equipment reliability example
At the end of the day, each of these measurements has a financial impact on the organization. The availability will not improve unless changes are made to upgrade the asset. However, if you are a pharmaceutical company, your best-to-worst plant may range from 1.5 to 6 percent. The result is 78.68 percent. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. Justifying the Cost of Preventive Maintenance », Federal Bureau of Investigation Careers », NFMT - Facilities Education and Conference. This measurement typically is expressed in hours. Oil Analysis and Its Role In Equipment Reliability. The chart on this page shows the follow times to repair. To perform a thorough … MTBF. by Mike Johnson & Matt Spurlock. Reliability Engineers are in charge of optimizing manufacturing processes by using their engineering knowledge. The Concepts of Reliability and Validity Explained With Examples. An example is misalignment leads to bearing overload, then to lubrication breakdown, then to metallic stress due to bearing wear, followed by bearing failure, and finally to equipment failure. 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 reliability of each component is 0.999. 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. By continuing with the above example of the AHU, its availability is: 300 divided by 360. 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. Primary Function- usually explain what the intention was for acquiring the asset. Not all failures can be prevented by maintenance. “You can’t manage what you don’t measure”, said Peter Drucker. Troubleshooting is trying to discover the physical or equipment cause of the failure. In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. This is a considerable difference in reliability. ... and the equipment used all affect reliability. Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. 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. • - 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 following are illustrative examples. Its inputs a… Let’s start by exploring what is the intention of a Reliability Program. Overall Equipment Effectiveness (OEE). For example, a facility is responsible for maintaining a standard air-handling unit (AHU) that has operated for 3,600 hours over the past two years. 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. Each impact criteria should have a numeric value and a definition for each value. 17 Examples of Reliability posted by John Spacey, January 26, 2016 updated on February 06, 2017. 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 … Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … What is the role of an Equipment Reliability Engineer? Incident & service metrics. The information gained during the troubleshooting is added to a SnapCharT® Diagram that displays what happened. This step is crucial since it creates the foundation for a well-implemented reliability program that will yield remarkable improvements in reliability and performance. It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. In the AHU example, the MTBF is 300, so 1 divided by 300 is 0.00333. Every improvement process needs a way to measure success and make decisions based on empirical data. This generally means ensuring that things continue to conform to requirements in the face of real world conditions. That may be okay in some circumstances but what if this is a paper machine? 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 Sometimes referred to as maintainability, MTTR is the measure of the department’s ability to perform maintenance to retain or restore assets to a specified condition. The actual percentiles can be calculated using the reliability function. 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. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. This is a considerable difference in reliability. (Learn more about availability metrics and the 9s of availability.) To see improvements, the recommendations that identified needs to be implemented. 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. If you are a mining company, your best site may be 7 percent and worst site may be over 20 percent. Impact criteria to be considered are: This exercise should be conducted with a facilitator that will guide a multidisciplinary team. I track my 401k, my gas mileage, and yes, even my budget. Availability. A pacemaker, for example, is expected to perform without failure during its useful life. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. There’s not a day that goes by that I don’t measure something. Testing classes are applicable to all commercial, military and aerospace requirements. Now is time to take a closer look at each key element for a reliability program. 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. It encompasses availability, performance, and quality, and when used correctly is removing waste. The average for North American business is about 7 to 8 percent. 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. Focus on design for reliability, operability, maintainability, safety and inspectability (ROMSI) Most … Equipment. I suggest you start with the “low hanging fruits” and built on top of those. See the example below. 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 Equipment manufacturers must design for reliability, and in particular High Cycle Fatigue (HCF) of stationary and rotating components is one area of focus. Modeling 2. Title: Microsoft PowerPoint - Equipment Reliability - INPO - George Manaskie.pptx Author: e25854 Created Date: 6/27/2017 7:06:30 PM In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. 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. For example the machine is down 6 minutes every hour. The equation is straightforward: the total repair time divided by the number of repairs or replacement events. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. Inventory Turns. Life-cycle long, holistic equipment health is a different way to think about what needs to be done to make operations successful. Establish KPI and Reports to monitor the success of the actions implemented. It is vital that each function and department links themselves to the overarching objective of the whole. 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. I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be on continuous improvement. For example, a 99.999% (Five-9’s) availability refers to 5 minutes and 15 seconds of downtime per year. One of the goals of this process is to define the functions of each asset by asking these two questions: Is the asset capable of doing what the users expect it to do? I don’t think that we can ever escape measuring, tracking or following things. •t is 1 divided by MTBF. Equipment reliability is about a client taking legal accountability of any damage or loss that comes to the equipment they borrow. 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. This calculation gets a little more complicated mathematically. It measures the average time required to restore an asset to its full operational condition after a failure. Every part of the organization is serving the same corporate goals and objectives even though each part is playing a vastly different role and carries different responsibilities. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. reliability analysis of mining equipment such as load-haul-dump (LHD) machines [1, 16, 17]. With HI analysis used in the Plant Wellness Way philosophy you would correct the misalignment so there could be no opportunity to overload the bearing. Sometimes this global goal is expressed in t… actions. To perform a thorough reliability exercise on a system or assets we should answer these seven basics questions: As you can imagine, these questions cannot be answered by the maintenance personnel on their own since some are closely related to the user intended function. 