Reliability Engineering and System Safety 80 (2003) 1–18

www.elsevier.com/locate/ress

Maintenance strategy for tilting table of rolling mill based on reliability

considerations
V.S. Deshpande*, J.P. Modak
Department of Mechanical Engineering, P.C.E. & A, Nagpur University, Nagpur 440 019, Maharashtra, India
Received 18 June 2002; accepted 15 July 2002

Abstract
Reliability centred maintenance (RCM) is a new strategic framework for ensuring that any asset continues to perform, as its users want it to
perform. RCM is a process used to determine the maintenance requirement of any physical asset in its operating context. RCM process entails
asking seven questions about each of the selected assets. It makes use of two documents namely, RCM information worksheet and RCM
decision worksheet. RCM decision diagram integrates all the decision processes into a single strategic framework. RCM concept developed
by US commercial airlines industry has been successfully implemented by Military, Navy, Nuclear power plants, electric power generation
and distribution undertakings and several other sectors. These projects have been carried out in the United Kingdom, The Republic of Ireland,
the United States, Hong Kong, Australia, Spain and Singapore. The fact that people has enthusiastically received RCM at all levels and has
enabled users to achieve some remarkable successes in all of these countries, suggests that it can be universally employed. Literature review
indicates that RCM approach is not conventionally applied in process industries in India. Presently, predictive maintenance (PDM) approach
along with conventional preventive maintenance is used in continuous/process industries. This approach if implemented in totality will
increase the production cost to a large degree and make the production uneconomical. Similarly breakdown maintenance (BDM) approach
cannot be applied in such industries as each breakdown involves huge costs. RCM approach is a compromise between PDM and BDM
approach for optimising the cost and ensuring the availability of machine.
The RCM approach has been applied to the tilting table system of rolling mill for the research work reported in this paper. In the present
study, preventive maintenance tasks suggested for power transmission subsystem, guiding and transportation subsystem and hydraulic
subsystem in tilting tables are 14 scheduled on-condition tasks, 10 scheduled on-restoration tasks, seven scheduled discard task. Whereas for
14 failure modes no scheduled maintenance has been proposed. Existing maintenance schedule for tilting tables indicates the maintenance
action as and when required. Hence RCM based schedule specifies that additional preventive maintenance tasks need to be executed as
compared to none initially. Cost incurred for this can be offset from the savings accrued from reduction in loss of production due to repetitive
breakdowns. The methodology of RCM adopted in western industries cannot be applied as it is to Indian industries because of labour oriented
nature, partially computerised information systems, non-availability of the information about cost of loss of production due to breakdown and
age-reliability pattern of equipment, insufficient maintenance database. These problems can be overcome by development of sound MMIS,
formulation of RCM review group and imparting suitable training to acquire the relevant skills in RCM. Thus RCM methodology can be
applied to Indian industry for reduction of breakdowns as well as optimisation of preventive maintenance cost. This can further boost up the
prospects of Indian industry to offer the products at globally competitive prices.
q 2003 Elsevier Science Ltd. All rights reserved.
Keywords: Reliability centred maintenance; Rolling mill

