INTEGRATING BOWTIE ANALYSIS INTO BAND SAW MAINTENANCE T. K. TsapiI*, M. K. Tongwa2 and B. D. Soh3 I,2*Department of Mechanical and Industrial Engineering, National Higher Polytechnic Institute, University of Bamenda, P.O Box, 39 Bambili, Cameroon. 3Department of Mechanical Engineering, Bandjoun University Institute of Technology, University of Dschang, P.O. Box: 134, Bandjoun, Cameroon *Corresponding author's email address: tsapimartial@yahoo.com ARID ZONE JOURNAL OF ENGINEERING, TECHNOLOGY & ENVIRONMENT AZOJETE September 2024. Vol. 20(3):633-644 Published by the Faculty of Engineering, University of Maiduguri, Maiduguri, Nigeria. Print ISSN: 1596-2490, Electronic ISSN: 2545-5818 www.azojete.com.ng Arid Zone Journal of Engineering, Technology and Environment, September 2024; Vol. 20(3)633-644. ISSN 1596-2490; e-ISSN 2545-5818; www.azojete.com.ng Tsapi et al: Integrating Bowtie Analysis into Band Saw Maintenance. AZOJETE, 20(3):633-644. ISSN 1596-2490; e-ISSN 2545-5818, www.azojete.com.ng 2 2 2 ARTICLE INFORMATION Submitted 29 February, 2024 Revised 25 March, 2024 Accepted 4 April, 2024 Keywords: Bowtie Analysis Band saw Cutting Machines Maintenance Manufacturing ABSTRACT Sawing machines used to cut raw materials to desired dimensions in industrial manufacturing operations are of great importance. Occupational injuries have occurred in the past as a result of failures in the risk management of these machines. In this paper, Bowtie analysis-based risk identification is developed based on the diagnosis of band saw cutting machine components. The results of the Bowtie risk assessment for hazards associated with the impeller, pump housing, saw blade, clamp, and seal pump were developed to structure the decision-making process with better information visualization. Hazards in the Bowtie were used to describe the root causes of failure (threats) that were identified, such as inadequate maintenance planning, foreign objects entering the pump, and inadequate maintenance. Based on the Bowtie diagrams, which capture the sufficient complexity of the real system behavior, the cutting tool was maintained following a corrective action plan that was developed. The assessment of the band saw performance rate after maintenance was 93%. This demonstrates that decision-makers can manage risk and reinforce a work culture that prioritizes actions to improve maintenance and safety outcomes using the Bowtie analysis method. 1.0 Introduction The semi-automatic band saw works on the principle of using a continuous toothed blade to cut metal sheets and bars. It is widely used in the woodworking, light, food, and metalworking industries where precision cutting is required (Tsapi et al., 2024, Kuldipia et al., 2023, Kohale et al., 2022). It is designed to provide higher efficiency and accuracy compared to traditional hand-operated tools such as hacksaws and angle grinders (Xue et al., 2024). Depending on the lateral flexibility and width of the band, band saws can be used to cut straight, irregular, or curved shapes (Alisinoglu et al., 2019). By automating the cutting process, the band saw reduces the risk of accidents and injuries that can occur with hand-operated tools. The semi-automatic band saw at Rolling Enterprise, located in the Northwest Region of Cameroon, was out of service. The company is involved in the machining of metal parts for automobiles. The company provides services in automobile maintenance, medical equipment maintenance and installation, electrical and electronic maintenance, and welding and fabrication of various components and parts. The prolonged downtime of the band saw significantly impacted the productivity of the manufacturing unit, resulting in delays in delivery times and a decrease in customer satisfaction. To address this issue, this research was initiated with the goal of rehabilitating the semi-automatic band saw, with a particular focus on improving the local work culture so that operators can develop a shared understanding of how their tasks contribute to the greater good of the company. This improves productivity and ensures timely delivery of products to customers. The Bowtie method, a visual risk assessment technique, was integrated into the corrective action process to analyze and communicate potential hazards, their causes, and related consequences and effects. 