Find the reliability of the module. Justifying the Cost of Preventive Maintenance », Federal Bureau of Investigation Careers », NFMT - Facilities Education and Conference. I’m a triathlete, so I measure an unusual amount of stuff. Maximize overall operating effectiveness of assets, Build a culture of pride and ownership in the workplace, Early detection, correction, and prevention of deterioration and avoidance of failure, Maintenance work performed on the equipment, Improvement of output, product quality, and customer service, Greater safety and environmental compliance, An asset historical database for performance monitoring and future improvements, Sense of ownership from operators and maintenance personnel. For example, a facility is responsible for maintaining a standard air-handling unit (AHU) that has operated for 3,600 hours over the past two years. A Computerized Maintenance Management System (CMMS) is a tool that can help maintain records and data of the assets such as: Once a system or process is established to retrieve the asset performance data a recurrent visual or numeric representation must be generated to measure the performance of the equipment and identify if the changes that were implemented are delivering the expected results. Below are examples of tracking and measuring that can produce tangible results for both departments and facilities. ... and the equipment used all affect reliability. Class A equipment – Most critical Assets. Institutionalize a program that engages operators with equipment reliability focus goals. Maintenance will also help you make sure that your equipment are still safe to be operated. Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities equipment that are subject to wear, erosion, deterioration, aging, etc., resulting in increasing breakdowns and outages. Maintenance, Measurement and Equipment Reliability. For example, Supplier 1's reliability at 10,000 miles is 36.79%, whereas Supplier 2's reliability at 10,000 miles is 50.92%. Reliability Engineers are in charge of optimizing manufacturing processes by using their engineering knowledge. The calculation for this is: R(t) = e (-t), where: •e is the weighted average value of a random variable, or the expected value. For example, the function of a conveyor belt system is to transport goods. This calculation gets a little more complicated mathematically. A pacemaker, for example, is expected to perform without failure during its useful life. The equipment selected should be critical in terms of its effect on operations, its previous costs of repair, and previous costs of preventive maintenance. It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. reliability if the i-th component is denoted by r i, the system reliability is R s = (r 1)(r 2 )L(r n) A B C 20 Components in Series Example 6: A module of a satellite monitoring system has 500 components in series. The equipment, however, is a mix of vintages from the 1950s to the 1970s, causing concern for system reliability due to the age of the equipment. Availability. •t is 1 divided by MTBF. Not all failures can be prevented by maintenance. MTBF is a basic measure of an asset’s reliability. See the example below. Before discussing how reliability and availability are calculated, let’s understand the incident service metrics used in these calculations. The average for North American business is about 7 to 8 percent. Although centrifugal compressors are less exposed than their axial counterparts, field experience has shown that inlet guide vanes and impellers can fail under very specific circumstances. Everyone who has worked in a complex organizational structure like that required in manufacturing knows that there is a need to constantly fight against the tendency towards thinking in silos. The Concepts of Reliability and Validity Explained With Examples. As goes our personal lives, so goes our work. Let’s start by exploring what is the intention of a Reliability Program. Let’s use “maintenance cost/replacement asset value” as an example. Focus on design for reliability, operability, maintainability, safety and inspectability (ROMSI) Most … The first step is to select the piece of equipment for reliability-centered maintenance analysis. Reliability is the ability of things to perform over time in a variety of expected conditions. Primary Function- usually explain what the intention was for acquiring the asset. Sometimes this global goal is expressed in t… reliability analysis of mining equipment such as load-haul-dump (LHD) machines [1, 16, 17]. What can be done to predict or prevent each failure? Whatever you call it — metrics, measurements, or key performance indicators (KPI) — maintenance and engineering managers must have performance measurements in place either to validate that the work their staffs are performing in achieving the departments’ goals and objectives or to identify opportunities for continuous improvement. Modeling 2. The equipment belongs to a system that performs a crucial function. Troubleshooting is trying to discover the physical or equipment cause of the failure. Establish KPI and Reports to monitor the success of the actions implemented. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. Reliability engineering is the design, production and operation of things to retain their quality over time. Champions the rotating equipment reliability efforts in assigned areas of responsibility by providing technical assistance in resolving equipment design, operation, and maintenance problems Ensure all work is performed safely and in accordance with all Calumet procedures We focus on three major areas: Energy efficiency, Maintenance Cost and Equipment Reliability. MTBF. How many miles I run, bike or swim? All research is conducted via the use of scientific tests and measures, which yield certain observations and data. This measurement typically is expressed in hours. These measurements enable managers to track equipment, personnel and reliability performance. Typical resume examples for this job mention duties like testing processes, identifying low performance areas, determining ways to cut costs, making inspections on the