1. Introduction of physical assets. Hence failure of these assets results in

In the current scenario continued operation of highly
mechanised and automated businesses is essential for
wealth generation. This depends on the continued integrity
* Corresponding author. Tel.: þ 91-712-263822; fax: þ 91-7104-37681.
E-mail address: vishwasd@nagpur.dot.net.in (V.S. Deshpande),
barlingay@satyam.net.in (V.S. Deshpande).
0951-8320/03/$ - see front matter q 2003 Elsevier Science Ltd. All rights reserved.
PII: S 0 9 5 1 - 8 3 2 0 ( 0 2 ) 0 0 1 5 2 - 7
wealth erosion, service interruption and some of the worst
accidents and environmental incidents in industrial history
such as Bhopal gas tragedy. As a result, the process by
which these failures occur and management of these failures
have to be accorded very high priority. The first industry to
deal with this issue was international civil aviation industry.
On the basis of continued research, this industry evolved a
completely new strategic framework for ensuring that any
2 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
asset continues to perform, as its users want it to perform.
This framework was referred as reliability centred main-
tenance (RCM) [1]. The brief considerations in this
approach are as follows.
Maintenance concept has evolved over three generations.
Third generation concept requires longer equipment avail-
ability in cost-effective fashion. Research has identified that
conventional bathtub curve is not applicable in almost 90%
of cases. Hence modern maintenance managers face several
challenges for ensuring equipment availability at affordable
cost. RCM provides a framework, which enables users to
respond to these challenges, quickly and simply.
RCM is a process used to determine the maintenance
requirement of any physical asset in its operating context. A
comprehensive plant register indicating the list of assets and
development of suitable numbering system is a prior
requirement before the application of RCM review process.
RCM process entails asking seven questions about each
of the selected assets. It makes use of two documents
namely, RCM information worksheet and RCM decision
worksheet. RCM decision diagram integrates all the
decision processes into a single strategic framework.
Answers to the questions regarding failure consequences,
preventive tasks and default actions in decision diagram are
recorded on decision worksheet.
Military and Navy also successfully implemented RCM
concept developed by US commercial airlines industry
[2 –4]. It has also been employed in Nuclear power plants
[5 – 7] and electric power generation and distribution
undertakings. The other sectors includes: railways, brew-
eries, offshore oil and gas industries, pharmaceutical
companies, steel mill, bank, oil refineries, aluminium
processing industries, several engineering and metalwork-
ing companies. These projects have been carried out in the
United Kingdom, The Republic of Ireland, the United
States, Hong Kong, Australia, Spain and Singapore. The
fact that RCM has been enthusiastically received by people
at all levels and has enabled users to achieve some
remarkable successes in all of these countries, suggests
that it is much less affected by cultural differences than
many other participative techniques of this nature [1].
2. RCM methodology
RCM starts with a comprehensive, zero-based review of
the maintenance requirement of each asset in its operating
context. RCM is called reliability centred maintenance
because it recognises that maintenance can do no more than
ensure that physical assets continue to achieve their built in
capability or inherent reliability. RCM starts with a
comprehensive, zero-based review of the maintenance
requirement of each asset in its operating context.
The ‘INTENDED FUNCTION’ of any asset can be
defined in a number of ways; depending on exactly
where and how it is being used (the operating context).
The ‘INTENDED FUNCTION’ also implies specific
performance expectation.
RCM process entails asking seven questions about each
of the selected asset as follows:
† What are the functions and associated performance
standards of the assets in its present operating context?
† In what ways does it fail to fulfil its function?
† What causes each functional failure?
† What happens when each failure occurs?
† In what ways does each failure matter?
† What can be done to prevent each failure?
† What should be done if a suitable preventive
maintenance task cannot be found?
The answers to the first four questions are recorded on
RCM information worksheet and answers to the remaining
three questions are recorded on decision worksheet. Thus
these two key working documents are used in the
application of RCM [1,8,9].
2.1. RCM information worksheet
These are used to record the functions of the asset under
review and to list all the associated functional failures,
failure modes and failure effects.
2.1.1. Functions and performance standard
Maintenance means ensuring that physical asset con-
tinues to fulfil its intended functions. The functions of the
assets and its desired standards of performance define the
objectives of maintenance with respect to any asset.
Functions. Functions can be divided into four categories
as stated below.
† Primary functions. Every asset is put into service to fulfil
specific functions known as primary functions.
† Secondary functions. Typical secondary functions
include containment, support, hygiene, appearance, and
gauges.
† Protective devices. In order to eliminate failure con-
sequences, increasing use is made of automotive
protective devices. Protective devices ensure that the
consequences of the failure functions being protected are
much less serious than they would be if there were no
protections.
† Superfluous functions. Superfluous items or com-
ponents are sometimes encountered when equipment
has been modified frequently over a period of years or
when new equipment has been overspecified. These
items although do not serve any useful function can
fail and reduce the overall system reliability.
Performance standards. Maintenance ensures that
physical assets continue to fulfil their intended functions
by anticipating, preventing or correcting situations where
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
the equipment has failed. Failure is defined as the inability
of an item to meet a desired standard of performance. The
two performance standards associated with every function
are the desired performance and the inherent reliability of
the asset with respect to that function. RCM recognises that
† The inherent reliability of any item is established by its
design and by how it is made.
† Maintenance cannot yield reliability beyond this inherent
level.
Listing of the desired performance is to be done when
functions and performance standards are recorded. Per-
formance standard includes output, product quality, safety,
energy efficiency and the environment.
Functions and the operating context. The presence of
redundancy or alternative means of production as well as
quality standards and standards of customer service are to be
considered when function of any asset is defined.
2.1.2. Functional failures
A functional failure is defined as the inability of any
physical asset to meet a desired standard of performance.
Operations and engineering people working together should
set performance standards. Different functional failures,
which can apply to a single function, include total and
partial loss of function.
2.1.3. Failure modes
The process of anticipating, preventing, detecting or
correcting failures is applied to individual failure modes, i.e.
maintenance is managed at failure mode level. Root causes
of failure are normal wear and tear, dirt, inadequate
lubrication, disassembly, incorrect set-up or operation,
incorrect process or packaging materials. Only failure
modes, which might reasonably be expected to occur in
the context in question, should be recorded. Failure modes
for stand by components are different from regular duty
components.
2.1.4. Failure effects
Listing of what actually happens when each failure mode
occurs is known as failure effect. Specifically when describing
the effects of failure the following should be recorded.
† What evidence (if any) that the failure has occurred?
Examples include warning lights or alarms to sound, loud
noises, fire, smoke, escaping steam, unusual smells or
pools of liquid and the floor?
† What physical damages (if any) is caused by the failure?
† What must be done to repair the failure?
Amount of down time with each failure is properly
accounted for. The effect of failure should be described if
nothing was being done to prevent it.
3
2.2. RCM decision worksheet
RCM decision worksheet provides answers to the
questions namely,
† In what way does each failure matter?
† What can be done to prevent each failure?
† What if a suitable preventive task not is found?
2.2.1. Failure consequences
Failure prevention has much more to do with avoiding or
reducing the consequences of failure than it has do with
preventing the failures themselves. A preventive task is
worth doing if it deals successfully with the consequences of
the failure, which it is meant to prevent. The RCM process
groups failure consequences into four categories and it does
so in two stages. The first stage separates hidden functions
from evident functions. A hidden function is one whose
failure will not become evident to the operating crew under
normal circumstances. The next stage is to classify evident
failure into three further categories in descending order of
importance as follows.
1. Safety and environmental consequences
2. Operational consequences
3. Non-operational consequences
Hidden failure consequences. The failure of duty
equipment when the standby equipment is in failed state
is known as a multiple failure. The only consequence of a
