1st Edition
Designing Food Safety and Equipment Reliability Through Maintenance Engineering
Existing maintenance engineering techniques pursue equipment reliability with a focus on minimal costs, but in the food industry, food safety is the most critical issue. This book identifies how to ensure food product safety through maintenance engineering in a way that produces added value and generates real profits for your organization.
Integrating food safety techniques with reliability and maintenance engineering techniques, Designing Food Safety and Equipment Reliability Through Maintenance Engineering details a maintenance design process that captures all conceivable critical factors in food manufacturing lines. While maintenance engineering normally starts with equipment reliability, this book starts with product safety to identify equipment criticalities and maintenance solutions.
The text examines the problems currently facing the food industry and introduces powerful solutions to help food producers and consultants manage both food safety and manufacturing effectiveness. It presents an innovative tool for weighing food, human, and equipment criticalities and also describes how to maximize maintenance design outcome through the empowerment of equipment operators and their close cooperation with maintenance and quality specialists.
Detailing how to design reliable task lists, the book includes case studies that illustrate the problems that low equipment reliability can create for your customers and your company’s image. It outlines key performance indicators that can help producers and suppliers easily identify quality, availability, and productivity gaps. It also highlights critical factors that can help you avoid process bottlenecks.
Introduction
The Food Industry Threat and Challenge: Increasing Regulation on Product Safety
Food Safety Problems Produced by Low Equipment Reliability
ALF Process and Criticalities
Food Product Processing (UHT Sterilization)
Aseptic Packaging (Aseptic Filling)
Container Distribution and Storage
Main Problem to Be Addressed
Effects of Equipment Stop in the Food Industry
Development of a Process to Design and Implement Maintenance Task Lists
Condition Monitoring to Reduce Human Errors and Their Impact on Product Safety
Scope of This Book
Conclusion
Link between Food Safety and Equipment Criticalities to Address Maintenance Needs
Introduction
Problems, Threats, and Opportunities in the Food Industry
Increasing Competition
Cost Reduction
Downsizing and Outsourcing
New Approaches to Maintenance
Equipment Criticalities in Food Industry
Heat Treatment of Milk
Thermization
LTLT Pasteurization
HTST Pasteurization
Ultra-Pasteurization
UHT Treatment
Sterilization in Container
Pasteurization of Milk Products
Sterilization of Milk Products
In-Container Sterilization
UHT Treatment
Aseptic Filling Equipment
Packaging Material (PM) Sterilization
Package Filling, Forming, and Sealing
Analysis of Case Studies to Address the Need of a Maintenance Process for Food Industry Packaging Lines
First Case Study: Product Contamination due to Scratch in the Packages
Second Case Study: Product Contamination due to Package Integrity Problems
Third Case Study: Product Contamination due to Mineral Oil Leakage
Fourth Case Study: Unsterile Packages Randomly Distributed Over Different Production Runs
Peanut Case Shows Holes in Product Safety Net
Analysis of Case Studies and Lessons Learned
Conclusion
Potential Contribution Given by Food Safety Certifications and GMPs
Food Safety System Certification (FSSC) 22000
Global View of the Whole Food Chain Criticalities
Primary and Secondary Sources of Contaminations
Good Manufacturing Practices (GMPs)
Buildings/Facilities and Equipment
Buildings/Facilities
Equipment
Personnel and Quality Assurance
Processes
Products
Conclusion
Critical Study of Quality and Maintenance Engineering Techniques
Introduction
Equipment Availability through Reliability, Maintainability, and Supportability (ARMS)
Availability
Reliability
Reliability Maintenance Techniques and Failure Curves
Product Law of Reliability
Failure Rate, MTTF, and MTBF
The Exponential Law of Reliability
Factors That Affect Reliability
Maintainability
Factors That Affect Maintainability
Supportability
Food Product Safety Techniques
Product Safety through the Application of HACCP Methodology
Application of Hazard Operability (HAZOP)
Definitions
The HAZOP General Overview
The HAZOP Process
