161

Misplaced pack alarm.
Downtime, 1 Hour.
Action.
No scheduled maintenance cylinder critical spare

2B8 Pack pusher cylinder fails. C190.

Pack formation would be incorrect.
Downtime, 1 Hour.
Action.
No scheduled maintenance. Cylinder critical spare

2B9 Pack pusher cylinder fails. C186.

Pack formation would be incorrect.
Downtime, 1 Hour.
Action.
Shire task, yearly to test operation.

2B10 Any of the 14 pack breaks stops fail. Y262-Y267 and

Y270-Y277
Pack formation would be incorrect.
Downtime, 2 hours.
Action
No scheduled maintenance.

2B11 Pusher 1 cylinder Fails. C172.

Pusher movement incomplete would alarm.
Downtime, 2 hours.
Action
No scheduled maintenance. Cylinder critical spare

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2B12 Pusher 1 drives fails.
Pusher movement incomplete would alarm.
Downtime, 3 hours.
Action.
Maintenance OPL. Check gearbox for leaks, wear on gears and
mounting bearings.
1 monthly

2B13 Pusher 1 brake fails.

Pusher movement incomplete would alarm.
Downtime, 3 hours.
Action.
No scheduled maintenance. Critical spare.

2B14 Any of the two pushers limit switches fail. S300,S331,

S344, S352, S353 and S354
The carriage would not be in the correct position, packs would
build back to the ZVT.
Downtime, 2 hours.
Action
Maintenance OPL. Check security and mechanical condition.

2B15 Pusher 2 cylinder Fails. C170.

Pusher movement incomplete would alarm.
Downtime, 2 hours.
Action
No scheduled maintenance. Cylinder critical spare

2B16 Pusher 2 drives fails. M213.

Pusher movement incomplete would alarm.
Downtime, 3 hours.
Action.
Maintenance OPL. Check gearbox for leaks, wear on gears and
mounting bearings.
1 monthly

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3C Pallets not transferring
through conveyors.
2B17 Pusher 2 brake fails.
Pusher movement incomplete would alarm.
Downtime, 3 hours.
Action.
No scheduled maintenance. Critical spare.
2B18 Any of the proximity switches fail. S340and S72
The carriage would not be in the correct position, packs would
build back to the ZVT.
Downtime, 2 hours.
Action
Maintenance OPL. Check sensor condition and clearance.
1 monthly
3C1 Motor gearbox drives for pallet transfer fails. M134,
M157, M84, M82, M81.
Alarm for waiting for empty pallet.
Downtime, 2 hours.
Action.
Maintenance OPL. . Gearbox oil leaks, chain tension/lubricated
and sprocket condition.
Shire task for M134 scheduled discard drive chain. 2 yearly.
3C2 Sensor for pallet present fails. B85.
Pallets would not be fed along conveyor.
Downtime, 1 hour.
Action
Maintenance OPL. Clean, check security, stability.
1 month
3C3 Motor gearbox for pallet stacker fails. M243
Alarm pallet stacker.
Downtime, 2 hours.
Action, Maintenance OPL. Gearbox oil leaks, chain
tension/lubricated and sprocket condition.
1 Monthly
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 3C4 Fails to dispense empty pallet.
Alarm waiting for empty pallet.
Downtime, 2 hours.
Action
Maintenance OPL. Check limit switches for mechanical
condition and security. Cylinder critical spare.C240a, C240b
1 monthly

3C5 Any of the conveyor limit switches fail. S41, S46, S47,
S40, S41, S40, S46, S341.
Pallets will not move.
Downtime, 1 hour.
Action.
Maintenance OPL. Check for mechanical integrity and free
movement.
1 monthly

4D Elevator does not transfer 4D1 Bomb bay doors fail.

layers. Alarm, packs will build back to ZVT.
Downtime, 1 hour.
Action.
Maintenance OPL. Gearbox oil leaks, chain tension/lubricated
and sprocket condition.
1 monthly

4D2 Pack tighteners fail.

