This study investigated the breakdown trend in an automated production with an aim to recommend the application of reliability-centered maintenance (RCM) for improved productivity via a new preventive maintenance (PM) program. An individual section-forming machine (ISM)—a glass blowing machine for making glass bottles—was used as the case study for an automated production system. The machine parts and the working mechanisms were analysed with a special focus on methods of processes and procedures. This will enable the ISM maintenance department to run more effectively and achieve its essential goal of ensuring effective machine operation and reduction in machine downtime. In this work, information is provided on the steps and procedures to identify critical components of the ISM using failure modes and effect analysis (FMEA) as a tool to come up with an optimal and efficient maintenance program using the reliability data of the equipment’s functional components. A relationship between the failure rate of the machine components and the maintenance costs was established such that using the recommended PM program demonstrates evidence of an improvement in the machine’s availability, safety, and cost-effectiveness and will result in an increase in the company’s profit margin.

This review investigates the impact of maintenance methods on machine reliability, focusing on their relationship with overall performance, durability, and availability. It emphasizes the importance of proactive maintenance, such as preventive maintenance, to identify and treat potential issues before they become significant failures. The review also examines the effectiveness of various maintenance procedures in enhancing machine reliability, examining the cost-benefit ratio of maintenance programs and the potential savings gained through improved reliability. The review highlights the role of maintenance methods in limiting risks and enhancing performance, emphasizing the importance of proper maintenance practices in ensuring smooth operations and reducing downtime.

The mechanism of graphite formation on gray cast iron metal during carburisation process using organic nano-carbon (ONC) was investigated at 900 °C for a holding time of three (3) hours. TEM and XRD were employed to characterize the pulverised nano-carbon to determine their phases and bonding potentials. Also, SEM/EDS, XRD and Vickers' hardness tester were employed to determine the microstructure, phase compositions as well as hardness and wear properties of the carburised material. The microstructural result showed that, there was uniform carbon diffusion into the substrate material which led to layers of graphite formation and subsequent surface modifications for each of the selected nano-carbon used. Also, the XRD results revealed variations in the peak patterns for each of the substrate carburised with different organic carbon with substrates showing graphite and iron phases as observed in that carburised in pulverised palm kernel shell having broad peaks at 35.50o, 44.4o, 65.12o and 82.395o. This is traceable to amorphous properties and crystalline behaviour of the organic carbon. Further to this, the micro-hardness measurement showed that substrate carburised using pulverised palm kernel shell performed better compared to other substrates in other media with a micro hardness value of 355.8 (HV) against as-received which is 116.9 (HV). Thus, this is a novel and possible method of improving the properties of grey cast iron to meet the increasing demand in gear applications.

The majority of wear-related problems are connected to crushing machines because hammer failure frequently causes machine failure which eventually leads to machine downtime. Therefore, improving the reliability of crushing materials is necessary for effective production. This research investigation focused on the development of crushing material with appropriate strength properties that can function in critical, impact-prone, corrosive, and abrasive conditions. The current study used palm kernel shell, coconut shell, and sawdust powder as the media for medium carbon steel in order to valorize the agro waste. Carburising media PKS-composition, CS-composition, and SD-composition were changed to 40%: 30%: 30%, PKS-composition 100%, CS-composition 100%, and SD-composition 100%. The process was carried out in 1 h (60 mims), 1 h:30 min (90 min), 2 h (120 min), 2 h:30 (150 min), and 3 h (180 min) soak period with varied carburising temperatures of 900, 950, 1000, and 1050 °C. However, several characterisation and mechanical tests were carried out using an optical microscope, a spark spectrometer, a scanning electron microscope coupled with an energy dispersive spectrometer, wear tester to explore their microstructural features. Vicker's hardness tester, sliding wear tester, and a thermal gravimetric analysis testing machine were also employed. In order to establish reasons for failure other than the cyclic loading on the materials, the results were compared with the properties of as-received un-failed, and carburised medium carbon steel. The results of carburisation show that PKS penetrates carbon at a rate that is noticeably higher than that of other materials at various temperatures and times, indicating that carbon diffuses deeply into the material. Hence, this enhances the wear resistance, and sample's hardness number but decreased its impact toughness respectively.

Condition monitoring is an essential technique which is usually deployed to monitor the health parameters and conditions of a boiler plant in such a way that variations or significant changes can like failure can be identified and proffer adequate solutions to it. It is an important aspect of condition-based maintenance which is used in maintaining an equipment according to its conditions. Thus, this study focused on the fundamental principles of condition monitoring which involve the identification and selection of a physical measurement that will show the deterioration stage and the importance of taking the readings at intervals. More so, the study established that monitoring and measurement should focus more at critical components that have high frequency of failure. Thus, condition-based maintenance of boilers will help in improving the ,availability of the boiler.

The study employed Fick’s second law of diffusion to discover some unknown aspect of carbon diffusion in grey cast iron during carburisation process. Emphasis on the experiments and theoretical modelling were established for better accomplishments. Pulverised palm kernel and eggshell additives of 70 (wt.%) and 30 (wt.%) according to the Voige law of mixture was considered as a continuous medium without considering the atomic nature of the mixture. Furthermore, a kinetic approach was described where a physical model of the substrate immersed in the carbon mixture was established while diffusion equations were modelled to establish the mechanism of carbon diffusion during carburisation. Initial composition and concentration of diffused atom remained constant which are 2.68 and 6.67% carbon. While the carburizing time used varied from 60 min, 90 min, 120 min, 150 min, 180 min and 210 min respectively at constant carburising temperature of 900° The results revealed varying composition gradient of carbon atom ranging from 5.4%, 5.42%, 5.44%, 5.46%, 5.51%, and 5.65 compared to the initial carbon content of 2.68%. The concentration of carbon atom on the substrate surface at varying time implies that the process was non-steady state diffusion which verified Fick’s second law of diffusion. Hence, the composition achieved is a function of boundary conditions such as time position and temperature. This novel study will enhance the understanding of heat treat treatment of metals such that their applications in the industry will be numerous.