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. RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. The system can be large or small, but the function of the system, and its inputs and outputs, should be known. At the end of the day, each of these measurements has a financial impact on the organization. Example: Calculating Reliability of a Series System. 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). What are the functions and associated performance standards of the asset in its present operating context? Availability. Impact criteria to be considered are: This exercise should be conducted with a facilitator that will guide a multidisciplinary team. Improvement The following formula is for calculating the probability of failure. • - 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. 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. 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. There’s not a day that goes by that I don’t measure something. Let’s use “maintenance cost/replacement asset value” as an example. Fig. Technicians can extend the equipment’s availability by increasing its reliability. Continue with example of the AHU. Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … The first step is to select the piece of equipment for reliability-centered maintenance analysis. For example, if a pump is producing less than the rated flow, we might want to know why. 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. Incident & service metrics. The first step in laying the groundwork for an FMEA-based reliability improvement effort is to identify candidate equipment. 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 Durability 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. In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. To this point, best maintenance strategies for medical equipment in their operating context have not been considered. Three subsystems are reliability-wise in series and make up a system. Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. Part one of a two part series. The information gained during the troubleshooting is added to a SnapCharT® Diagram that displays what happened. 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. This chapter addresses all causes of … This generally means ensuring that things continue to conform to requirements in the face of real world conditions. 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. How many miles I run, bike or swim? The result is 300 operating hours. It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. 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. The equation is straightforward: the total repair time divided by the number of repairs or replacement events. 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. For example the machine is down 6 minutes every hour. In this liability form, they are informed of releasing liability and instructions or conditions in handling the borrowed equipment. The equipment belongs to a system that performs a crucial function. This step is crucial since it creates the foundation for a well-implemented reliability program that will yield remarkable improvements in reliability and performance. A manager needs to ensure the availability of the AHU for the next 72 hours. MTBF. I suggest you start with the “low hanging fruits” and built on top of those. “You can’t manage what you don’t measure”, said Peter Drucker. This measurement expresses the probability that an asset can perform its intended function satisfactorily when needed in a stated environment. 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. Act on the recommendations and opportunities identified. 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. Maintenance will also help you make sure that your equipment are still safe to be operated. A pacemaker, for example, is expected to perform without failure during its useful life. The AHU’s blower unit has failed 12 times over this period. Measurement 3. PM optimization- an in-depth evaluation of maintenance job plans for the asset that takes into consideration failure history and operators/mechanics experience to supplement data available. 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 … Is the probability that an asset, item, or unit will perform its prescribed duty without failure for a given time in a specified environment. Primary Function- usually explain what the intention was for acquiring the asset. The criticality analysis provides a ranking of all equipment in a plant according to the level of importance and its probability of failure. Reliability engineering is the design, production and operation of things to retain their quality over time. Testing classes are applicable to all commercial, military and aerospace requirements. The availability will not improve unless changes are made to upgrade the asset. The reliability of each component is 0.999. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. 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 user (operations) and the keeper (maintenance) must participate in this exercise since they fully understand what contribution each asset makes to the organization. These measurements enable managers to track equipment, personnel and reliability performance. F or decades, oil analysis has been considered a cornerstone for predictive maintenance programs in a variety of industries. Focus on design for reliability, operability, maintainability, safety and inspectability (ROMSI) Most … 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. Find the reliability of the module. For example, after experiencing a rare equipment failure, a plant instituted A traceability matrix must be maintained to keep track of the recommendations that were implemented. In the AHU example, the MTBF is 300, so 1 divided by 300 is 0.00333. To see improvements, the recommendations that identified needs to be implemented. The average for North American business is about 7 to 8 percent. Overall Equipment Effectiveness (OEE). All research is conducted via the use of scientific tests and measures, which yield certain observations and data. The origins of the field of reliability engineering, at least the demand for it, can be traced back to the point at which man began to depend upon machines for his livelihood. MTTR. Equipment. It is vital that each function and department links themselves to the overarching objective of the whole. What can be done to predict or prevent each failure? The result is 83.3 percent availability. 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%. The following are illustrative examples. To perform a thorough … Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. Maintenance, Measurement and Equipment Reliability. Sometimes this global goal is expressed in t… Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. 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. 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.