This chapter addresses all causes of … The first step is to select the piece of equipment for reliability-centered maintenance analysis. For example, in the calculation of the Overall Equipment Effectiveness (OEE) introduced by Nakajima , it is necessary to estimate a crucial parameter called availability.This is strictly related to reliability. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. 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. This step is crucial since it creates the foundation for a well-implemented reliability program that will yield remarkable improvements in reliability and performance. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. Let’s start by exploring what is the intention of a Reliability Program. The following are reliability engineering techniques and considerations. There’s not a day that goes by that I don’t measure something. Below are examples of tracking and measuring that can produce tangible results for both departments and facilities. 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. This is a considerable difference in reliability. 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. 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 RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. by Mike Johnson & Matt Spurlock. In other words, reliability of a system will be high at its initial state of operation and gradually reduce to its lowest magnitude over time. reliability analysis of mining equipment such as load-haul-dump (LHD) machines [1, 16, 17]. 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. This measurement expresses the probability that an asset can perform its intended function satisfactorily when needed in a stated environment. Availability. Class A equipment – Most critical Assets. For example, if a pump is producing less than the rated flow, we might want to know why. The study of component and process reliability is the basis of many efficiency evaluations in Operations Management discipline. Technicians can extend the equipment’s availability by increasing its reliability. Justifying the Cost of Preventive Maintenance », Federal Bureau of Investigation Careers », NFMT - Facilities Education and Conference. The user (operations) and the keeper (maintenance) must participate in this exercise since they fully understand what contribution each asset makes to the organization. Focus on design for reliability, operability, maintainability, safety and inspectability (ROMSI) Most … Sometimes this global goal is expressed in t… The availability of an asset will diminish over time as the equipment is being used. These measurements enable managers to track equipment, personnel and reliability performance. Assemble a multidisciplinary team to participate in the equipment reliability process. For example, after experiencing a rare equipment failure, a plant instituted 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 … The following are illustrative examples. Some examples of Key Performance indicators to measure the success are: Our reliability engineers experts evaluate your plant mainteance program maturity, and develop a strategies to achieve short, middle and long terms benefits using proven world-class best practices. 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. What is the probability of failure? Maintenance will also help you make sure that your equipment are still safe to be operated. 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. As goes our personal lives, so goes our work. I suggest you start with the “low hanging fruits” and built on top of those. For example, a 99.999% (Five-9’s) availability refers to 5 minutes and 15 seconds of downtime per year. It measures the average time required to restore an asset to its full operational condition after a failure. Life-cycle long, holistic equipment health is a different way to think about what needs to be done to make operations successful. Probability of failure. Reliability is the probability that a system performs correctly during a specific time duration. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. F or decades, oil analysis has been considered a cornerstone for predictive maintenance programs in a variety of industries. • - 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. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. 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. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. Investing in automation can increase your equipment’s reliability — and as technology develops, more and more options are now available for incorporating automation into your plant. 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®. Its inputs a… The AHU’s blower unit has failed 12 times over this period. We streamline any production and manufacturing process by applying a blend of proven methodologies such as Six Sigma Lean, Overall Equipment Effectiveness (OEE) and Total Productive Maintenance (TPM). 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. The average for North American business is about 7 to 8 percent. 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%. We focus on three major areas: Energy efficiency, Maintenance Cost and Equipment Reliability. For example the machine is down 6 minutes every hour. After years of operating, many CPI plants lose track of the main goals of their maintenance program. What is the overall reliability of the system for a 100-hour mission? Tracking the reliability of facility equipment can help maintain and decrease time spent on repairs. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. Impact criteria to be considered are: This exercise should be conducted with a facilitator that will guide a multidisciplinary team. At the end of the day, each of these measurements has a financial impact on the organization. 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. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). The main goal of the operator asset care program is: This is where some organizations do not follow through and do not reap the benefits of the reliability program. From a maintenance and reliability perspective, an example of using this type of informative inspection would be performing Weibull analysis to constantly adjust the maintenance strategy for a piece of equipment or system within the plant. Among the most commonly used measurements that managers can put into practice to determine performance are: • mean time to repair (MTTR) • mean time between failure (MTBF) • availability. The information gained during the troubleshooting is added to a SnapCharT® Diagram that displays what happened. In this liability form, they are informed of releasing liability and instructions or conditions in handling the borrowed equipment. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. 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. 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