hidden failure is increased risk of a multiple failure. The
main objective of maintenance program for a hidden
function is to prevent—or at least to reduce the risk of—
the associated multiple failure. The performance standard
for a hidden function is the availability needed to reduce
the risk of the associated multiple failure to an acceptable
level.
Safety and environmental consequences. Evident failure
modes are grouped into three categories, as follows
† Those which could affect safety
† Those which affect production or operations
† Those which involve the direct cost of repair
The RCM process considers the safety implications of
each failure mode first. A failure mode has safety
consequences if it causes a loss of function or other damage,
which could hurt or kill someone. The RCM process always
assesses safety consequences at the most conservative level.
A failure mode has environmental consequences if it causes
a loss of function or other damages which could lead to the
breach of any known environmental standard or regulation.
If a failure mode could affect the safety or environment, the
RCM process stipulates that one must try to prevent it.
For failure modes, which have safety or environmental
4 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Fig. 1. The evaluation of failure consequences.
consequences, a preventive task is only worth doing if it
reduces the risk of failure to an acceptably low level.
Operational consequences. A failure has operational
consequences if it has a direct adverse effect on operational
capability. In general, failures affect operations in four ways
namely, output, product quality, customer service, increased
operating cost in addition to the direct cost of repair. All of
these consequences are economic. To assess the economic
impact of these failures it is needed to assess how much they
are likely to cost over a period of time. For failure modes
with operational consequences, a preventive task is worth
doing, if over a period of time, it costs less than the cost of
the operational consequences plus the cost of repairing the
failure, which it is meant to prevent. This type of analysis is
carried out for each individual failure mode and not for
machine as whole. This is because each preventive task is
designed to prevent a specific failure mode. So the economic
feasibility of each task can only be compared to the cost of
failure mode which it is meant to prevent.
The non-operational consequences. The consequence of
an evident failure, which has no direct adverse effect on
safety, the environment or operational capability, is
classified as non-operational. For failure modes with
non-operational consequences, a preventive task is worth
doing if over a period of time; it costs less than the cost of
repairing the failures, which it is meant prevent.
Thus the RCM process,
† Provides a comprehensive strategic framework for
managing failures. As summarised in Fig. 1, this
framework classifies all failures on the basis of their
consequences. In doing so it separates hidden failures
from evident failures, and then ranks the consequences of
the evident failures in descending order of importance.
† Provides a basis for deciding whether preventive
maintenance is worth doing in each case.
† Suggests what action should be taken if a suitable
preventive task cannot be found.
2.2.2. Preventive tasks
The actions which can be taken to deal with failures can
be divided into two groups—preventive tasks and default
tasks which must be undertaken if suitable preventive tasks
cannot be found. Whether or not a preventive task is
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Fig. 2. P–F curve.
technically feasible depends on the technical characteristics
of the failure mode and of the tasks as shown in Fig. 4.
The three principal categories of preventive tasks are
scheduled on-condition tasks, scheduled restoration tasks
and scheduled discard tasks.
Scheduled on-condition tasks. On-condition maintenance
is based on the fact that many failures develop over a period
of time. If evidence can be found that this failure process is
under way it may be possible to prevent failure and/or to
avoid its consequences.
Potential failures. The point in the failure process at
which it is possible to detect that the failure is occurring or
about to occur is known as potential failure. Examples of
potential failures include hot spots showing deterioration of
furnace refractors, vibrations indicating imminent bearing
failure, cracks showing metal fatigue and excessive tread
wear on tyres.
The general process of occurring of failures is illustrated
in Fig. 2. It is called the P – F curve because it shows how a
failure starts, deteriorates to the point at which it can be
detected (the potential failure point ‘P’) and then if it is not
detected and corrected, continues to deteriorate usually at a
accelerating rate until it reaches the point of functional
failure (‘F’). If a potential failure is detected between the
point P and the point F, there are two possibilities namely, to
prevent the functional failure and to avoid the consequences
of the failure.
On-condition maintenance is defined as checking items
for potential failures so that action can be taken to prevent or
avoid the consequences of the functional failure. On-
condition tasks are so called because the items which are
inspected are left in service on the condition that they
continue to meet specified performance standards. The
frequency of on-conditional tasks must be less than the P –F
interval. On-condition tasks are technically feasible if:
5
† It is possible to define a clear potential failure condition.
† The P –F interval is fairly consistent.
† It is practical to monitor the item at intervals less than the
P – F interval.
† The net P –F interval is long enough to prevent or
avoid the consequences of the functional failure.
Categories of on-condition techniques. The four major
categories of on-condition techniques are as follows:
† Condition monitoring techniques
† Product quality variation
† Primary effects monitoring: primary effects such as
speed, flow rate, pressure, temperature, power, current
are monitored to provide information about equipment
condition.
† The human senses
Schedule restoration tasks. Scheduled restoration entails
remanufacturing a single component or overhauling an entire
assembly at or before specified age limit, regardless of its
condition at the time. Scheduled restoration tasks are also
known as scheduled rework tasks. They include overhauls at
regular intervals. The frequency of scheduled restoration task
is governed by the age at which the item or component shows
a rapid increase in the conditional probability of failure.
Scheduled discard tasks. Scheduled discard means
replacing an item or component with a new one at preset
intervals.
Selecting preventive tasks. The basic order of preference
for selecting preventive tasks is as follows:
On-condition tasks, scheduled restoration tasks, sched-
uled discard tasks. Two preventive options, which are
available for age related failures are scheduled restoration
tasks and scheduled discard tasks.
6 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Fig. 3. RCM decision diagram.
2.2.3. Default actions
If a preventive task cannot be found which is both
technically feasible and worth doing for any failure mode,
then the default action, which must be taken, is governed by
consequences of the failure. The default actions are
scheduled failure-finding tasks and no scheduled mainten-
ance redesign.
Scheduled failure-finding tasks. Scheduled failure-find-
ing entails checking hidden function at regular intervals to
find out whether it has failed. The more often a hidden
function is checked, the higher will be its overall
availability. For higher reliability, i.e. greater MTBF, the
failure-finding frequency should be low. Failure-finding
task is only worth doing if it secures the desired availability
of the hidden function.
No scheduled maintenance. No scheduled maintenance is
valid if
† a suitable scheduled task cannot be found for a hidden
function and the associated multiple failure does not have
safety or environmental consequences.
† A cost-effective preventive task cannot be found for
failures, which have operational or non-operational
consequences.
Redesign. Redesign refers to any change to the specifica-
tion of any item of equipment. Basically this means any
action which should result in a change to drawing or a parts
list. It includes changing the specification of a component,
adding a new item, replacing an entire machine with one of
a different make or type or relocating a machine. It also
means any other change to a process or procedure, which
affects the operation of the plant. In case of failures, which
have safety or environmental consequences, redesign is the
compulsory default action.
2.2.4. The RCM decision diagram
The RCM decision diagram integrates all the decision
processes into a single strategic framework. This frame-
work is applied to each of the failure modes listed on the
RCM worksheet. The RCM decision diagram is as shown
in Fig. 3.
2.2.5. RCM decision worksheet
The answers to the last three questions are recorded on
RCM decision worksheet The RCM decision worksheet is
as shown in Tables 4 – 6. It is used to record the answers to
the questions in the decision diagram covering the aspects of
failure consequences, preventive tasks and default actions
and in the light of these answers, to record:
† What routine maintenance (if any) is to be done, how
often it is to be done and by whom?
† Which failures are serious enough to warrant redesign?
† Cases where a deliberate decision has been made to let
failures happen.
The decision worksheet is divided into columns. The
columns headed F, FF and FM identifies the failure mode
under consideration. They are used to cross-refer
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18 7