0. Materials and methods 0. Materials The maintenance was performed on the band saw with the machine designation Behringer Band saw KS 280HY. The semi-automatic band saw machine consists of several components and subsystems that work together to perform cutting operations on materials. The basic block diagram of a semi-automatic band saw machine includes the following parts (Patil and Waghmode, 2014); material stock, base or bed, cutting blade, blade guides, clamping system, cutting head, motor, control panel, cooling system, and belt that controls blade speed and feed adjustment. Figure I: Behringer band saw KS 280HY 2.0 Methods Within the framework of the research, several methods were used in the investigation. First, the diagnostic process was performed, followed by the implementation of the "Bowtie Methodology" to provide an overview of the risk associated with component failure and to identify the root causes of the failures. A comprehensive corrective action plan was then formulated. The Bowtie contains various risk elements; including hazards, root causes (threats), consequences, barriers and controls. The process for constructing the Bowtie diagram with the generic structure shown in Figure 2 was as follows: Figure 2: Generic structure of a Bowtie diagram (Aust and Pons, 2020) 1. Hazard: Identifying the hazard, which sets the scope and context of the risk assessment, was the first step in constructing the Bowtie diagram for the semi-automatic band saw. The hazard represented any condition of the band saw components that had the potential to cause harm or damage, including injury, to personnel; damage to equipment, property, or the environment; loss of material; or reduction in the ability to perform a prescribed function (ICAO, 2012). Start End Build a team Problem identification: diagnosis, problem condition description Corrective actions acceptable? Determine root causes from Bowtie diagram Determine corrective and preventive actions YES NoO Figure 3: Methodology by steps for root cause analysis and corrective actions (Tsapi et al., 2024) 1. Top event: Defining the top event was the next step, describing the point at which we lose control of the hazard. It has not yet caused any damage or impact, but can lead to undesirable outcomes if all prevention barriers fail (Aust and Pons, 2020). 1. Threats: Identify the threats that describe the causes that can lead to the release of the top event. In Bowtie, these threats are used to describe the root causes (Ispășoiu et al., 2021). 1. Barriers: Another important element of the Bowtie was the development of "controls" or "layers of protection" known as barriers. These controls are put in place to prevent the threat from occurring (left side of the Bowtie diagram) or to mitigate the consequences of the top event (right side of the Bowtie diagram) (Ispășoiu et al., 2021). 1. Consequences: Identifying the outcome of the top event, known as the consequences, was the last major component in developing the Bowtie diagram (Aust and Pons, 2020; Ispășoiu et al., 2021). The flowchart in Figure 3 was used throughout the root cause corrective action process and was adapted from the maintenance on a power hack saw (Tsapi et al., 2024). These root causes were identified using the Bowtie diagram. According to the Bowtie, the threats correspond to the root causes. 0. Results and discussion 0. Diagnosis and Bowtie analysis According to the diagnosis performed, the machine was visually inspected, checked for erosion, corrosion, cracks, setup and adjustment, etc., and a diagnosis table was prepared. Detailed information of the diagnosis performed on the semi-automatic band saw machine is shown in Table 1. Figure 4 shows some of the failed band saw components after the machine was thoroughly inspected. Figure 4: Failed band saw component example Based on the information presented in Table 1, a Bowtie Diagram was constructed using BowtieXP software to structure the relationships between the Top Event, Causes, Consequences, Proactive Barriers and Reactive Barriers (Figure 5-9). It consisted of identifying the damage, hazards and accidents that could occur with each failure and the consequences that could result. One of the risk reduction measures is to identify the barriers needed to reduce the likelihood of a particular accident occurring Table I: Diagnosis results No Component Symptom(s) 1 Impeller Cracks , Rust 2 Pump Housing Corroded and clearance of 2mm 3 Saw blade Broken teeth, Blond teeth … … … 10 Clamp Cracks 11 Seal Leakage … … … With this comprehensive view of the risk associated with the failure of the semi-automatic band saw, it was possible to develop a Bowtie model to structure the decision-making process, such as maintenance (resuscitation of the band saw), risk management with better information visualization. Through the Bowtie, the risk faced at any given time can be managed to an acceptable level by implementing barriers to prevent an undesirable incident from occurring (Abia et al., 2019) or by limiting its consequences. 