Parameter estimation, reliability and maintainability analysis of sugar manufacturing plant

A sugar manufacturing plant is a complex industrial system having five subsystems arranged in a series configuration and each subsystem followed a different failure rate. Upon ensues of a random failure, the failed subsystem stops working and forces the complete system to stop and results in a downstate of the plant. The impact of downstate directly influences the production of plant and its reliability. Here, a reliability and maintainability analysis of the sugar manufacturing plant has been carried out at the subsystem and plant level. Data collection has been performed for six months from the sugar plant and descriptive statistical analysis has been made for time to repair and time between failures. The best-fitted distribution and parameters were determined along with trend and serial correlation analysis to attain the best performance of the plant. Additionally, graphs for reliability and hazard rate modes for five subsystems and the entire plant were depicted. The suggested models might be a suitable tool towards (a) considering the recent conditions, and (b) forecasting reliability for refining the sugar manufacturing plant by applying proper maintenance policy.

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