Reliability and Preventive Maintenance Analysis of Case Packer and Carton Taping Machines

Abstract

Packaging lines depend on the reliable operation of mechanical, pneumatic, electrical, and control components, and the failure of even one small component can stop an entire production line. This study presents a failure-part analysis and preventive maintenance study of two machines commonly used together on a packaging line: a case packer machine, used to group and load bottles or products into cartons or cases, and a carton taping machine, used to close and seal the loaded cartons with adhesive tape. Using a functional decomposition and criticality-classification approach drawn from reliability-centred 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, together with a framework for future failure-data collection to support calculation of MTBF, MTTR and availability.