Güvenilirlik merkezli bakım ve bir endüstriyel işletmede uygulama çalışması
Reliability centered maintenance and implementation study in an industrial business
Yazar: BARIŞ EVCİN
Danışman: DOÇ. DR. MURAT BASKAK
İstanbul Teknik Üniversitesi / Lisansüstü Eğitim Enstitüsü / Endüstri Mühendisliği Ana Bilim Dalı / Mühendislik Yönetimi Bilim Dalı
Derece: Yüksek Lisans, 2021
Konu: Mühendislik Bilimleri = Engineering Sciences
Dizin: Bakım = Maintenance ; Bakım yönetim sistemi = Maintenance management system

Özet:
20. yüzyıl dünyasına göz attığımızda kazanan kaybeden, katılan katılmayan, neredeyse her ülkeyi ve toplumu etkileyen iki dünya savaşı ile karşılaşmaktayız. Kısa sürede içerisindeki (yaklaşık 30 yıl) bu savaşlar toplumları derinden etkilemiş, 1950 sonrasında sıcak savaş yerini soğuk savaşa bırakmış ve ülkeler güçlerini geri kazanmak, süper güç olabilmek için birbirleri ile yarışa girmişlerdir. Askeri ve ekonomik olarak güçlü olmak adına, teknolojik atılımlar yaparak üretim hacimlerini arttırmışlardır. Gelişen ve refah seviyesi artan toplumlar mevcut ve yeni ürünlere olan talebi arttırmış, talep artışı ise arz artışına neden olmuştur. Mevcut pazarlardaki talep artışı ve yeni pazarların oluşmasıyla, şirketler üretim hacimlerini arttırmak için üretim teknolojilerini yenilemişler ve daha fazla makineleşme yoluna gitmişlerdir. Ayrıca pazara yeni oyuncular katılmış ve rekabet artmıştır. Şirketler bir yandan üretim hacimlerini arttırmaya çalışırken bir yandan da yeni rakipler ile mücadele etmeye çalışmışlardır. Birçok şirket için daha önce tecrübe etmedikleri bu deneyim büyük baskılar oluşturmuştur. Bundan dolayı şirketler varlıklarını korumak ve rekabette güçlü olmak için müşteri memnuniyeti, kalite, verimlilik ve mâliyet gibi kavramlara önem vermeye başlamışlardır. Dolayısıyla bu kavramlar üzerinde yadsınamaz etkisi olan bakım kavramı ön plana çıkmış ve zamanla bakımın üzerinde geliştirme yapılması ve yönetilmesi gereken bir olgu olduğu anlaşılmıştır.
Günümüzde ise iletişim araçlarının gelişmesi ve çeşitlenmesi, ulaşımın kolaylaşması, ticari ortaklıkların artması, -geçmiş yüzyıllar ile kıyasladığımızda- sıcak savaşların azalması siyasi sınırları adeta harita üzerinde birer çizgiden ibaret kılmıştır. Pazarlar yerel olmaktan çıkıp küresel olmuştur. Değişen ortam şartları şirketleri de izledikleri politikaları değiştirmeye zorlamıştır. Birçok şirket teknolojik altyapılarını güncelleyerek bakım politikalarında değişikliğe gitmiş ve modern bakım yöntemlerinin sistemlerine uygulamaya başlamışlardır.
Bu çalışmada bakım yöntemleri kavramı tarihsel bir pencereden el alınmış; günümüze nasıl gelindiği, günümüzde neler yapıldığı ve gelecekte neler olabileceğinden bahsedilmiştir. Bakım ile ilgili kavramlardan bahsedilerek, bakım yöntemleri ve yönetim sistemleri anlatılmış ve devamında da bu çalışmanın temelini oluşturan güvenilirlik merkezli bakım (RCM) konusu incelenmiştir. Bir endüstriyel işletmede uygulama yapılmış, sonuçları analiz edilerek değerlendirilmiş ve öneriler sunulmuştur. Çalışmanın sonunda ise gelecekteki araştırmalar için tavsiyelerde bulunulmuştur.
Bakımın kendi başına bir alan olduğu ve bu kadar önem kazandığı günümüzde işletmeler, kendi sistemlerine uygun bakım eylemlerini seçmeli ve kaynaklarını doğru kullanarak süreci yönetmelidirler. Bu sayede kendileri, toplumlar ve çevre için bir katma değer oluşturmaları mümkündür.