Guidewords, Selection of Parameters, and Deviations
The Concept of Point of Reference (POR)
Screening for Causes of Deviations
Consequences and Safeguards
Deriving Recommendations (Closure)
Conclusions
Maintenance Engineering Techniques
Reliability-Centered Maintenance (RCM) Technique
RCM Logic Tree
Determining the Task Interval
Failure Reporting, Analysis, and Corrective Action System (FRACAS)
Quantitative Failure Measures through Statistical Analysis
Application of SPC to Potential and Functional Failures
Failure Distribution
Distribution of Variations
Qualitative Analysis through Ishikawa, Cause Mapping, and Root Cause Analysis
Other Qualitative Failure Analysis Tools
Critical Investigation of Maintenance Engineering Techniques to Define an Implementation Process for the Food Industry
Total Productive Maintenance (TPM) Technique
Total Productive Maintenance (TPM) Implementation Principles
Operator Empowerment through Cooperation with Maintenance Specialists
TPM Organization
World-Class Manufacturing (WCM)
Total Quality Maintenance (TQMain) Technique
Terotechnology Principles
Conclusion
Critical Review of Condition Monitoring (CM) Techniques
Introduction
Online Monitoring Systems
Continuous Condition Monitoring and Remote Diagnosis
Analysis of Condition Monitoring Systems to Increase Maintenance Effectiveness
Infrared (IR) Thermography
Problems and Limitations of Infrared Thermography
Vibration Analysis
Types of Defects Detected by Vibration Analysis
Techniques Used to Measure Vibration
Oil Analysis (Tribology)
Application of Dempster–Shafer (D-S) Theory to Oil Monitoring
Tribological Failure Types and Their Features
Sensors for Continuous Monitoring (CM) of Critical Parameters
Conductivity Sensor for Cleaning in Place (CIP) Applications
Continuous Monitoring of Liquids
Continuous Monitoring of Liquid Concentration
Water pH Control
Water Treatment and Bacteria Measurement
Continuous Monitoring of Air Quality through Electronic Nose
Conclusion
The Process to Design Maintenance Procedures for the Food Industry
Introduction
Step 1: Application of HACCP Methodology
Activity 1: Listing All Hazards and Considerations of Any Control Measures to Eliminate or Minimize Hazards Depending on Equipment Functions and Operational Tasks
Activity 2: Establishment of Critical Control Points (CCPs)
Activity 3: Establishment of Critical Limits for Each CCP
Activity 4: Establishment of Monitoring System for Each CCP
Activity 5: Establishment of Corrective Actions
Activity 6: Establishment of Verification Procedures
Activity 7: Establishment of Record Keeping and Documentation
Step 2: Application of Reliability-Centered Maintenance (RCM)
System Selection
Boundary Definition and Operational Mode Summary
Failure Analysis
First: Fault Tree and What’s Different Analysis
Second: Root Cause Analysis and Cause Mapping
Third: Ishikawa with His Fishbone Diagram
Fourth: Five Why’s Technique
Functional and Potential Failure Determination
Failure Modes and Effects Analysis (FMEA)
Review of Maintenance History
Determine Maintenance Approach for Each Failure Effect
RCM Logic Tree for Task Selection
Determining the Task Interval
Step 3: Safety and Reliability Analysis through HACCP and RCM
Step 4: List of Priorities (Safety and Reliability Analysis)
Step 5: Design of Maintenance Tasks
Conclusion
Step 1: Application of HACCP Methodology to Manage Product Safety Criticalities
Step 2: Application of Maintenance Engineering Techniques to Manage Equipment Reliability Criticalities
Step 3: Safety and Reliability Analysis to Manage Product Safety and Equipment Reliability Criticalities
Step 4: List of Priorities (Safety and Reliability Analysis)
Step 5: Design of Maintenance Tasks
Proposals for a Maintenance Implementation Model for the Food Industry
Introduction
Analysis of Implementation Principles Considered
Total Productive Maintenance (TPM)
World-Class Manufacturing
First Step: Assess Current Situation
Second Step: Restore Basic Conditions/Deploy Quality Losses
Third Step: Eradicate Sporadic Losses
Fourth Step: Eradicate Chronic Losses
Fifth Step: Build the Zero Defect System
Sixth Step: Improve the Zero Defect System
Seventh Step: Maintain the Zero Defect System
Total Quality Maintenance
Terotechnology Principles
Proposal of a Maintenance Implementation Model for the Food Industry
First Step: Situation Analysis
Second Step: Define the Food Packaging Line Mandatory Requirements
Third Step: Top Management Involvement and Commitment