Alarm, packs will build back to ZVT.
Downtime, 2 hours.
Action.
No scheduled maintenance, cylinder critical spare.

4D3 Elevator drive fails. M127.

Elevator would not move.
Downtime, 2 hours.
Action
Maintenance OPL. Check for oil leaks and support bearings.

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 4D4 Elevator chains fail.
2) To be able to stretch wrap pallets Elevator would not move.
at 15 per hour. Downtime, 2 hours.
Action.
Maintenance OPL, Check chain stretch/tension and lubrication.
Check support bearings.

4D5 One of the elevator sensors fail. B43, B44, B40, B324.
Alarm
Downtime, 1 hour.
Action
Maintenance OPL. clean, check security, stability.
1 month

4D6 Any of the limit switches fail. S357, S334, S42, S333
Alarm
Downtime, 1 Hour.
Action
Maintenance OPL Check for mechanical integrity and free
movement.
1 monthly

5E Layer pad does not feed.
5E1 Scissors lift fails. M204.
Alarm, intersheet cycle in complete.
Downtime, 2 hours.
Action.
Maintenance OPL. Check for oil leaks on pump and hydraulic
system.
1 week

5E2 Layer pad transfer fails.

Alarm, intersheet cycle incomplete.
Downtime, 2 hours.
Action
No scheduled maintenance, check for critical spare.

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 5E3 Any of the limit switches fail. S293, S282, S293.
Alarm, intersheet cycle incomplete.
Downtime, 2 hours.
Action
Maintenance OPL. Check for mechanical integrity and free
movement.

6F Pallets are not stretched 6F1 Rotation drive fails. M86

wrapped. Pallets would not be stretched wrapped.
Downtime, 3 hours.
Action.
Maintenance OPL Check for oil leaks and condition of drive.

6F2 Transfer conveyor drive fails. M83

Pallets would not be transferred into stretch wrap area.
Downtime, 2 hours.
Action
Maintenance OPL. Check chain stretch/tension and lubrication.
Check support bearings.

6F3 Stretch wrap drive fails. M130

Stretch wrap would brake.
Downtime, 2 hours.
Action
Maintenance OPL. Check condition of drive and lubrication.
3) Sizechange within 5 minutes.
6F4 Rise/fall stretch wrap drive fails. M93.
Stretch warp bottom of pallet.
Downtime, 2 hours.
Action
Maintenance OPL. Check gearbox for oil leaks and chain
stretch/tension and lubrication.
1 month

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 6F5 Arm drive fails. M101.
Stretch warp bottom of pallet.
Downtime, 2 hours.
Action
Maintenance OPL. Check gearbox for oil leaks and chain
stretch/tension and lubrication.
1 month

6F6 Limit switches fail. S10, S11, S12, S13, S6, S7.
Wrap would be incorrect.
Downtime, 1 hour.
Action
Maintenance OPL. Check for mechanical integrity and free
movement.
1 month

6F7 Clamp cylinder fails.

Incorrect stretch wrap
Downtime, 1 hour.
Action
No scheduled maintenance

7G Safety operation 7G1 Emergency stop fails.

Dangerous fault
Downtime, 1 hour.
Action
Maintenance OPL
1 month

7G2 Interlock guards fail.

Dangerous fault
Downtime, 1 hour.
Action
Maintenance OPL
1 month

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7G3 Warning lights fail.
Dangerous fault
Downtime, 1 hour.
Action
Maintenance OPL
1 month

7G4 Main panel fails.

Dangerous fault
Downtime, 2 hour.
Action
Electrical shire task
1 month

7G5 Intrusion sensors fail.

Dangerous fault
Downtime, 2 hour.
Action
Maintenance OPL.
1 month

7G6 Air non-return valve fails.

Dangerous fault
Downtime, 2 hour.
Action
Maintenance OPL.
1 month

7G7 Fixed guards fail.

Dangerous fault
Downtime, 1 hour.
Action
Maintenance OPL.
Start up.

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