Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. These measurements enable managers to track equipment, personnel and reliability performance. If you are a mining company, your best site may be 7 percent and worst site may be over 20 percent. The equipment selected should be critical in terms of its effect on operations, its previous costs of repair, and previous costs of preventive maintenance. 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. 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. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. 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. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. Before discussing how reliability and availability are calculated, let’s understand the incident service metrics used in these calculations. The average for North American business is about 7 to 8 percent. A Reliability program is designed to increase the availability and performance of the plant’s equipment by identifying potential failures and eliminating their cause or minimizing the possibility of failure and its impact. This calculation gets a little more complicated mathematically. The Concepts of Reliability and Validity Explained With Examples. I’m a triathlete, so I measure an unusual amount of stuff. Find the reliability of the module. This step is crucial since it creates the foundation for a well-implemented reliability program that will yield remarkable improvements in reliability and performance. The criticality analysis provides a ranking of all equipment in a plant according to the level of importance and its probability of failure. 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. The reliability of each component is 0.999. 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. reliability analysis of mining equipment such as load-haul-dump (LHD) machines [1, 16, 17]. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. Three subsystems are reliability-wise in series and make up a system. Before diving into the reliability program key elements, we must understand the meaning of equipment reliability. I suggest you start with the “low hanging fruits” and built on top of those. Sometimes this global goal is expressed in t… If the number of components is reduced to 200, what The equation is straightforward: the total repair time divided by the number of repairs or replacement events. For example, the function of a conveyor belt system is to transport goods. It encompasses availability, performance, and quality, and when used correctly is removing waste. Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … Impact criteria to be considered are: This exercise should be conducted with a facilitator that will guide a multidisciplinary team. •t is 1 divided by MTBF. Reliability is the ability of things to perform over time in a variety of expected conditions. So the MTTR is one hour. The result is 300 operating hours. Availability. 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, however, is a mix of vintages from the 1950s to the 1970s, causing concern for system reliability due to the age of the equipment. The result is 83.3 percent availability. Fig. 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. In the AHU example, the MTBF is 300, so 1 divided by 300 is 0.00333. The availability will not improve unless changes are made to upgrade the asset. 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. At times, managers need to calculate the probability that a piece of equipment will fail. Title: Microsoft PowerPoint - Equipment Reliability - INPO - George Manaskie.pptx Author: e25854 Created Date: 6/27/2017 7:06:30 PM What are the functions and associated performance standards of the asset in its present operating context? 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. The AHU’s blower unit has failed 12 times over this period. Let’s start by exploring what is the intention of a Reliability Program. 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 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. All research is conducted via the use of scientific tests and measures, which yield certain observations and data. It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. Performed an Assets Criticality Assessment to identify work areas for maintenance reliability improvement actions. F or decades, oil analysis has been considered a cornerstone for predictive maintenance programs in a variety of industries. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. 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. It measures the average time required to restore an asset to its full operational condition after a failure. Class A equipment – Most critical Assets. This measurement expresses the probability that an asset can perform its intended function satisfactorily when needed in a stated environment. The result is 78.68 percent. 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. • - 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. In this example, because the Weibull distribution is not a symmetrical distribution, the MTTFs do not correspond to the 50 th percentile of failures. Modeling 2. For example, if a pump is producing less than the rated flow, we might want to know why. So the calculation is: R(72) = e -(72)(0.00333). Primary Function- usually explain what the intention was for acquiring the asset. Reliability Testing can be categorized into three segments, 1. A piece of equipment can be available but not reliable. 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. 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? To perform a thorough … It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. RCM or Reliability Centered Maintenance is an effective approach for determining the appropriate strategy based on this understanding of equipment failures. That may be okay in some circumstances but what if this is a paper machine? 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. Not all failures can be prevented by maintenance. Measurement 3. A manager needs to ensure the availability of the AHU for the next 72 hours. The calculation for this is: R(t) = e (-t), where: •e is the weighted average value of a random variable, or the expected value. Inventory Turns. This generally means ensuring that things continue to conform to requirements in the face of real world conditions. Next week, we will cover the use of a RCM methodology designed for industry which will deliver significant improvements in … An example of an equipment failure related SnapCharT® is shown below… Notice that the Causal Factor (Mechanic installs impeller backward) is included on the SnapCharT®. The availability of an asset will diminish over time as the equipment is being used. Implement a system or process to capture equipment performance data. 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. 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%. Act on the recommendations and opportunities identified. See the example below. What can be done to predict or prevent each failure? The following are illustrative examples. What is the overall reliability of the system for a 100-hour mission? 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. 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. by Mike Johnson & Matt Spurlock. 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. (Learn more about availability metrics and the 9s of availability.) Every improvement process needs a way to measure success and make decisions based on empirical data. To this point, best maintenance strategies for medical equipment in their operating context have not been considered. MTBF. In this liability form, they are informed of releasing liability and instructions or conditions in handling the borrowed equipment. 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. Let’s use “maintenance cost/replacement asset value” as an example. “You can’t manage what you don’t measure”, said Peter Drucker. The probability that a PC in a store is up and running for eight hours without crashing is 99%; this is referred as reliability. What is the probability of failure? Accept Failures. To see improvements, the recommendations that identified needs to be implemented. The following are reliability engineering techniques and considerations. Title: Microsoft PowerPoint - Equipment Reliability - INPO - George Manaskie.pptx Author: e25854 Created Date: 6/27/2017 7:06:30 PM Equipment reliability is about a client taking legal accountability of any damage or loss that comes to the equipment they borrow. Availability. Oil Analysis and Its Role In Equipment Reliability. 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.

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