Fig. 4. Using the decision worksheet to record failure consequences.

the information and decision worksheets. The headings on † If it becomes necessary to answer any of the default
the next columns refer to the questions on the RCM decision questions the columns headed H4 and H5 or S4 are
diagram as follows: used to record the answers.

† The columns headed H, S, E, O and N are used to record

the answers to the questions concerning the conse-
quences of each failure mode.
† The next three columns (headed H1, H2, H2) record
whether a preventive task has been selected and if so
what type of task?
The last three columns record the task, which has
been selected (if any), the frequency with which it
is to be done and who has been selected to do it.
The proposed task column is also used to record
the cases where redesign is required or it has been
8 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Fig. 5. Failure consequences-a summary.
decided that the failure mode does not need scheduled
maintenance.
Failure consequences. The questions for failure con-
sequences H, S, E and O are asked for each failure mode and
the answers are recorded on the basis shown in Fig. 4. Fig. 5
shows how these answers are recorded on decision
worksheet.
Preventive tasks. The eighth to tenth columns on decision
worksheet are used to record whether a preventive task has
been selected as follows:
† The column headed H1/S1/O1/N1 is used to record
whether a suitable on-condition task could be found to
anticipate failure mode in time to avoid the
consequences.
† The column headed H2/S2/O2/N2 is used to record
whether a scheduled restoration task could be found to
prevent the failures.
† The column headed H3/S3/O3/N3 is used to record
whether a suitable discard task could be found to prevent
the failures.
In each case, a task is only suitable if it is worth doing
and technically feasible. Technical feasibility criteria are
as shown in Fig. 6. If a task is selected a description of the
task and its frequency must be recorded.
The default questions. The columns headed H4, H5 and S4
on the decision work sheet are used to record to the answers to
the three default questions. The default questions are only
asked if the answers to the previous questions are all ‘no’.
1. Default action (H4)
Is a failure-finding task technically feasible and worth
doing?
Record yes if it is possible to do the task and it is
practical to do it at required frequency and it
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18 9

Fig. 6. Technical feasibility criteria.

reduces the risk of multiple failure to an acceptable
level.
2. Default action (H5)
Could the multiple failure affect the safety or
environment? (This question is only asked if
answer to question H4 is no. If the answer to the
question is yes then redesign is compulsory If the
answer is no the default action is no scheduled
maintenance but redesign may be desirable.
3. Default action (S4)
Is a combination of task technically feasible and
worth doing?
Yes if the combination of any two or more
preventive task will reduce the risk of failure to
the acceptable level. If the answer is no redesign is
compulsory.
In case of evident operational and non-operational
consequences the consequence of the failure are purely
economic and no suitable preventive task has been found.
As a result, the initial default decision is no scheduled
maintenance but redesign is desirable.
3. Scope of this article
Application of methodology of RCM for selection of
proper maintenance strategy is still a new concept in Indian
industry. Although this concept has been applied widely in
various countries, its relevance to the Indian industry has not
been realised so far. Indian industry is labour oriented and
information system specifically in context of maintenance
is not fully computerised. In the present study, RCM
10 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18

Fig. 7. Rolling mill.