1. Damaged impeller There was rust and cracking on the surface of the impeller, which severely affected the cooling efficiency of the cutting machine. Rust obstructed airflow, reducing the impeller's ability to effectively cool the machine. Cracks also lead to further damage or failure of the impeller, resulting in inadequate cooling and potential overheating problems. Based on similar findings of impeller corrosion failure (Ul‐Hamid et al., 2015), significant rust was observed on the impeller of a water pump as a result of exposure to oxygen and moisture, which was also the case for the pump of the semi-automatic band saw machine at Rolling Enterprise. The suggested impeller Bowtie Diagram, Figure 5, shows the preventive and mitigating controls for each of the causes. Implementing any of these controls will prevent the impeller from failing, without which there will be a reduction in pump efficiency, reduction in flow, lubricant contamination, pump failure and impeller wear. To limit the impact of this reduced pump efficiency, only a few mitigation barriers were practiced by the machine operators and maintenance personnel. It should be noted that not all controls need to be in place to prevent the hazards from occurring or to mitigate the consequences of the failed impeller, because ideally, the control measures, or barriers should be independent of each other to avoid any common mode of failure (Xie et al., 2018). 1. Pump Housing A clearance of 2 mm in the casing, another important part of the pump (Olorunfemi et al., 2018), shown in Figure 4, was found between the impeller shaft and the pump casing ideal, which resulted in reduced pump efficiency. A Venier caliper was used to measure this clearance. The clearance in the pump casing indicated excessive wear or improper assembly. This clearance resulted in reduced flow and leaks or malfunctions in the cooling system. Figure 6: Bowtie diagram of a pump housing Figure 6 shows some of the preventive and mitigating controls that can be put in place to reduce the impact of the consequences and prevent the pump from failing. It shows on the left and right, respectively, the mitigating and preventive controls that can be implemented to prevent the hazard from occurring, and the mitigating barriers that can limit or reduce the impact of the consequences that can result from foreign matter entering the pump as observed during the diagnosis (Figure 4). 1. Saw Blade The saw blade had broken and blunt teeth, resulting in poor cutting performance. Comparing the results of the diagnosis with the modeling of wear and blunt blade transformations (Zhuo et al.,2022), the diagnosis of a saw blade revealed that the blade was warped and bent when visually inspected or when its straightness was measured using tools such as precision straight edges. Figure 7 shows the bowtie diagram for the saw blade with recommended prevention and mitigation measures. Figure 7: Bowtie diagram of a saw blade 1. Clamp Visual inspection of the clamp revealed cracks that compromised the safety and functionality of the machine. That is, its ability to securely hold the work piece during cutting becomes questionable. Replacement/repair of the clamp was required to ensure proper and secure holding of the work piece during cutting. Figure 8 shows the Bowtie diagram for a cracked clamp on the band saw as observed during inspection (see Figure 10, weld clamp) with preventive and mitigating barriers. Figure 8: Bowtie Diagram of a Clamp 1. Pump Seal Poor sealing of the pump seal caused fluid loss and reduced pump efficiency. This resulted in an ineffective seal, which led to fluid loss and reduced pump efficiency. Leaks also caused problems throughout the cooling system. Repair or replacement of the pump seal was necessary to prevent further damage and ensure proper operation (Shiels, 2002). Figure 9 shows the Bowtie diagram for the seal on the cooling system of the semi-automatic band saw machine. The seal was worn out. Figure 9: Bowtie diagram of a pump Seal 0. Root causes from Bowtie diagram The root cause corrective action process is a valuable tool for maintenance professionals who want to address and prevent problems in a structured and systematic way. The root causes of previously reported failures were identified using the bowtie diagram because the threats in the bowtie diagrams in Figures 5-9 correspond to the root causes. 