RCM Analysis CTN ZVT Wrapping station

Function Function failure Failure mode/consequences

1)To shrink wrap trays at 40
packs a minute
1A Film does not feed. 1A1 Pack sensor 63B fails.
Packs will continue until sensor 79B2 stops machine.
Downtime to repair, 30 minutes
Action
Maintenance OPL.

1A2 Film mandrels fail to rotate.

Film will snap
Downtime to repair, 2 hours
Action
Maintenance OPL

1A3 Dancer fails.

Film will snap
Downtime to repair, 1 hour
Action
Maintenance OPL

1A4 Cutting clutch mechanism fails.

Film would not be cut or continuously be operated
Downtime to repair, 2 hours
Action
Run to failure.

1A5 Feed clutch mechanism fails

Film would not feed
Downtime to repair, 2 hours
Action
Run to failure
1A6 Film feed conveyor drive fails.
Film would not be fed onto tray
Downtime to repair, 4 hours
Action
Maintenance OPL

1A7 Film feeds at wrong time.

Incorrect film wrap
Downtime to repair, 1 hour.
Action
Maintenance OPL

1A8 Film breaks.

No film alarm operates
Downtime to repair, 10 minutes
Action
OPL

1A9 Static bar fails.

Bad film feed
Downtime to repair, 1 hour
Action
Shire task.

1A10 Dirty film wrap.

Bad film feed
Downtime to repair, 1 hour
Action
Specific improvement
 1A11 Knife does not cut.
No film alarm
Downtime to repair, 30 minutes
Action
OPL

1B Film feeds continuously 1B1 Pack sensor 63B1 fails.

Film will feed until operators stops machine
Downtime to repair, 30 minutes
Action
Maintenance OPL.

1C Film does not wrap 1C1 Arms do not rotate.

Film sensor 79B2 stops machine
Downtime to repair, 1 hour
Action
Maintenance OPL

1C2 Arms out of time.

Film sensor 79B2 stops machine
Downtime to repair, 1 hour
Action
Maintenance OPL

1C3 Arms do not trip.

Breaks film wrap arms, machine stops on film sensor
79B2
Downtime to repair, 2 hours
Actions
Maintenance OPL
1D Film does not shrink 1D1 Shrink too high.
correctly Operator will notice eventually
Downtime to repair, 2 hours
Action
Maintenance OPL

1D2 Shrink too low.

Operator will notice eventually
Downtime to repair, 2 hours
Action
Maintenance OPL
Set points/baffles/drive too fast.

1D3 Film not on pack central.

Sensor 79B2 will alarm
Downtime to repair, 10 minutes
Action
OPL

1D4 Heat tunnel fan fails. 92M1

Alarm low heat temperature.
Downtime to repair, 2 hours
Action
Shire task

1D5 Heating elements fail.

Low temperature alarm
Downtime to repair, 2 hours
Action
Shire task

1E To detect incorrect film
wrap
1F Does not transfer pack
through machine.
1D6 Temperature control fails.100N1
Low temperature alarm
Downtime to repair, 2 hours
Actions
Shire task
1E1 Pack sensor 79B1 fails.
Incorrect film not been detected, operator would
eventually notice
Downtime to repair, 1 hour
Action
Maintenance OPL
1E2 film sensor 79B2 fails.
Incorrect film not been detected, operator would
eventually notice
Downtime to repair, 1 hour
Action
Maintenance OPL
1F1 Flat belt drive fails
Packs would build back and trip overhead flight chain
Downtime to repair, 1 hour
Action
Maintenance OPL
Chain driven
1F2 Heat tunnel roller fails. 90M1
Packs would build back and trip wrapping station
Downtime to repair, 2 hours
Action
 Shire task.

1F3 Synchronisation of conveyors out.

Packs would build back and trip machine
Downtime to repair, 1 hour
Action
Maintenance OPL

1F4 Heat tunnel conveyor drives fails. 90M1

Packs would build back and trip wrapping station
Downtime to repair, 3 hours
Action
Maintenance OPL

2)Fails to sizechange in 30 No action Run to failure.

minutes