reliability maintenance engineering 1 - 2 max benefits

Reliability Engineering

Fred Schenkelbergfms@fmsreliability.com

Introduction

• Reliability is about time to failure

• Maintenance is about restoring equipment and processes to operation

• Engineering is finding the right balance between cost and action

MAXIMIZING POTENTIAL BENEFITS OF MAINTENANCE ACTIVITIES

Session 2

Objectives

• Reduce operating cost while boosting productivity though equipment maintenance

• Analyzing equipment failures for proactive, predictive & preventative maintenance

• Selecting the appropriate maintenance approach

• Developing a maintenance program

Cost of Maintenance

• Spares• Labor• Training• Diagnostic Equipment

• It takes an investment

Cost of Downtime

• Loss production• Restart Costs• Loss of Revenue• Opportunity Costs

• Unscheduled downtime

Benefit of Operating

• Revenue• Production• Efficiency• Uptime

• Less downtime means More uptime and value

Discussion & Questions

Reliability

• Common Understanding

• Function• Environment/Use• Duration• Probability

Availability

• Common Understanding

• Inherent – ideal

• Achieved – PM & CM included

• Operational – actual with all downtime

Maintainability

• Two elements

• Design for maintainability

• Effectiveness of repairs– Good as new– Bad as old– Somewhere between

Uptime

• Operating when it should be operating

• Who defines and how is this defined?

Discussion & Questions

Equipment Failure

• Provides guide to maintenance approach

• What are the results of failure?

• What is known about failure modes and mechanisms?

Types of Failures

• A range

• Nobody cares

• Degradation

• Shut down

Failure Impact

• A range of impacts

• Nobody cares (why is the equipment here?)

• Degraded operation

• Major repair/restart

Failure Signs

• Is there a warning?

• Measured and predicted

• Slow degradation of throughput or quality

• Sudden and unforeseen

Discussion & Questions

Reactive

Consider for

• Small items• Non-critical• Inconsequential• Unlikely to fail• Redundant

Preventive

Consider if

• Subject to wear out• Consumable

replacement• Failure pattern known

Predictive

Consider when

• Random failure pattern• Not subject to wear• PM induce failures

Proactive

Consider with

• Root Cause Failure Analysis

• Age Exploration• FMEA

Discussion & Questions

Interval v. Conditional

Interval or time based

• Fixed schedule• Assumes wear or

predictable time to failure

• Easy to manage and plan

Condition based

• Focus on failure mechanisms

• Consider cost of failure• May require health

monitoring• Cost effective

How to decide an approach

Ask these questions:

• Nature of failures?• Able to detect ?• Predictable?• Indicators?• Cost of failure?• Cost of maintenance?

Approaches

• Reactive

• Preventive

• Predictive

• Proactive

Discussion & Questions

Get the data

• Data, Data, Data

• Convert to information

• Do the math

• Look for Stability and Exceptions

Where to start

• Use data you have to start – build case for better data collection

• Run experiments to get better data

• Next focus on high value areas

Build a program

• Maintenance procedures

• Tools and training

• Engineering– Design, Reliability &

Operations

• Connect to business

Metrics

• Not MTBF

• Business metrics– Revenue, throughput,

etc.

• Time to failure– Mean Cumulative

Function or Life Distributions

Discussion & Questions

Summary

• Value – do what adds value

• Understand failure mechanisms

• Time to failure & Environmental data

• Breadth of Maintenance Engineering

Maximize potential benefits of maintenance activities