field, and reporting to … May 2017 Special Focus: Maintenance and Reliability Equipment critical analysis: The need for an effective maintenance program. Its inputs a… After years of operating, many CPI plants lose track of the main goals of their maintenance program. Title: Microsoft PowerPoint - Equipment Reliability - INPO - George Manaskie.pptx Author: e25854 Created Date: 6/27/2017 7:06:30 PM Oil Analysis and Its Role In Equipment Reliability. It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. Reliability Distributions One of the goals of this process is to define the functions of each asset by asking these two questions: Is the asset capable of doing what the users expect it to do? A traceability matrix must be maintained to keep track of the recommendations that were implemented. I suggest you start with the “low hanging fruits” and built on top of those. Durability Subsystem 1 has a reliability of 99.5%, subsystem 2 has a reliability of 98.7% and subsystem 3 has a reliability of 97.3% for a mission of 100 hours. research in the area of reliability engineering for medical equipment mainly considers the devices in their design or manufacturing stage and suggests some techniques to improve the reliability. The result is 300 operating hours. It is vital that each function and department links themselves to the overarching objective of the whole. With HI analysis used in the Plant Wellness Way philosophy you would correct the misalignment so there could be no opportunity to overload the bearing. This step is crucial since it creates the foundation for a well-implemented reliability program that will yield remarkable improvements in reliability and performance. The result is 78.68 percent. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. Assemble a multidisciplinary team to participate in the equipment reliability process. For example the machine is down 6 minutes every hour. Taking the total time to repair the unit and dividing that number by the number of failures produces an average time to repair the unit of 60 minutes. Impact criteria to be considered are: This exercise should be conducted with a facilitator that will guide a multidisciplinary team. For example, Supplier 1's reliability at 10,000 miles is 36.79%, whereas Supplier 2's reliability at 10,000 miles is 50.92%. reliability analysis of mining equipment such as load-haul-dump (LHD) machines [1, 16, 17]. RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. Overall Equipment Effectiveness (OEE). Performed an Assets Criticality Assessment to identify work areas for maintenance reliability improvement actions. The term equipment reliability and maintenance (ERM) encompasses not only equipment, such as machines, tools, and fixtures, but also the technical, operational, and management activities, ranging from equipment specifications to daily operation and maintenance, required to sustain the performance of manufacturing equipment throughout its useful life. Utilizing hydraulic energy from the flow of a river or stream, the Noria utilized buckets to transfer water to troughs, viaducts and other distribution devices to irrigate fi… Using the SnapCharT® Diagram is also taught on Day 1. The result is 300 operating hours. Tracking the reliability of facility equipment can help maintain and decrease time spent on repairs. What should be done if a suitable proactive task cannot be found? Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. Reliability is the probability that a system performs correctly during a specific time duration. (Learn more about availability metrics and the 9s of availability.) Equipment manufacturers must design for reliability, and in particular High Cycle Fatigue (HCF) of stationary and rotating components is one area of focus. For managers, measuring and monitoring their departments’ activities is essential in determining the way that these activities affect the facility’s overall condition and performance. In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. MTTR. The reason I do these things is that I want to improve in some way. Three subsystems are reliability-wise in series and make up a system. actions. The AHU’s blower unit has failed 12 times over this period. An example of an equipment failure related SnapCharT® is shown below… Notice that the Causal Factor (Mechanic installs impeller backward) is included on the SnapCharT®. There’s not a day that goes by that I don’t measure something. A piece of equipment can be available but not reliable. For example, one of the key factors affecting the reliability of electronic components and systems is temperature – basically the higher the temperature of the device the higher the failure rate. I don’t think that we can ever escape measuring, tracking or following things. Before diving into the reliability program key elements, we must understand the meaning of equipment reliability. To perform a thorough reliability exercise on a system or assets we should answer these seven basics questions: As you can imagine, these questions cannot be answered by the maintenance personnel on their own since some are closely related to the user intended function. Some of the recommendations will be easy to implement and others will require a project to be implemented. It is recommended to include departments that directly or indirectly have an interest in the equipment reliability such as, finance, quality, safety/environmental, among others. In these studies, graphical and analytical techniques have been used to fit probability distributions for the characterization of failure data, and reliability assessments of repairable mining machines have been reported in these papers. Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … This chapter addresses all causes of … The first step in laying the groundwork for an FMEA-based reliability improvement effort is to identify candidate equipment. Secondary Function- what is embedded in its function such as safety, ergonomics, efficiency, compliance, etc. Equipment reliability is about a client taking legal accountability of any damage or loss that comes to the equipment they borrow. What is the probability of failure? In this liability form, they are informed of releasing liability and instructions or conditions in handling the borrowed equipment. For example, if a pump is producing less than the rated flow, we might want to know why. Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … For example, reliability can develop the following lists: top 10 list of defective equipment — based on maintenance and lost opportunities bad actors — equipment with three or more failures in a two-year period repeat offenders — equipment with repeated failures in the past six months. The target will be zero failures, Class B equipment – Demand for maximum availability is required, Class C equipment – Maintenance task must be kept to a minimum. Technicians can extend the equipment’s availability by increasing its reliability. Since additional pumps were added to the original system, there was also a concern as to whether the overall system reliability was prop-erly considered with each addition. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. What is the overall reliability of the system for a 100-hour mission? So the MTTR is one hour. MTBF is a basic measure of an asset’s reliability. This generally means ensuring that things continue to conform to requirements in the face of real world conditions. The optimal maintenance and reliability program for a plant provides the right maintenance on the right assets at the right time. It is a maintenance best practice to maintain the asset historical data archive for future evaluation. Assemble a multidisciplinary team to participate in the reliability studies. RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. Probability of failure. Contributes to and develops maintenance and repair procedures used to improve equipment reliability, safety and efficiency and control equipment repair costs Responsible for computer data entry into work orders, ordering equipment and parts through SAP reservations and requisitions, and performing root cause analysis on equipment malfunctions To perform a thorough … For example, a 99.999% (Five-9’s) availability refers to 5 minutes and 15 seconds of downtime per year. The study of component and process reliability is the basis of many efficiency evaluations in Operations Management discipline. That may be okay in some circumstances but what if this is a paper machine? If you are a mining company, your best site may be 7 percent and worst site may be over 20 percent. I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be on continuous improvement. In what ways does it fail to fulfill its functions? The availability of an asset will diminish over time as the equipment is being used. Some failures are the result of … By continuing with the above example of the AHU, its availability is: 300 divided by 360. In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. Testing classes are applicable to all commercial, military and aerospace requirements. At the end of the day, each of these measurements has a financial impact on the organization. For example, after experiencing a rare equipment failure, a plant instituted If we discover that the impellor on a double volute pump was installed backward, we have completed the troubleshooting of … Fig. This measurement expresses the probability that an asset can perform its intended function satisfactorily when needed in a stated environment. • - In probability theory and statistics, the exponential distribution, which is also known as negative exponential distribution, is the probability that describes the time between events. So the calculation is: R(72) = e -(72)(0.00333). Reliability Testing can be categorized into three segments, 1. The user (operations) and the keeper (maintenance) must participate in this exercise since they fully understand what contribution each asset makes to the organization. A Reliability program is designed to increase the availability and performance of the plant’s equipment by identifying potential failures and eliminating their cause or minimizing the possibility of failure and its impact. Measurement 3. “You can’t manage what you don’t measure”, said Peter Drucker. Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. I track my 401k, my gas mileage, and yes, even my budget. Time and usage can decrease a machine’s performance and you don’t want to learn this fact by having one of your employees be the victim of an equipment-related mishap. The Noria, for instance, is an ancient pump thought to be the world’s first sophisticated machine. The availability will not improve unless changes are made to upgrade the asset. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. However, if you are a pharmaceutical company, your best-to-worst plant may range from 1.5 to 6 percent. Testing classes are applicable to all commercial, military and aerospace requirements. S F. ∆ = * λ( ) For example, if there are 200 surviving components after 400 seconds, and 8 components fail over the next 10 seconds, the failure rate after 400 seconds is given by λ (400) = 8 / (200 x 10) = 0.004 = 0.4% This simply means that 0.4% of the surviving components fail in each second. The information gained during the troubleshooting is added to a SnapCharT® Diagram that displays what happened. The following are reliability engineering techniques and considerations. Inventory Turns. Improvement The following formula is for calculating the probability of failure. Based on the numeric product/value the assets are divided into three major groups: Numerous approaches exist to evaluate the failure modes for a system or an asset but the most common ones on the industry are: It is essential to evaluate the benefits vs. the investment to implement the suggested actions before allocating resources to perform the reliability studies to a piece of equipment. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. If the number of components is reduced to 200, what The chart on this page shows the follow times to repair. The actual percentiles can be calculated using the reliability function. Now is time to take a closer look at each key element for a reliability program. 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