methodology has been applied to tilting table system of a (v) Mill stands:
rolling mill. An attempt has been made to compare the RCM (a) Roughing stand
based tasks with the existing ones. Limitations in appli- (b) Intermediate stand
cation of RCM are also highlighted along with possible (c) Finishing stand
remedial solutions. (vi) Skids
(vii) Roller conveyors
(viii)
4. Rolling mill application Hot saw
(ix) Turnover cooling bed (TOCB)
The methodology of RCM has been applied to the rolling
mill. In rolling mill, blooms are pressed between the rolls to 4.1. Manufacturing process
reduce the cross-sectional area. The capacity of rolling mill
is expressed as follows. The bloom is heated in reheating furnace up to the
required temperature (1000 –1200 8C) depending upon the
(a) To roll sizes from 25- to 160-mm diameter. grade of blooms. It takes 4 – 7 h of heating. When bloom is
(b) To roll sizes from 40- to 140-mm square section. heated to required temperature it is taken out by ejector on
(c) Rectangular bars from 100 £ 18 mm 2 to turning table. From turning table, it is taken on the approach
2 table. In approach table, rollers are provided for the forward
160 £ 12 mm
movement of blooms. From approach table, the blooms go
Layout of rolling mill is shown in Fig. 7. Rolling mill to the TT-1 (tilting Table 1) through extension table. The
consists of the following equipment. tilting table provides specific angle and direction to enter in
the roughing stand. For the tilting operations, hydraulic
(i) Reheating furnace system is provided in the tilting table.
(ii) Turning table In roughing stand reduction of bloom dimensions is
(iii) Tilting table done, then it goes to TT-2. Forward and backward
(iv) Approach table movement of bloom is done till the exact dimension is
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Table 1
RCM information worksheet for power transmission subsystem
RCM information worksheet
Sr. no Function
1 The function of reduction gearbox is to supply
the reduced speed to the shaft from the motor.
The full-geared coupling connects the two shafts.
The purpose of coupling is to connect the shaft and
transmit the torque
2 Sprocket is provided at the side of the
roll for the transmission of power through
the duplex chain Key is provided for fixing
the sprocket on the roll shaft
11
Unit: power transmission subsystem
Component: (a) reduction gear box; (b) full geared coupling; (c) sprocket; (d) chain; (e) key;
(f) V-belt; (g) pulley
Functional failure Failure mode Failure effect
(A) Reduction gear box (i) Oil contamination Frictional power loss increase. After some limit
not working load torque will not be overcome
(ii) Low oil level Tooth wear and transmitted speed variation
will increase. This may contribute to some
extent increased traction
(iii) Teeth damaged For excessively worn out teeth transmitted
speed variation level will increase For great
alteration in dimensions, transmitted motion
will be jerkish which will induce sever impact
in the driven shaft
(B) Full geared (i) Teeth worn Impact will increase. Due to this induced stress
coupling fails in coupling increase. Hence coupling fails.
It results in interruption of motion
transmission
(ii) Hub damaged Transmitted speed will be very low, may lead
to breakage of damaged hub
(A) Sprocket fails (i) Teeth wear Increase in chordal action causing greater angular
velocity variation band It will increase
vibrations and that will affect the
microstructure of bloom
(ii) Key failure Sudden stoppage and severe shock. Life of roller
shaft gets reduced
(B) Chain fails (i) Misalignment of sprocket Alteration in geometry of chain motion path
which will cause enhanced chordal action and
therefore shock impact
(ii) Misalignment of roll Cause variation in chain tension, effect on driven
sprocket, causes tooth wear and friction energy
loss
(iii) Hot service condition— Induces thermal stresses in chain which will
permanent deformation induce low cycle thermal fatigue. It will dry up
of chain the chain bush lubricant which will increase
chain bush friction and cause wear
(iv) Change in length Change in length will vary the chain sag. It will
enhance the tendency of chain climbing. Cyclic
load on driven shaft is increased It exhausts the
fatigue life of shaft
(v) Increase Chordal action Greater variation in angular velocity band It
increases variable load on driven sprocket
which in turn increase shaft torsional vibrations
It will affect microstructure of bloom
(vi) Increase in variation Causes variation in supply torque if load torque
in chain tension on driven sprocket is constant cyclic variation
of shaft stress increase
(vii) Lock fails Interruption of power transmission
(C) Incorrect Key (i) Loose key Impact on driven rotating member Therefore it
clearance can reduce the life of driven rotating member.
It can cause key failure
(ii) Tight key Rise in initial compressive and shear stress.
It will further increase during power
transmission. Cause early key failure and
reduces life
(iii) Shear deformation Heavy pressure on edges of key. Under the
effect of slight relative displacement between
edges of key and shaft at one end and driven
wheel at other, key edges gets worn out
(D) V-Belt (C-55) (i) V-Belt loose Slipping of belt will occur. It will not transmit
the required effort torque to overcome the
load torque. This will make movement of
bloom jirkish
(ii) Overload Slippage of belt in the V groove of drive pulley
will increase. It enhances wear on the side of
V BELT
(iii) Worn Resistance torque will not be overcome because
of insufficient effort torque and no movement
(E) Pulley (i) Overload Reduction in pulley life
(ii) Damaged No transmission of power
12 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Fig. 8. Power transmission subsystem.
achieved. Blooms are allowed to undergo fixed number of
passes on each of the three stands depending upon the size
of incoming bloom and requirement of the customer.
The blooms are transferred from one stand to another
through skids. These transfers are known as skid transfer.
By this skid arrangement in the extension table, billet is
transferred into platform no. 2. In the platform no. 2 there
is TT-3 and TT-4. From TT-3 billet is transferred to the
intermediate rolling stand (S2). In S2 forward and back-
ward movement achieves the required dimension. Now the
billet is transferred to the platform no. 3 by the help of skid
arrangement in the extension table.
After the final pass on third, i.e. finishing stand the
blooms are taken to the hot saw through roller conveyor.
Here the blooms are cut to the required size and then passed
to turn over cooling bed (TOCB). Product is inspected after
cooling.
4.2. Identification and formulation of proposed work
Analysis of machine breakdown/shutdown list for a span
of about 2 years has revealed that most of the failures, which
have occurred, are due to failure of roller chain of tilting
tables. Hence it has been decided to focus attention on
maintenance aspects of tilting table system.
4.3. Approach
RCM concept has been applied to tilting table system as
illustrated herein. Tilting table system has been categorised
into three subsystems, power transmission subsystem,
guiding and transportation subsystem and hydraulic
subsystem.
4.3.1. Power transmission subsystem
Power transmission subsystem is as shown in Fig. 8. The
motor is coupled with the reduction gearbox by full geared
coupling. The reduction gearbox is equipped in the system
to reduce the speed as per the requirement by changing the
gears. If the speed of the motor is higher than required, it can
be reduced by reduction gearbox. The reduction gearbox is
connected with 3-grooved pulley where the C-55 belt is used
for power transmission. This 3-grooved pulley is attached
with sprocket of the driving roll. The sprocket along with
the chain of the driving roll is connected with sprocket of
driven roll in series. The driving roll drives the driven rolls.
The duplex chain is used. One tilting table consists of 10
rolls. All these rolls start rotating with the drive obtained
from driven roll. Power transmission subsystem consists of
the following components.
(a) Sprocket
(b) Chain
(c) Key
(d) V-belt
(e) Pulley
(f) Reduction gear box
(g) Full geared box coupling
4.3.2. Guiding and transportation subsystem
Side view of the rollers of the tilting table is as shown in
Fig. 9. The rollers are fitted with double spherical roller
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18 13

Fig. 9. Guiding and transportation subsystem.