1. Impeller From the Bowtie diagram for the impeller, the presence of rust and holes on the impeller of a water pump led to a failed impeller. Rust is known to create rough surfaces and irregularities on the impeller blades, which disrupts the flow of fluid (Zhuo et al., 2022, Zariatin et al., 2019). The underlying factors or hazards that led to this failed impeller include; 1. Inadequate maintenance: If a centrifugal pump is not properly or regularly maintained, there is a high probability that individual components such as the impeller will fail. Of the 6M categories (Aust and Pons, 2020), this root cause was method, meaning the maintenance procedures and processes were not the best to prevent rust from affecting the impeller blades. The Bowtie diagram in Figure 5 provided controls that should be used to prevent this particular threat from occurring; training personnel on proper pump maintenance, performing regular inspections and others from the left side of the Bowtie. 1. Foreign Objects: The impeller could have failed because the working environment (Mother Nature) was not conducive, an example is when iron fillings get into the pump during cutting, causing abrasion, metals rubbing against each other causing wear. When these foreign bodies such as iron fillings enter the water pump, it reduces the flow rate of the fluid or lubricant because the impeller transfers some of the energy received from the motor to the foreign particles and their presence has already contaminated the fluid leaving the centrifugal pump. 1. Poor Quality Pump: The material of the pump was not the best and this could cause the impeller to fail and eventually cause the pump to fail completely. The barriers to mitigate and prevent this cause are shown in the Bowtie diagram (Figure 5). 1. Air entering the pump: The impeller transfers energy from the motor to the fluid and during this process there is a change in temperature, so if air gets into the pump while the impeller blades are rotating, it will create bubbles and when they collapse it will cause cavitation wear which will eventually cause the pump to fail. This cause was caused by Mother Nature according to the 6M categories. 1. Pump Housing The Bowtie diagram of the pump housing (Figure 6), which has a clearance of 2mm and was experiencing rust as shown in Figure 3, originated from one of the following causes: 1. Lack of regular inspection: A machine or component cannot run optimally for weeks, months and years if it isn't inspected from time to time. The lack of regular inspection on the pump casing resulted in a 2mm clearance between the impeller shaft and the pump casing bushing. This resulted in further damage to the brass bushing in the pump casing. 1. Inadequate repair and replacement procedures, training and awareness could also have resulted in reduced pump efficiency and performance, which could have further resulted in unplanned downtime of the semi-automatic machine. 1. Improper pump installation and/or inadequate protective coating, such as anti-rust paint, may also have caused clearance in the pump casing; vibration that can damage the impeller shaft and result in increased maintenance costs. 1. Saw Blade The saw blade damage with blunt and broken teeth as shown in Figure 4 resulted in the saw blade becoming stuck during operation. The causes of this top event were improper use of the blade because the band saw blade has been used to form keyways on pulleys, causing the blade to lose some of its teeth and become blond. This cause is man-made and results in damage to the work piece because the cuts are very rough. 1. Clamp Clamp damage due to fatigue and wear caused by constant stress and strain on the clamp, resulting in cracks in the clamp that can cause accidents during operation. The use of inferior clamps, overloading of the clamp, and improper installation are also factors that can cause the clamp to crack. 1. Seal The seal had been used without maintenance, causing it to wear out and leak fluid, and other factors that caused the seal to leak included improper installation and the use of inferior seals. 0. Corrective actions Cleaning and descaling were the initial corrective actions for the rusted impeller. After cleaning the impeller, a rust inhibitor was applied to the surface of the impeller blade to dissolve and remove any remaining scale. After corrosion prevention and rust removal techniques in steel structures (Gowri-Shankar and Ponnsahana, 2021), the impeller was then polished/grinded with sandpaper. By removing the uneven surfaces caused by rust, the impeller regained its original shape and improved performance. Rust inhibitor was then applied and left to cure in the sun to protect the machine part from rust and corrosion, thereby extending its life and reducing maintenance costs (Thompson et al., 2007). Corrective action