Implementation of Reliability Centered Maintenance (RCM) and Design out for Reliability (DOFR) Approaches to Milk Powder Drying Unit of Dairy Plant - A Case Study

This paper presents a structured approach to RCM and DOFR, and discusses the various steps in the approach for critical components in a dairy plant as a continuous. The homogenizer, Air heating system, drying chamber and vibrofludiser are most critical equipments in drying unit of milk powder plant in dairy industry. The proper combination of RCM and DOFR method provides a framework for utilizing operating experience in a more systematic way. The requirements for reliability parameters and data are therefore highlighted. The effort is made to fill gap between existing maintenance and new plan, together with some future challenges. After the application of RCM and DOFR process to critical components of the milk powder drying unit, there is a considerable improvement of 12-15% in uptime. Moreover, there is also considerable savings on setup loss, equipment failure time etc. Finally at the end the paper suggestions for maintenance of homogenizer, air heater, drying chamber and vibrofludiser are indicated to ensure trouble free operation and maximum service life, which may ultimately improve uptime and productivity.