Skip to main content
SpringerLink
Log in

Parameter estimation, reliability and maintainability analysis of sugar manufacturing plant

  • Original Article
  • Published:
International Journal of System Assurance Engineering and Management Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

References

  • Aggarwal A, Kumar S, Singh V (2015) Performance modeling of the skim milk powder production system of a dairy plant using RAMD analysis. Int J Quality Reliab Manage 32(2):167–181

    Article  Google Scholar 

  • Arvanitoyannis IS, Traikou A (2005) Implementation of HACCP to bread and fine based industry. Critical Rev Food Sci Nutr 45(5):327–370

    Article  Google Scholar 

  • Barabady, J, 2005. Reliability and maintainability analysis of crushing plants in Jajarm Bauxite Mine of Iran. In Proceedings of the annual reliability and maintainability symposium, USA, pp. 109–115.

  • Barak MS, Barak SK (2018) Profit analysis of a two-unit cold standby system model operating under different weather conditions. Life Cycle Reliab Safety Eng 7(3):173–183

    Article  Google Scholar 

  • Barak, M. S., and SUDESH KUMARI. "Profit Analysis of a Two Unit Cold Standby System Operating Under Different Weather Conditions Subject to Inspection." Applications & Applied Mathematics 13, no. 1 (2018)."

  • Barak MS, Yadav D, Barak SK (2018) Stochastic analysis of a two-unit redundant system with priority to inspection over the repair. Life Cycle Reliab Safety Eng 7(2):71–79

    Article  Google Scholar 

  • Barak MS, Garg R, Kumar A (2021) Reliability measures analysis of a milk plant using RPGT. Life Cycle Reliab Safety Eng. https://doi.org/10.1007/s41872-020-00163-8

    Article  Google Scholar 

  • Chillar, S (2014). Analysis of System Reliability Models Subject to Degradation and Random Shocks. Ph.D. thesis. M.D. University, Rohtak.

  • Crow LH (1974) Reliability analysis for complex, repairable systems. In: Proschan F, Serfling RJ (eds) Reliability and Biometry. SIAM, Philadelphia, pp 379–410

    Google Scholar 

  • Dahiya O, Kumar A, Saini M (2019) Mathematical modeling and performance evaluation of A-Pan crystallization system in the sugar industry. SN Appl Sci. https://doi.org/10.1007/s42452-019-0348-0

    Article  Google Scholar 

  • Dai Y, Zhou Y-F, Jia YZ (2003) Distribution of time between failures of machining center based on type I censored data. Reliab Eng Syst Saf 79(3):377–379

    Article  Google Scholar 

  • Devi, K (2019). Analysis of Redundant System of Non-identical Units using Weibull Distribution. Ph.D. thesis. Manipal University Jaipur, Jaipur.

  • Diallo M, Perreval H, Quillot A (2001) Manufacturing cell design with flexible routing capability in presence of unreliable machines. Int J Prod Econ 74(1–3):175–182

    Article  Google Scholar 

  • Ebeling A (2000) An introduction to reliability and maintainability engineering. New Delhi: Tata Mcgraw Hill Company Ltd.

  • https://en.wikipedia.org/wiki/Log-normal_distribution#media/File:PDF-log_normal _distributions. SVG

  • https://www.weibull.com/hotwire/issue14/relbasics14.htm

  • Kadyan S, Barak MS (2020) Stochastic analysis of a non-identical repairable system of three units with priority for operation and simultaneous working of cold standby units. Int J Statist Reliab Eng 7(2):269–274

    Google Scholar 

  • Kadyan MS, Kumar R (2015) Availability and profit analysis of a feeding system in the sugar industry. Int J Syst Assurance Eng Manage 8(1):301–316

    Google Scholar 

  • Kadyan MS, Kumar R (2017) Availability based operational behavior of B-Pan crystallization system in the sugar industry. Int J Syst Assurance Eng Manage. https://doi.org/10.1007/s13198-017-0614-8

    Article  Google Scholar 

  • Kumar, R (2015). Availability and profit analysis of sugar industrial systems. Ph.D. thesis. Kurukshetra University, Kurukshetra.

