reliability maintenance engineering 1 - 2 max benefits
DESCRIPTION
Reliability Maintenance Engineering Day 1 Session 2 Max Benefits Three day live course focused on reliability engineering for maintenance programs. Introductory material and discussion ranging from basic tools and techniques for data analysis to considerations when building or improving a program.TRANSCRIPT
Reliability Engineering
Fred [email protected]
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