Abstract:
When we look at the world of the 20th century, we come across two world wars, winning, losing, participating, not participating, and affecting almost every country and society. In a short time (about 30 years), these wars deeply affected societies, after 1950, the hot war gave way to the cold war, and the countries competed with each other to regain their power and become a superpower. They increased their production volumes by making technological breakthroughs in order to be strong in military and economic terms. Developing and increasingly prosperous societies increased the demand for existing and new products, and the increase in demand led to an increase in supply. With the increase in demand in existing markets and the creation of new markets, companies have renewed their production technologies to increase their production volumes and have made more mechanization. In addition, new players joined the market and competition increased. Companies tried to increase their production volumes on the one hand, and struggled with new competitors on the other. For many companies, this experience that they have never had before has put great pressures. Therefore, companies have started to attach importance to concepts such as customer satisfaction, quality, efficiency and cost in order to protect their assets and to be strong in competition. Therefore, the concept of maintenance, which has an undeniable effect on these concepts, came to the fore and it was understood that care should be developed and managed over time.
Today, the development and diversification of communication tools, the ease of transportation, the increase in commercial partnerships, and the decrease in hot wars-when compared to the past centuries- have made political boundaries almost a line on the map. Markets have become global rather than local. Changing environmental conditions have also forced companies to change their policies. Many companies have changed their maintenance policies by updating their technological infrastructure and have started to apply modern maintenance methods to their systems.
In this study, basic definitions of maintenance have been made, its historical development has been examined, and its importance and necessity in industries are mentioned. Maintenance methods that can be applied in enterprises have been researched, methods have been mentioned sufficiently and subjects such as application conditions, advantages and disadvantages have been explained sufficiently.
Nowadays, where maintenance is a field on its own and gains such importance, businesses should choose the maintenance actions appropriate to their systems and manage the process by using their resources correctly. In this way, it is possible for them to create an added value for themselves, societies and the environment.
Looking at the historical development of care, we see that various care actions have developed over time. We can list these maintenance actions as follows:
1. Reactive Maintenance (No Repair Plan)
2. Run Until Broken (Repair Plan Available) (RtF: Run to Failure)
3. Routine Maintenance
4. Periodic Maintenance
a) Time Based
b) Usage Based
5. Predictive Maintenance
6. Regular Care
7. Planned Revision
Over time, the change in industrial requirements (production volume, quality, reliability, cost, etc.) and technological developments made the existing maintenance actions inadequate, and the number of maintenance actions increased over time, with the development in itself.
However, when the necessary researches were made, it was seen that maintenance actions were not understood correctly and were not applied effectively, and the idea that many factors that have direct or indirect effects on maintenance should be managed, especially maintenance actions. This management approach has changed the perception of the concept of maintenance in the industry. Nowadays, businesses have stopped evaluating the concept of maintenance as "an act of control or repair of equipment" and started to consider maintenance as a concept that needs to be planned, monitored and managed from the beginning to the end of the process. The result was maintenance methods such as productive maintenance (PM), total productive maintenance (TPM), and reliability centered maintenance (RCM).
With the changing and developing maintenance actions, the idea of "repair only when it breaks down" has left its place - with the development of technology - comprehensive examination, planning and implementation. We can summarize the point reached today as follows:
•High facility suitability and reliability
•Much safer and ergonomic work environment
•Increase in product quality
•Reduction in environmental damage and pollution
•Increase in equipment life
•Maintenance actions with high benefit / cost ratio
•Effective time management
The benefits that companies can derive from contemporary maintenance approaches are obvious. At this point, what companies need to do is to adapt and apply contemporary maintenance methods to their own production systems and management strategies.
In our practice, the existing maintenance status of an industrial enterprise that manufactures pumps and is a pioneer in its field has been examined, necessary evaluations have been made and data have been collected for the RCM approach. The data were separated by various analyzes and made available for RCM application. After determining critical equipment by performing risk analysis, appropriate maintenance actions are suggested. When the recommended maintenance actions are implemented, an increase in machine reliability and availability is expected, and a decrease in cost values is expected. Another noteworthy issue is not only the implementation of the recommendations, but also the continuous monitoring of the equipment functions after implementation. Thus, it will be possible to compare the target and existing equipment parameters, if necessary, the system will be intervened or reorganized in the RCM plan.
Maintenance management is a very comprehensive and worth examining topic. As technology develops and machines exist in our lives, it will remain important. Moreover, with robots and machines undertaking most of the production, it will increase its importance in the future. The replacement of large but slow computers by small but fast computers in the first quarter of the 21st century, and the advancement of artificial intelligence and machine learning day by day, shed light on us for the years to come. For this reason, artificial intelligence and machine learning will play an active role in maintenance, as in many areas, in the coming years. In addition, with the further development of virtual reality (VR) and augmented reality (AR), remote control and maintenance of many machines will become possible, and training and implementation will be easier.
Nowadays, where maintenance is a field on its own and gains such importance, businesses should choose the maintenance actions appropriate to their systems and manage the process by using their resources correctly. In this way, it is possible for them to create an added value for themselves, societies and the environment.