bearing. Roller bearing is enclosed with the plummer block.
It is covered by mild steel plate, 50 – 75 mm thick, as per the
requirement. This mild steel plate is fixed at both sides by
foundation bolts so that rolls should not move (vibrate) at
different loads of blooms. Guiding and transportation
subsystem consists of the following components.
from other end of the cylinder through hose-pipe, which
brings down the tilting table. Counter weight system is
attached to the hydraulic subsystem as shown in Fig. 11.
One arm and counterweight assembled by the brass bush
and key at its end are provided. Major components of
hydraulic subsystem are,

(a) Rolls (a) Hydraulic power pack

(b) Double spherical roller bearing (b) Hydraulic Cylinder
(c) Plummer block (c) Hose-pipe
(d) Foundation bolt (d) Spherical bearing with pin
(e) Counterweight and arm
4.3.3. Hydraulic subsystem
Hydraulic subsystem (Fig. 10) is used for upward and 4.4. RCM information worksheet
downward movement of the tilting table. In the tilting
operation, the hydraulic cylinder helps in upward movement RCM information worksheets were prepared for power
of tilting table. Hydraulic cylinder is attached with the transmission subsystem, guiding and transportation sub-
power pack system. Hydraulic power pack supplies power system and hydraulic subsystem to indicate the functions,
to the hydraulic subsystem. In this system, the oil goes functional failures, failure modes, i.e. causes of failure.
inside the cylinder through hose-pipe and provides the RCM information worksheet for power transmission
upward movement to the tilting table. Then oil comes out subsystem is as shown in Table 1. Significant function is

Fig. 10. Hydraulic subsystem (hydraulic cylinder).

14 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18

Table 2
RCM information worksheet for guiding and transportation subsystem

RCM information worksheet Unit: guiding and transportation subsystem

Sr. no Function Component: (a) Roll; (b) Roll bearing; (c) Plummer block; (d) Foundation bolt

Functional failure Failure mode (cause of failure) Failure effect

1 The function of the system
is forward movements of billets.
It is achieved by the
continuous rolling movement of the
rolls for the smooth rolling.
For smooth rolling movement of
roll, bearing is provided at
both the ends of roll.
Roller bearing is enclosed with
Plummer block. Foundation bolts are
bolted in the Plummer block.
Thus it performs guiding and
transportation functions
(A) Roll not working (i) Due to failure of
key, sprocket is free
(ii) Due to bearing seizure
(B) Double spherical (i) Due to wear out,
roller bearing fails sieve bearing fails
(ii) Scant lubrication
(iii) High temperature
(iv) Roller wear
(C) Plummer block (i) Dynamic load
damaged
(ii) Vibrations
(iii) High temperature
(D) Foundation bolt fails (i) Dynamic load
(ii) Vibrations
(iii) Thread wear
Sprocket does not get motion.
Roll does not move. Transportation
stops
Shaft gets jammed. Roll does
not move transportation stops
Interrupted contact between rollers and
driven shaft. Rubbing of cage
element with roller increases. This
causes additional friction and power
loss. Hence sieve bearing fails
Frictional power loss increases. Bearing
temperature rises. Bearing parts
surface damage takes place
Considerable expansion of roller which
might cause considerable Jamming
between roller inner and outer race
Cause impact in bearing which
will lead to dynamic severity
(increase in stresses and vibrations)
Stresses will increase. Vibrations will
increase which may lead to
initiation of crack and eventual
failure
Additional stress due to vibrations
will increase leading to crack
initiation. This may ultimately lead
to failure
Lubricant evaporation will occur and
friction will increase. This leads
to increased power loss which
may in turn increase bearing
temperature and damage of bearing
part surface. This will ultimately
lead to bearing Jamming
Will increase stress and vibration.
This leads to accelerated crack
formation and eventually the actual
fracture
Vibrations will increase stress under
vibration. Therefore it will add
to all adverse effects of
increase in dynamic load. It
will loosen the foundation bolts
It will weaken the thread.
Because of weak thread, it
will lead to shear off
and thread failure

transmission of power from motor to rollers. Loss of this
function can occur due to failure of individual components
such as gearbox, coupling, 3-grooved pulley, belt, and
sprocket and roller chain. Root causes of functional failures,
i.e. failure modes are identified with each failure such as
worn out parts, overloading, misalignment, etc.
RCM information worksheet for guiding and transpor-
tation subsystem is as shown in Table 2. Important function
is supporting and guiding and ensuring the smooth forward
movement of billets. Failure of components namely, rolls,
double spherical roller bearing, plummer block, foundation
bolts can result in functional loss. Movement of roller can
stop due to failure of key or bearing seizure. Failure of
roller bearing can be attributed to wearout, scant lubrica-
tion, temperature rise or roller wear. Plummer block can
get damaged due to dynamic load, vibrations or high
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
Table 3
RCM information worksheet for hydraulic subsystem
RCM information worksheet
Sr. no. Function
1 Hydraulic system is used for
tilting operation of the table.
It consists of cylinder, power
pack, hose-pipe. Hydraulic power pack is
component for supplying power to
the hydraulic system
temperature. Foundation bolts can fail due to vibrations or
thread wear. These details are summarised in the
information worksheet.
RCM information worksheet for hydraulic subsystem is
as shown in Table 3. Important function is tilting operation
of table by upward or downward movement. Failure of
components Hydraulic power pack, Hydraulic Cylinder,
15
Unit: hydraulic subsystem
Component: (a) hydraulic power pack; (b) cylinder; (c) hosepipe; (d) spherical bearing with pin;
(e) counter weight arm
Function failure Failure mode Failure effect
(A) Hydraulic power (i) Pressure drop Tractive effort will not be
pack fails obtained. It will slow down
the process or will interrupt
the motion
(ii) Hose-pipe leakage Will lead to pressure drop.
Hence tractive effort will not
be obtained
(iii) Piston ring damage Tractive force on piston will
not be built. Friction between
cylinder and piston will increase
and will lead to power loss
(iv) Strainer damaged Will cause increase in dirt
in system which will affect
the functioning of all parts
(B) Hydraulic cylinder (i) Corroded Increase in friction between piston
and cylinder will increase power
loss. This may interrupt the
motion which may even increase
the wear of piston ring
(ii) Damaged (Inside surface roughness increases or
distortion along the axis takes
place). Will cause piston ring
damage and associated failure. It
will also cause the impact
between piston and cylinder which
will increase additional unwanted
vibrations
(C) Hose-pipe (i) Ruptured No oil flow. No motion
(ii) Leakage Will not supply enough oil
flow rate to cylinder. This
will not create enough tractive
force on piston. It will
also slow down the motion
or interrupt the motion
(D) Spherical bearing (i) Damaged Friction in bearing will be
with pin increased. This will generate heat
resulting in increase of temperature.
This will further deteriorate bearing
function and eventually it may
seize the bearing
(E) Counterweight (i) Bush wear Motion will become jerkish. Increase
and Arm impact at the bush which
will cause additional unwanted stresses,
initiation of crack and eventual
early failure
(ii) Pin broken Interrupts the motion. No Tilting
movement
Hose-pipe, Spherical bearing with pin, Counterweight and
arm can result in functional loss. Failure of Power pack can
be attributed to pressure drop, leakage of hose-pipe, leakage
of piston ring, or jamming of strainer. Hydraulic cylinder
can get damaged or corroded. Hose-pipe can leak or rupture.
Spherical bearing with pin can get damaged. Counterweight
and arm can fail due to bush wear or breaking of pin.
16 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18