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. Continue with example of the AHU. What is the probability of failure? This measurement expresses the probability that an asset can perform its intended function satisfactorily when needed in a stated environment. Availability. Develop a maintenance strategy based on equipment criticality- RCM, PMO or RTF. Some of the recommendations will be easy to implement and others will require a project to be implemented. A Computerized Maintenance Management System (CMMS) is a tool that can help maintain records and data of the assets such as: Once a system or process is established to retrieve the asset performance data a recurrent visual or numeric representation must be generated to measure the performance of the equipment and identify if the changes that were implemented are delivering the expected results. As goes our personal lives, so goes our work. 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. 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. Time and usage can decrease a machine’s performance and you don’t want to learn this fact by having one of your employees be the victim of an equipment-related mishap. The equipment selected should be critical in terms of its effect on operations, its previous costs of repair, and previous costs of preventive maintenance. If we discover that the impellor on a double volute pump was installed backward, we have completed the troubleshooting of … Reliability is the ability of things to perform over time in a variety of expected conditions. The equipment belongs to a system that performs a crucial function. Maintenance, Measurement and Equipment Reliability. Act on the recommendations and opportunities identified. Some failures are the result of … Durability 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. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). 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. Find the reliability of the module. Part one of a two part series. Below are examples of tracking and measuring that can produce tangible results for both departments and facilities. This translates into an availability of 90% but a reliability of less than 1 hour. RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. What should be done if a suitable proactive task cannot be found? The following are reliability engineering techniques and considerations. In what ways does it fail to fulfill its functions? I’m a triathlete, so I measure an unusual amount of stuff. Maintenance will also help you make sure that your equipment are still safe to be operated. The result is 83.3 percent availability. Reliability Distributions During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. But for this data to be of any use, the tests must possess certain properties like reliability and validity, that ensure unbiased, accurate, and authentic results. If the number of components is reduced to 200, what Probability of failure. How many miles I run, bike or swim? Accept Failures. Sometimes call autonomous maintenance or operator asset care program is an essential tool not only in preventing failures but also with the identification of opportunities for improvements. What can be done to predict or prevent each failure? There might be small leaks and malfunctions in your machine that only maintenance can discover.Maintenance can also help you prolong the life of your equipment. For example, the function of a conveyor belt system is to transport goods. A traceability matrix must be maintained to keep track of the recommendations that were implemented. The availability of an asset will diminish over time as the equipment is being used. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. What is the overall reliability of the system for a 100-hour mission? 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. RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. Reliability Testing can be categorized into three segments, 1. Measurement 3. Technicians can extend the equipment’s availability by increasing its reliability. For example, if a pump is producing less than the rated flow, we might want to know why. Institutionalize a program that engages operators with equipment reliability focus goals. The first step is to select the piece of equipment for reliability-centered maintenance analysis. What are the functions and associated performance standards of the asset in its present operating context? For example, after experiencing a rare equipment failure, a plant instituted Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … 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. Testing classes are applicable to all commercial, military and aerospace requirements. The system can be large or small, but the function of the system, and its inputs and outputs, should be known. For example, reliability can develop the following lists: top 10 list of defective equipment — based on maintenance and lost opportunities bad actors — equipment with three or more failures in a two-year period repeat offenders — equipment with repeated failures in the past six months. 1 shows the pumphouse A piece of equipment can be available but not reliable. The criticality analysis provides a ranking of all equipment in a plant according to the level of importance and its probability of failure. 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. 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. MTBF is a basic measure of an asset’s reliability. Improvement The following formula is for calculating the probability of failure. Before discussing how reliability and availability are calculated, let’s understand the incident service metrics used in these calculations. F or decades, oil analysis has been considered a cornerstone for predictive maintenance programs in a variety of industries. For example, a simple processor such as a sequencer allows multiple compressors to communicate with one another and coordinate demand to improve each machine’s operating efficiency and extend equipment … 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. 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. It is a maintenance best practice to maintain the asset historical data archive for future evaluation. 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. After years of operating, many CPI plants lose track of the main goals of their maintenance program. The reason I do these things is that I want to improve in some way. Let’s use “maintenance cost/replacement asset value” as an example. The result is 300 operating hours. Performed an Assets Criticality Assessment to identify work areas for maintenance reliability improvement actions. 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. To this point, best maintenance strategies for medical equipment in their operating context have not been considered. This chapter addresses all causes of … So the calculation is: R(72) = e -(72)(0.00333). The result is 300 operating hours. The first step in laying the groundwork for an FMEA-based reliability improvement effort is to identify candidate equipment. The AHU’s blower unit has failed 12 times over this period. Implement a system or process to capture equipment performance data. Reliability Institute ( ERI ) offers specialized technical short course training in Shock Vibration. Reliability focus goals reliability follows an exponential failure law, which means that it reduces as the duration... 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