All these considerations are highly crucial to lowering cost of ownership and achieving high maintainability of the equipment. The Equipment Reliability Process focuses the maintenance of physical asset reliability on the business goals of the company. Develop and monitor an Asset Maintenance Plan for effective utilization of strategies and designed for identifying and isolating reliability problems. Reliability of capital equipment is critical to the success of any manufacturing operation, mobile fleet, facility operation or any combination thereof. Equipment reliability, and the importance of it, is something that is rarely questioned. The contrary connection between equipment risk and reliability is not obvious, but it reveals itself to us when the risk equation is divided into its fundamental elements. This step is performed in collaboration with the production process. Developing a maintenance strategy to ensure performance. What is reliability? Availability refers to the duration of time that a plant or a particular equipment is able to perform its intended task. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. One of the fundamental roles of the Reliability Engineer is to track the production losses and abnormally high maintenance cost assets, then find ways to reduce those losses or high costs. Some of the highly accurate balances can give false results if they are not placed upon a completely level surface, so this calibration process is the best way to avoid this. A reliability engineer is an individual responsible for tracking the equipment behavior to avoid any downtime that may affect company revenues. Technicians can extend the equipment’s availability by increasing its reliability. Simply put, the Reliability Engineer will assist the company saves money through continuous monitoring and maintenance of the equipment. 4. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. Availability is, in essence, the amount of time that an item of equipment or system is able to be operated when desired. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. Last year, we defined reliability cultureas “the overall cultural shift that’s required for an organization to fully understand the big picture when it comes to asset reliability.” More recently, we talked about the difference between maintenance and reliability, noting that reliability is a much more holistic, long-term approach to asset management than maintenance. Determining equipment and process performance expectations from the business plan. How have you or your organization connected equipment reliability … This may include how to select and apply the most appropriate maintenance practices so the equipment and processes … Reliability engineers call these parallel systems. Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. Atlanta, GA 30339, USA, Copyright 2021 . Reliability-centered maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company or facility. But what exactly is reliability, and why is it important to understand the difference between it and other maintenance-relate… 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. The probability that a PC in a store is up and running for eight hours without crashing is 99%; this is referred as reliability. The goal of reliability engineering is to carry out an assessment as to the reliability of facility equipment and identify potential areas for improvement. operating the equipment beyond the design specifications (no capital to upgrade or replace the assets) excess break and lunchtime were observed across shifts; particular crews were able to consistently achieve higher performance (they were the most senior and knew the equipment and process) … When the equipment does what it needs to do when it needs to do it, plant output and profitability is maximized. Reliability. Overall Equipment Effectiveness (OEE). A reliability engineer is an individual responsible for tracking the equipment behavior to avoid any downtime that may affect company revenues. It is an inductive approach used for evaluating the process and its events leading to a possible accident. Effects are how such errors can result in faults or damaging results. Reviewing performance and adjusting the maintenance strategy. 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. In other words, all of the units in a series system must succeed for the system to succeed. These systems may be designed as active parallel systems or standby parallel systems. Failure modes are how a process can fail. We’ve talked around it before. Describe the importance of incorporating condition-based monitoring (diagnostic/ predictive technologies into equipment in the design 8. These are reliability-wise in series and a failure of any of these subsystems will cause a system failure. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. To develop and promote excellence in maintenance, reliability and physical asset management. Should apply different techniques like Fault Tree Analysis, Weibull Tree Analysis, Six Sigma Methodology, Root Cause Analysis and Statistical Process Control for developing engineering solutions to repetitive failures. If you want world class reliability, then you will need to ensure failure-free design, manufacture, assembly, installation, operation, and maintenance is always done to your plant and equipment. Referenced also is the well-known military handbook, MIL-HDBK-781, a comprehensive guide in developing reliability test plans and environmental test profiles for defense-related equipment; the MIL-HDBK-2164 provides further guidance on the traditional Environmental Stress Screening (ESS) process. No organization wants assets to break down, to produce poor quality products, or to operate inefficiently. Not all failures can be prevented by maintenance. 