to maintain the pump casing included cleaning it with detergent and an iron brush. Rust inhibitor was sprayed on the pump casing to dissolve any rust deposits. The iron brush was then used to remove any remaining rust. The casing was then sanded to remove any uneven surfaces (Gowri-Shankar and Ponnsahana, 2021). A 12 mm brass cone was mounted on a lathe (see Figure 10) and turned to reduce the outside diameter by 2mm. The steel cone was then mounted into the pump housing and pressed by hand to fill the space in the pump with clearance. Figure 10: Maintenance: resurfacing brass cone, welding clamp, maintained parts It was critical to replace the saw blade with a new one suitable for the specific application. The saw blade was replaced by purchasing a new blade as shown in Figure 10. The new blade was then installed and properly tensioned using a wrench. Corrective action on the clamp included cleaning with a liquid chemical and an iron brush. The clamp was then allowed to dry and CHE-40 electrodes were used in conjunction with a welder to fill in the cracks. An angle grinder was then used to smooth the surface of the clamp. Table 2: Summary of Corrective actions carried out Main Corrective Actions State of Resolution Verification Method 1. Impeller was sand papered to ensure smooth surface and sprayed with anti-rust operational Poured lubricant into tank and impeller was able to provide energy to move the lubricant 2. Pump housing was filled with brass material Failed The impeller shaft and the housing had spacing between them 3. Saw blade replaced Operational Cut various pieces of different dimensions 4. Clamp was welded using Sarf 40mm electrode Operational Held different pieces together 6. Pump Seal replaced Operational No leakage on the pump when lubricant is placed in it A new gasket was then designed on solid blocks and tests were conducted to determine the best material to form a gasket. In the first test, a slipper (PVC) was cut with an industrial blade and used to form a seal. After the seal was installed, there was severe leakage at the pump outlet and the lubricant could not flow because the seal could not withstand the pressure from the impeller. In the second test, an EPDM synthetic rubber from automobile tires was used to form the seal. The seal was able to withstand the pressure from the impeller, allowing the lubricant to flow more efficiently to the blade. Table 2 summarizes the main activities for maintaining the band saw, while Figure 11 shows the band saw after corrective action and ready for control testing. According to the corrective actions performed, PVC plasticizes and becomes brittle and even shatters at certain temperatures, whereas EPDM synthetic rubber can withstand certain temperatures and pressures. Figure 11: Band saw after Maintenance 0. Monitoring and evaluation The performance rate, which compares the time the machine should be cutting (ideal time) to the actual time the machine spent cutting 60x30mm round tubing, was 93% (Table 3). This indicates that the machine was achieving 93% of its maximum speed or output efficiency; therefore, it was operating close to its optimum performance level with minimal downtime, interruptions, or inefficiencies that would affect its overall productivity. Table 3: Performance Calculation Operating Time Per Shift (min) 21 22 20.3 22.7 22 Output per shift (Numbers) 6 6 6 6 6 Ideal Cycle time 4 4 4 4 4 Performance rate 0.9523 0.909 0.985 0.881 0.909 Average Performance 0.927 1. Conclusion The main objective of the research was to restore the semi-automatic band saw machine owned by Rolling Enterprise to a functional state with improved reliability. After conducting a comprehensive analysis, numerous conclusions were drawn from the research. The results showed that the malfunction of more than 11 components, including the impeller, pump housing, seal, saw blade, clamp, bearings, gears, belts, and motor, prevented the machine from working successfully. After using Bowtie diagrams, a visual risk assessment tool, to analyze potential hazards or root causes, it was determined that the failures were due to several factors, including poor maintenance, the presence of foreign objects such as iron filings, poor quality of certain components, fatigue, wear and numerous others. Through the use of diagnostics, root cause analysis and corrective maintenance, a successful resuscitation of the semi-automatic band saw was achieved. It was imperative to demonstrate that the methods used in the research could be implemented by numerous manufacturing and production companies to optimize the maintenance and effectiveness of their production equipment. Acknowledgement The authors acknowledge the support received from Mr. Simon Ngumbi Audi, Manager of Rollings Enterprise, which enabled the timely completion of this research. References Abia, D., Iwegbu, M., Onofeghara, C. and Anozie, I. 2019. 