Fig. 11. Hydraulic subsystem (counter weight and arm).

4.5. RCM decision worksheet
RCM decision worksheets were prepared for power
transmission subsystem, guiding and transportation sub-
system and hydraulic subsystem, to reveal the nature of
hidden, safety, environmental and operational failure
consequences, for the specific failure modes. With the
questions based on RCM decision diagram (Fig. 7)
consequences of failure were evaluated. Accordingly,
preventive tasks were specified for each failure mode.
This information has been compiled in RCM decision
worksheet.
Table 4
RCM decision work sheet for power transmission subsystem
RCM decision worksheet for power transmission sub-
system is as shown in Table 4. Totally 22 failure modes
were recorded. Out of these five were allocated on-condition
tasks, eight scheduled restoration tasks, five scheduled
discard tasks, no scheduled maintenance as an initial default
decision was suggested for four.
RCM decision worksheet for guiding and transportation
subsystem is as shown in Table 5. Totally 12 failure modes
were recorded. Out of these seven were allocated on-
condition tasks, one scheduled restoration task, one
scheduled discard task and no scheduled maintenance was
suggested for three.

RCM decision work sheet Unit Power transmission subsystem

Component (a) Reduction gear box; (b) Full geared coupling; (c) Sprocket; (d) Chain; (e) Key;
(f) V-belt; (g) Pulley

Information Consequence H1 H2 H3 Default Proposed task

reference evaluation S1 S2 S3 action
O1 O2 O3
F FF FM H S E O N1 N2 N3 H4 H5 S4

1 A i Y N N N N Y Schedule restoration. Checking of oil

1 A ii N N N N Y – Schedule on-condition. Human senses
1 A iii Y N N Y N N Y Schedule discard
1 B i Y N N Y N N Y Schedule discard
1 B ii N N N Y N N N No scheduled maintenance
2 A (i) N – – – Y – – – – – Check wear of sprocket teeth by oil testing. On-condition
2 A (ii) Y N N Y N N N – – – No scheduled maintenance
2 B (i) Y N N N N Y – – – – Align the sprocket. Schedule restoration
2 B (v) N – – – N Y – – – – Tighten the chain. Schedule restoration
2 B (ii) Y N N N N Y – – – – Align rolls. Schedule restoration
2 B (iii) Y N N Y N Y – – – – Change the deformed link. Schedule discard
2 B (iv) Y N N N Y – – – – – Tighten the chain. On-condition
2 B (vi) Y N N N N Y – – – – Restore chain tension. Schedule restoration
2 B (vii) Y N N Y N N N – – – No scheduled maintenance
2 C (i) Y N N Y N Y – – – – Fit proper key size. Schedule discard at major overhaul
2 C (ii) Y N N N N Y – – – – Fit proper key size. Schedule discard at major over haul
2 C (iii) N N N Y Y – – – – – Change key. On-condition
2 D (i) Y N N Y N Y – – – – Tighten V-belt. Schedule restoration
2 D (ii) Y N N Y N Y – – – – Schedule restoration
2 D (iii) Y N N Y N N Y – – – No scheduled maintenance
2 E (i) Y N N Y N Y – – – – Schedule restoration
2 E (ii) Y N N Y Y – – – – – NDT during major over haul. On-condition
 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18 17

Table 5
RCM decision work sheet for guiding and transportation subsystem

RCM decision work sheet Unit: guiding and transportation subsystem

Component: (a) roll; (b) roll bearing; (c) plummer block; (d) foundation bolt

Information Consequence H1 H2 H3 Default Proposed task

reference evaluation S1 S2 S3 action
O1 O2 O3
F FF FM H S E O N1 N2 N3 H4 H5 S4

1 A (i) Y N N Y N N N – – – No scheduled maintenance

1 A (ii) N – – – N Y – – – – Greasing of bearing. Schedule restoration
1 B (i) N – – – N N N N N – No scheduled maintenance
1 B (ii) N – – – Y – – – – – Check bearing for lubrication. Schedule on-condition
1 B (iii) N – – – Y – – – – – Temperature rise check. Schedule on-condition
1 B (iv) N – – – N N Y – – – Bearing replacement. Schedule discard
1 C (i) Y N N Y Y – – – – – Plummer block check. Schedule on-condition
1 C (ii) Y N N N Y – – – – – Vibration check. Schedule on-condition
1 C (iii) Y N N N Y – – – – – Temperature rise check. Schedule on-condition
1 D (i) Y N N Y Y – – – – – Check for foundation bolts. Schedule on-condition
1 D (ii) Y N N N Y – – – – – Vibration check. Schedule on-condition
1 D (iii) N – – – N N N N N – No scheduled maintenance

