reliability maintenance engineering 2 - 4 purpose and equipment

Reliability Engineering

Fred Schenkelbergfms@fmsreliability.com

EQUIPMENT SELECTION AND REVIEW

Day 2 Session 4

Objectives

• Examining the lifecycle process• RAM modeling to evaluate designs• Conducting the Maintainability Design Review• Developing a MDR checklist

Lifecycle Process

Concept

Design

MFGUse

End of life

Concept & Design

Concept

• System Architecture• Reliable v Available• Goal setting

Design

• Selection of materials• Selection of

components• Risk identification• Tradeoffs

Production & Use

Production (manufacture)

• Process variation• Materials variation• Shipping variation• Installation variation

Reliability only gets worse

Use

• Operation Stress• Environment Stress

• Maintenance Plan• Failure Detection

End of life

Decommissioning

• Lessons learned• Tear down and analysis• Reliability Differences

with today’s model

Discussion & Questions

Reliability Modeling

• Focus on function– Common– Perfect product

• Focus on reliability– Uncommon– Imperfect product

• CAD, FEA, Simulations

Design Comparison

• Reliability occurs in the design

• Selecting the most robust options

• DOE, Stress/Strength, Aging, Maintenance Costs, Failure Costs

What if analysis

• What could go wrong?

• Explore changes to – Environment– Construction– Use profile– Materials

Good designer do this naturally

System Modeling

• Simulate different– Maintenance policies– Maintenance practices– Supply chain changes

• DOE to design the experiments

• Output is cost of ownership and availability

Discussion & Questions

Design Reviews

• Adversarial or Constructive

• Formal or informal

• Status update or detailed design check

How do you approach reviews?

Stages of Review

• During design– Risk assessment– Options and benefits– Decisions

• During review– Increase awareness– Identify errors (Petroski)– Celebrate failures

• After review– Process improvement– Lessons learned

Hosting a review

• What is the purpose?

• What decisions are being made?

• What is desired outcome?

Be clear on why

Considerations

• People– Knowledgeable– Stakeholder– Perspective

• Timeline– Time for details– Time for action

• Meetings– One on one– Group

Discussion & Questions

Review checklists

• Avoid using a checklist or database– Detailed checks, i.e.

keepouts, sizing, etc.– Goal is do the checklist

• Do use the approach guided by checklist– Higher level– Range of stresses

Review guidelines

• Brainstorming approaches– Day in the life– Range of stresses– Change one thing

• Make it safe to talk about failure– Not personal– No attacks– No solutions (take offline)

Checklist cautions

• Design checklists

• Testing checklists

• Review checklists

Only works if you know everything and follow the spirit of the checklist

Golden Nuggets

• An example that has been very effective

• Identify key failure patterns

• Review before and after project– What will you do?– What did you do?

Discussion & Questions

Summary

• Examining the lifecycle process

• RAM modeling to evaluate designs

• Conducting the Maintainability Design Review

• Developing a MDR checklist

Equipment Selection & Review