The growths of present day industries are forced towards the use of more and more complex systems. The production system consists of thousands of parts and components. The failure of one or more components may lead to affect the entire production system. So, with the increase in automation and usage of complex systems, evaluation of Reliability has recently been recognized for effective maintenance. Reliability has been evaluated mostly for electronic components since and presently we are going to calculate reliability for components in a process industry. For this purpose, the break down time is calculated from sugar Industry. The data is analyzed and reliability is calculated for each component by Weibull distribution in probability. Reliability is analyzed and criticality of each component is found by using FMEA(Failure Mode Effect Analysis) to suggest some of the preventive maintenance schedules. The study was carried in sugar mills limited in TamilNadu. The crushing capacity of the plant is 3500 Tones per day. The various processing sections of the factory are namely loading section, Mill section and boiling section. The preliminary discussions with the official's concerned reveal that the plant is often giving rise to problems due to break down of various components. Hence, it is decided to carry out failure analysis in this industry and to suggest measures to improve the availability of the components. The objective of this study is to estimate availability, reliability of the component system and also to perform the FMEAanalysis to identify the critical components to prepare Preventive Maintenance (PM) schedules by the officials. The methodology followed to achieve this are Collection of the historical failure data of the production system, Calculating the down time and the availability of the equipment from the past data, Modeling the failure history using Weibull statistical distribution, Estimation of Reliability usingWeibull parameters, Calculating criticality index of all the components using FMEA software and finally the preparation of maintenance schedule. It is possible to correlate the equipment reliability with maintenance requirements. To attain maximum productivity it is necessary that man minimize failure. This can be achieved by proper maintenance and timely replacement of some parts of machines or at times the whole equipment. An attempt has been made in this work to study the failure pattern and down time of the components. The critical components are also identified by carryingFMEAanalysis.

Keywords: Failure Mode Effect Analysis,Weibull Distribution parameters, Criticality Index, Maintenance schedule  &Sugar Industry.