2 Introduction 3. That’s what TPM does. Equipment history makes it possible to refine preventive and predictive maintenance programs by targeting maintenance tasks to failure modes actually observed. Like or follow us to stay up-to-date with SMRP. 4 Equipment Reliability Training Series Learning Objectives (Continued) 7. Reliability Testing can be categorized into three segments, 1. Prerequisite Knowledge . Troubleshooting IS NOT Root Cause Analysis. If you think about how we use the word “reliable” in everyday language, you might get a hint. If our maintenance and reliability strategies are effective and are solving the problems that cause failures in our equipment, this should show a continuous upward trend, which stabilizes at industry benchmark levels. When you understand the behaviour of equipment over its lifetime you will understand why proactive maintenance (as opposed to repairs) is critical. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. We hear the term used a lot in research contexts, but what does it really mean? Equipment History The use of historical repair and maintenance information is critical to continuous improvement in reliability. The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. If you want world class reliability, then you will need to ensure failure-free design, manufacture, assembly, installation, operation, and maintenance is always done to your plant and equipment. The contrary connection between equipment risk and reliability is not obvious, but it reveals itself to us when the risk equation is divided into its fundamental elements. The first step is to select the piece of equipment for reliability centred maintenance analysis. • Explain what “classification consistency” and “classification accuracy” are and how they are related. Unfortunately, we don’t live in an ideal world; no physical asset operates flawlessly forever. Notify management of upcoming inspections and recommendations, deficiencies in processes, and corrective actions. 1 EQUIPMENT RELIABILITY TRAINING SERIES LEVEL 1: AWARENESS 2. In the non-physical sciences, the definition of an instrument is much broader, encompassing everything from a set of survey questions to an intelligence test. Rank the criticality of the new asset with respect to the rest of the plant. 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. Describe how the Purchasing Function can affect equipment reliability and the important elements for a Purchase for Reliability … Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. While a reliability engineer’s role differs from company to company, their objective is always the same: to minimize equipment downtime, lower maintenance cost, and to avoid business operations interruption. the manufacturing processes and equipment reliability. It is most often expressed as a percentage, using the following calculation: Availability = 100 x (Available Time (hours) / Total Time (hours)) For equipment and/or systems that are expected to be able to be operated 24 hours per day, 7 days per week, Total Time is usually defined as being 24 hours/day, 7 days/week (in other words 8,760 hours per year). Reliability is the ability of the equipment unit to perform its stated duty without a forced (unscheduled) outage in a given period of time. Modeling 2. Measuring Reliability. Cost-justifying (budget) tactics selected for implementation. To achieve a step change toward a culture of reliability, however, requires that all parts of the organization are involved, not just the operating areas. It encompasses availability, performance, and quality, and when used correctly is removing waste. A Reliability Engineer must determine the optimal maintenance strategies for different pieces of machinery, how to maintain the equipment performing its prescribed duty as intended by the user. The one at the plant level is the number of production incidents, no matter how small and no matter if they had any affect on supply availability. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. The equipment selected should be critical in terms of its effect on operations, its previous costs of repair, and previous costs of preventive maintenance. Utilizing hydraulic energy from the flow of a river or stream, the Noria utilized buckets to transfer water to troughs, viaducts and other distribution devices to irrigate fi… If the equipment has already been purchased, the inherent reliability is fixed but you can still impact the operational reliability and life cycle costs. And, reliability increases stakeholder value. often affects its interrater reliability. Definitions of associated terms, a structured approach to the logging of data for proper evaluation are provided. View our submission and article guidelines and write your article. The first key area where Maintenance can impact on equipment reliability is by having an appropriate preventive and predictive maintenance program in place. How does that engineer prioritize the work? No amount of maintenance can raise the inherent reliability of a design. Rotating Machinery Health Management and Rotating Equipment Maintenance and Reliability Training Course Content Course Content Day 1 - Machinery Health and Reliability Excellence - Introduction COURSE OVERVIEW First day – Cause of Rotating Machinery failures Second day – Standards, condition monitoring and top-class maintenance Third day – Shafts, bearings and seals for reliability … The goal of an equipment reliability program is to effectively monitor equipment, procedures, and data covering the life of equipment. Applied technology preventive maintenance. The opportunities for improving the reliability of equipment and production processes can be significant and is often a strong area of focus for operators. The potential contribution of the equipment asset base to these goals is evaluated. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. The block diagram for a simple two component parallel system is shown in Figure 10. You can deliver high equipment reliability by ensuring the … Simply put availability is a measure of the % of time the equipment is in an operable state while reliability is a measure of how long the item performs its intended function. To a great extent you can choose how long you want between equipment failures. You can deliver high equipment reliability by ensuring the chance of incidents that cause failures The design, construction, maintenance, adjustment, calibration, and use of measuring and of manufacturing equipment are factors which impact on the reliability of the product. Inventory Turns. Reliability optimization is an important part of plant revenue and profit. 2. In this concept, operations and maintenance both deliver reliability as a result of their work. What is Reliability? The largest contributors are recognized as critical assets and specific performance targets are identified. Asset integrity activities range from technical meetings involving experts seeking to advance the state-of-the art in equipment design, inspection, testing, or reliability, to a plant operator on routine rounds spotting leaks, unusual noises or odors, or detecting other abnormal conditions. TapRooT® - Changing the Way the World Solves Problems. 1.5 The analyses presented in this document are designed to identify deficiencies in equipment support resources as well as in the equipment itself. Provide technical assistance to manufacturing, maintenance, and technical staff. Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. Reliability quantifies the likelihood of equipment to operate as intended without disruptions or downtime. Subjects would include: Examples of topics that might fit into this area also include: Ready to write? The fundamental role of a reliability engineer is to develop a plan for monitoring equipment downtime, increasing equipment availability, reducing the production losses and maintenance costs by utilizing different techniques and tools. Quality Glossary Definition: Reliability. Availability, also known as operational availability, is expressed as the percentage of time that an asset is operating compared to its total scheduled operation time. Equipment Reliability Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. To perform a thorough … Reliability testing can generally be looked at as any interruptions in usage or performance during the lifetime span of a product, part, material, or system. Society for Maintenance & Reliability Professionals, SMRP Professional Development Webinar Content Submission Form, Artificial Intelligence & Increasing Reliability of Facility Assets, Operational Excellence in the Maintenance & Reliability. Simple. Our technologically based society depends on machinery and equipment to keep it operating. Reliability is the probability that a system performs correctly during a … The analysis also provides useful information to determine what measures will decrease the risk for all plant assets. Equipment Reliability. Operations focuses on reliable process and maintenance focuses on reliable equipment. The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. That’s why it is our belief that the overall competitiveness of your organization depends on establishing stable and reliable processes and equipment. Equipment Reliability Basics 101 for Reliability Management. That is the exact purpose and duty of a Plant Wellness Way EAM system-of-reliability. Equipment reliability is measured in terms of quality, performance, and productivity. The Reliability Engineer (in full partnership with the operations team) develops a plan to eliminate or reduce the losses through root cause analysis, obtains approval of the plan and facilitates the implementation. Establishing current performance levels and analyze gaps. Every manufacturing facility wants production equipment to operate reliably. At the equipment level, the MTBR is measured for all … TapRooT® was built (and is continuously improved) to help your company meet the ever increasing demands for reliable equipment, process reliability, improved safety, environmental … Improvement The following formula is for calculating the probability of failure. The data collected and its The downtime that is associated with equipment failures will depend both on the equipment reliability (the number of equipment failure events) and the length of time that it takes to restore the functionality of the equipment each time one of these events occurs (typically measured by Mean Time to Repair - MTTR). Overall Equipment Effectiveness (OEE). Knowing how equipment … The astute reliability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. Perform analysis of the assets including assets utilization, equipment effectiveness, and remaining useful life, etc. 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. This application of “guessing” as the primary tool for root cause analysis of equipment reliability and maintenance problems is probably the biggest challenge to achieving equipment reliability excellence. Figure 10. Participate in design development and implementation phase. To achieve a step change toward a culture of reliability, however, requires that all parts of the organization are involved, not just the operating areas. 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. What is the criticality of the new asset? Work with Project Engineering to guarantee that new and altered installations are reliable and maintainable. The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. Some failures are the result of … This shows the need for the Reliability Engineer to participate in project design and installation phases for new resources and current asset alteration.