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Research on online intelligent monitoring system of band saw blade wear status based on multi-feature fusion of acoustic emission signals. The International Journal of Advanced Manufacturing Technology, 121(7-8): 4533-4548. image3.jpeg image4.png image5.jpeg image6.jpeg image7.jpeg image8.jpeg image9.jpeg image10.emf image11.emf image12.emf image13.emf image14.emf image15.jpeg image16.jpeg image17.jpeg image18.jpeg image19.jpeg image20.jpeg image21.jpeg image1.png image2.jpeg Faulty Impeller Rusted Impeller with small small holes Regular monitoring and evaluation of pump performance Develop and implement a comprehensive maintenance schedule Regular inspection and testing of pumps to identify potential issues Train personels on proper pump maintenance procedures. Inadequate Maintenance planning Regular lubricant analysis to detect contamination early Employee traning on proper lubricant handling and storage Regular cleaning and Regular inspection Foreign object entering the pump Proper pump selection and sizing to ensure that it meets the operational requrements Regular monitoring and evaluation of pump performance Poor quality pump Regular Inspection and maintenance of seals. Mother nature: Air entering the water pump Regular evaluation and optimization of pump operation Use performance monitoring and optimization techniques to identify and resolve the efficiency problems Implementation of pump maintenance and repair procedures 1. Reduced pump efficiency Timely maintenance and cleaning of the pump Performance evaluation and optimization Proper lubicant storage implementation 2. lubricant contamination and reduced flow rate Investigate and analyse the past pump failures to identify root causes and prevent future occurence Implement a robust maintenance and inspection program 3. Pump failure Implement immediate shutdown and carrryout maintenance on the impeller 4. Cavitation/erosion wear Pump Failure Pump housing clearance and rust Schedule regular maintenance activities to clean and lubricate pump housing Routine inspections to detect clearance issues and rust formation Lack of regular inspection Purchase spare parts for replacement Establish maintenance procedures Insufficient repair and replacement procedures Ensure precision alignment during pump housing installation Improper installation Provide trainings on proper maintenance techniques and raise awareness about the risks of clearance and rust issues Inadequate training and awareness Apply corrosion- resistant coating Inadequate Protecting coatings Conduct timely repairs or replacements of damaged components Implement preventive maintenance procedures Damaged Pump Components Regularly monitor pump performance and conduct performance evaluation Reduced pump efficiency and performance Develop contigency plans and spare parts inventory for quick replacements Unplanned machine downtime Utilize predictive maintenance techniques to identify issues befor they escalate Increased maintenance cost The saw blade becomes stuck during operation Sawblade with blunt and broken teeth Regular maintenance and inspection Inadequate maintenance Training and awareness Improper use Use high quality blades Poor quality or worn-out blade Implement safety measures Operator safety threats Robust repair /replacement of the sawblade Workpeice damage Monitoring the blade performance and feedback Equipment damage Clamp failure during operation Partial cracks on clamp Regular inspection and maintenance Fatigue due to constand stress and strain on the clamp Ensuring proper material selection and quality control during clamp manufacturing Poor quality clamps Ensure clamp is not overloaded Overloading the clamp Proper allignment and installation Improper installation of the clamp Implement NDTE Environmental factors such as extreme heat or cold Conduct risk assesment to identify the hazard and implement safety protocols Accidents that could harm operator Repair or replacement cost Extended downtime and delay in project timelines Leakage seal of the pump Fluid leakage Regular Maintenance Wear and tear Quality control by using high quality seals during installation Poor quality seal Proper Installation Incorrect installation Emergency response Machine downtime Backup pumps Production Delays Robust Maintenance Air will get into the waterpump which can lead to cavitation wear.