RCM decision worksheet for hydraulic subsystem is
as shown in Table 6. Totally 11 failure modes were
recorded. Out of these two were allocated on-condition
tasks, one scheduled restoration task, one scheduled
discard task and no scheduled maintenance was
suggested for seven.
5. Conclusion
In the present study, preventive maintenance tasks
suggested for power transmission subsystem, guiding and
transportation subsystem and Hydraulic subsystem in tilting
tables are 14 scheduled on-condition tasks, 10 scheduled on-
restoration tasks, 7 scheduled discard task. Whereas for 14
failure modes no scheduled maintenance has been proposed.
Existing maintenance schedule for tilting tables indicates the
maintenance action as and when required. Hence RCM based
schedule specifies that additional preventive maintenance
tasks need to be executed as compared to none initially.
In power transmission subsystem, significant aspects are
correct chain tension and proper key clearance. Equipment
history records reveals that breaking of roller chain is a
frequently occurring failure resulting in breakdown main-
tenance. In order to prevent recurrence of this, chain tension
needs to be adjusted. This implies that schedule restoration

Table 6
RCM decision work sheet for hydraulic subsystem

RCM decision work sheet Unit: Hydraulic subsystem

Component: (a) Hydraulic power pack; (b) Cylinder; (c) Hosepipe; (d) Spherical bearing with pin; (e) Counter weight
arm

Information Consequence H1 H2 H3 Default Proposed task

reference evaluation S1 S2 S3 action
O1 O2 O3
F FF FM H S E O N1 N2 N3 H4 H5 S4

1 A (i) Y N N Y Y – – – – – Check pressure value. Schedule on-condition

1 A (ii) Y N N Y N N N – – – No scheduled maintenance
1 A (iii) N – – – N N N N N – No scheduled maintenance
1 A (iv) N – – – N Y – – – – Clean the strainer. Schedule restoration
1 B (i) N – – – Y – – – – – Check cylinder when shutdown. Schedule on-condition
1 B (ii) Y N N Y N N N – – – No scheduled maintenance
1 C (i) Y N N Y N N N – – – No scheduled maintenance
3 C (ii) Y N N Y N N N – – – No scheduled maintenance
1 D (i) N – – – N N N N N – No scheduled maintenance
1 E (i) N – – – N N Y – – – Replace bush. Schedule discard during major over haul
1 E (ii) N – – – N N N N N – No scheduled maintenance
18 V.S. Deshpande, J.P. Modak / Reliability Engineering and System Safety 80 (2003) 1–18
tasks needs to be executed regularly. In every tilting table
there are 10 rollers provided. Machine breakdown list does
not specifically provides the information regarding frequency
of breaking of particular roller chain. Hence initially a period
of 1 week can be recommended for adjustment of belt
tension. Subsequently this can be altered with the collection
of additional relevant data. Selection of key of proper size is
major consideration for achieving desired clearance.
In supporting system failure of bearing occurs due to scant
lubrication, wearing out and high temperature. Maintenance
tasks such as greasing of bearing, proper lubrication,
temperature monitoring, are to be carried out. In the absence
of sufficient maintenance, data base exact frequency for
these tasks is not specified presently. Exhaustive mainten-
ance data needs to be generated to deal with this aspect.
In hydraulic subsystem in majority of the cases no
scheduled maintenance is proposed because these are related
to breakage or damage of hose-pipe, bearing pin, etc. Hence
RCM based schedule is in conformity with existing mainten-
ance strategy. For hydraulic power pack, monitoring of
pressure is essential aspect. Hence on-condition task has been
suggested. Similarly on-condition task has been suggested
for cylinder. For cleaning of strainer and replacement of
bush of counterweight-arm, on-schedule and schedule
discard tasks have been suggested, respectively.
6. Discussion
Existing maintenance schedule for tilting tables indicates
the maintenance action as and when required. Hence RCM
based schedule specifies that additional preventive main-
tenance tasks need to be executed as compared to none
initially. Cost incurred for this can be offset from the savings
accrued from reduction in loss of production due to
repetitive breakdowns. In the present case, an attempt has
been made to apply the concept of RCM in Indian industry.
The following difficulties were faced.
† Original equipment manufacturer’s recommendations
were either not available or provides insufficient
information.
† Very often the corrective/breakdown maintenance strategy
is followed since breakdown time is less, say 15 min or so.
The effect of this breakdown in terms of lost production
is unaccounted. Hence the significance of effectiveness
of preventive maintenance strategy is not realised.
† Existing maintenance database generated from equip-
ment breakdown/shutdown list does not cater the detailed
information required for RCM analysis.
† No information is available about age-reliability pattern
for most of the equipment.
† Traceability of scientific reasoning of existing mainten-
ance strategy is difficult.
These problems can be overcome through extensive
consultation between production/operations and mainten-
ance people. For this purpose, RCM review group needs to
be formulated. An RCM review can result in outcomes
namely, learning about functions, a better understanding of
how the assets can fail and of the root cause of each failure,
list of proposed tasks and greatly improved team-working.
Suitable training is to be provided to large number of people
to acquire the relevant skills in RCM. The training courses
are to be provided to people such as craftsmen and
operators, engineers, operation managers, supervisors,
senior technicians and facilitators. The issues considered
in implementation of routine tasks are grouping the tasks
into suitable work packages, implementing planning and
control systems, ensuring that any faults found are dealt
with speedily. For this purpose, sound maintenance
management information system (MMIS) needs to be
developed. Thus RCM methodology can be applied to
Indian industry for reduction of breakdowns as well as
optimisation of preventive maintenance cost. This can
further boost up the prospects of Indian industry to offer the
products at globally competitive prices.
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