Failure Part Analysis and Preventive Maintenance of Bottle Filling Machine and Bottle Capping Machine

Abstract

Bottling and packaging lines depend on the reliable operation of mechanical, pneumatic, electrical, and control components, and a failure in even one small component can stop the complete production line. This paper presents a failure-part analysis and preventive maintenance study of two machines commonly used together on a bottling line: a bottle filling machine, used for dispensing a measured quantity of liquid product into bottles, and a bottle capping machine, used for placing and tightening caps on the filled bottles. Using a functional decomposition and criticality-classification approach drawn from reliability-centered maintenance and failure mode and effect analysis practice, the study identifies individual failure-prone components, their typical failure modes, effects on production, detection methods and preventive or corrective actions, for a continuous operating basis of 24 hours per day, 7 days per week, and 365 days per year (8,760 operating hours annually). A qualitative criticality classification and a structured preventive maintenance checklist are presented, along with a framework for future failure-data collection to support calculation of MTBF, MTTR and availability.