Fourth Step: Training and Education Campaign for Implementation of New Maintenance Procedures
Fifth Step: Design the Organization to Implement New Maintenance Procedures
Sixth Step: Restore Basic or Standard Conditions
Seventh Step: Develop a Scheduled Maintenance Checklist
Eighth Step: Develop Autonomous and Specialist Maintenance Integration
Key Performance Indicators (KPIs) to Monitor Production and Maintenance Effectiveness
Definitions
Stop Reasons
Performance Based on Producer View
Total Equipment Utilization (TEU)
Total Time Utilization (TTU)
Gross Production Time (GPT)
Production Gross Time Utilization (PGTU)
Overall Equipment Effectiveness (OEE)
Total Equipment Productivity (TEP)
Performance Based on Specific Equipment Focus
Simple Equipment Efficiency (SEE)
Mean Time between Failures (MTBF)
Mean Time to Restore (MTTR)
Performance Based on Containers Used
Containers’ Utilization (CU)
Containers’ Efficiency (CE)
Examples of Calculation
Examples of Data Collected to Calculate the Equipment Performance
Calculations Based on Data Collected
Overall Equipment Effectiveness
How to Measure Maintenance Effectiveness
How to Measure Maintenance Cost
Analysis of KPIs and Task List Improvement
Conclusion
End Product Quality Control
Quality Control Carried Out by the Equipment Operator
Pre- and Postproduction Cleaning and Maintenance Activities on Packaging Machines
Production Quality Control Procedures
End Product Criticalities
Statistical Sampling
Sampling Plan
How and When to Sample Containers
Distribution of Defective Units
Why Process Quality Is So Important
Quality Key Performance Indicators (KPIs)
Critical Factors to Manage in the Design and Implementation Process
Introduction
Technical Drawbacks
Equipment Reliability and Technological Problems
Lack of Technical Documentation, Training, and Service Support
Organizational Drawbacks
Lack of Autonomous Maintenance Carried Out by the Equipment Operator
Lack of Management Commitment and Involvement
Lack of a Planning and Measuring System
Cultural Drawbacks
Old Management Culture
Workforce Culture
Training for Equipment Operators and Maintenance Specialists
Conclusion
Conclusions
Introduction
Conclusions on Food Packaging Line Problems
Solutions to Manage the Effects Produced by Equipment Downtime and Failures
Solutions to Establish Compliance with Product Safety Directives and Standards
Solutions to Risks Depending on the Human Factor
Conclusions about the Critical Factors to Manage during the Design and Implementation Process
Solution to Technical Drawbacks
Solution to Organizational Drawbacks
Solution to Cultural Drawbacks
Solution to Old Management Culture
Solution to Lack of Workforce Commitment
Solution to Establish a Close Cooperation between Equipment Operators and Maintenance Specialists
Conclusions about Food Safety and the Equipment Reliability Problem
Possible Solutions
Software Program
Production Line Monitoring
Working Team
Contribution of This Book to the Achievement of Higher Product Safety and Equipment Reliability
Future Work on This Subject
Limitations
Summary
References
Biography
Dr. Sauro Riccetti obtained a graduate diploma in electrical and electronic engineering and membership to the Society of Engineers (London), then a postgraduate diploma and a master of science (MSc) degree in manufacturing engineering at the Open University (UK). He continued his research studies on maintenance and process engineering applied to the food industry, receiving his doctor of philosophy (PhD) degree in manufacturing engineering from the School of Engineering and Design at Brunel University (London). He is a member of the Institution of Engineering and Technology (UK) and a chartered engineer of the Engineering Council (UK).
Dr. Riccetti has worked in the food industry for more than 30 years. He carried out his research activities on maintenance and process engineering applied to the food industry and is actively involved in developing new products and services to improve food safety and equipment reliability in the food industry’s packaging lines.
His experience at Tetra Pak Italy and in holding several different positions including training manager, customer service director, and business development director, in addition to his involvement in improvement projects for the food industry, have enabled him to gain wide experience on maintenance and process engineering applied to the food industry.
Dr. Riccetti lives in Modena, Italy, and can be contacted at [email protected].