  • Kumar A, Saini M (2018) Mathematical modeling of sugar plant: a fuzzy approach. Life Cycle Reliab Safety Eng 7(1):11–22

    Article  MathSciNet  Google Scholar 

  • Liberopoulos G, Tsarouhas P (2002) Systems analysis speeds up Chipita’s food processing line. Interfaces 32(3):62–76

    Article  Google Scholar 

  • Liberopoulos G, Tsarouhas P (2005) Reliability analysis of an automated pizza processing line. J Food Eng 69(1):79–96

    Article  Google Scholar 

  • Malik SC, Yadav RK, Barak MS (2021) Stochastic analysis of a unit wise redundant computer system with priority to hardware repair and failure of service facility during software up-gradation. Int J Statist Reliab Eng 7(3):342–349

    Google Scholar 

  • MIL-HDBK-189 (1981), “Reliability growth management”, Headquarters, US Army Communication Research and Development Command, ATTN: DRDCO-PT, Fort Monmouth, NJ.

  • Saini M, Kumar A (2019) Performance analysis of evaporation system in sugar industry using RAMD analysis. J Braz Soc Mech Sci Eng 41:4

    Article  Google Scholar 

  • Seifoddini S, Djassemi M (2001) The effect of reliability consideration on the application of the quality index. Comput Ind Eng 40(1–2):65–77

    Article  Google Scholar 

  • Tsarouhas P (2018) Reliability, availability, and maintainability (RAM) analysis for wine packaging production line. Int J Quality Reliab Manage 35(3):821–842

    Article  Google Scholar 

  • Tsarouhas P (2019) Statistical analysis of failure data for estimating reliability, availability, and maintainability of an automated croissant production line. J Qual Maint Eng. https://doi.org/10.1108/JQME-04-2018-0029

    Article  Google Scholar 

  • Tsarouhas P, Arvanitoyannis L (2011) Quantitative analysis for peach production line management. J Food Eng 105(2011):28–35

    Article  Google Scholar 

  • Tsarouhas P, Besseris G (2017) Maintainability analysis in shaving blades industry: a case study. Int J Quality Reliab Manage 34(4):581–594

    Article  Google Scholar 

  • Varzakas T, Arvanitoyannis IS (2007) Application of failure mode & effect analysis (FMEA), cause & effect analysis, and Pareto diagram in conjunction with HACCP to a strudel manufacturing plant. Int J Food Sci Technol 42:1156–1176

    Article  Google Scholar 

  • Waghmode LY, Patil RB (2016) Reliability analysis and life cycle cost optimization: a case study from Indian industry. Int J Quality Reliab Manage 33(3):414–429

    Article  Google Scholar 

  • Wang YQ, Jia YZ, Jiang WW (2001) Early failure analysis of machining centers: a case study. Reliab Eng Syst Saf 72(1):91–97

    Article  Google Scholar 

  • Zerwick AY (1996) A focussed approach to reliability, availability, and maintainability for critical pressure vessels and piping. Int J Press Vessels Pip 66:155–160

    Article  Google Scholar 

Download references

Funding

The present work was not supported by any funding agency.

Author information

Authors and Affiliations

  1. Department of Mathematics and Statistics, Manipal University Jaipur, Dehmi Kalan, Jaipur, Rajasthan, 303007, India

    Monika Saini & Ashish Kumar

  2. Department of Computer and Communication Engineering, Manipal University Jaipur, Dehmi Kalan, Jaipur, Rajasthan, 303007, India

    Deepak Sinwar

Authors
  1. Monika Saini
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ashish Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Deepak Sinwar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Monika Saini or Ashish Kumar.

Ethics declarations

Conflict of interest

The Authors declare that they have no conflict of interest.

Ethical approval

This article does not contain any studies with human participants or animals performed by any of the authors.

Informed consent

Informed consent was obtained from all individual participants included in the study.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Saini, M., Kumar, A. & Sinwar, D. Parameter estimation, reliability and maintainability analysis of sugar manufacturing plant. Int J Syst Assur Eng Manag 13, 231–249 (2022). https://doi.org/10.1007/s13198-021-01216-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13198-021-01216-6

Keywords

Search

Navigation