PLC Training by Business Industrial Network 12/29/03 www.bin95.com Business Industrial Network www.BIN95.com See http://www.bin95.com/ebooks/index.htm#powerpoints to download full 4 day course of 354 slides in 4 PPT files and 54 page workbook. And download other related course powerpoints.
Welcome to the final day of the course. Four days straight in any training situation is hard work. This course is a useful overview of the many issues that you need to get right if you want rotating equipment health with a lifetime of excellent operation. Use the course to focus your future maintenance management strategies and workforce training efforts on those things that make the big difference to your operation’s rotating equipment performance.
Just a quick reminder of what was done on Day 3 to provide some continuity between the days of the course.
Day 4 list of topics to present and simple exercises to do. Most of the day is about systems and processes that provide and support rotating equipment excellence. The mechanics of what must be done to get RE reliability was covered in Days 1 to 3. Today you will learn how to put them into business systems that make them happen.
Maintenance is a risk management device. You need to understand the game of risk that you are really playing with your business if you want to get the right results.
We live in a probabilistic universe where nothing is certain. Anytime a situation can go a number of ways, you have a probabilistic event. Sometimes things will go one way, sometimes another way. If the path taken leads to bad outcomes, where there is loss, you have suffered a bad risk. Risk is a measure of the value of a chance event.
Each threat or escalation barrier can be represented as a piece of Swiss cheese The holes represent weaknesses in the processes that form part of the barrier. The weakness can relate to the design of the process or its implementation. If the holes in the threat barriers line up this forms the chain of events that lead from a hazard to an event. If the holes in the escalation barriers line up this forms the chain of events that leads from an event into a consequence.
PLC Training by Business Industrial Network 12/29/03 www.bin95.com Business Industrial Network www.BIN95.com
1. Copyright 2009 Business Industrial Network www.BIN95.com Sample of … Rotating Equipment Reliability Excellence PowerPoint These are sample slides from complete 4 day course presentation available for download at http://www.bin95.com/ebooks/index.htm#powerpoints (354 slides) See www.BIN95.com to learn more about our PLC training.
2. Rotating Equipment Health and Reliability Excellence Presented by Mike Sondalini Lifetime Reliability Solutions Day 4 Copyright 2009 Business Industrial Network www.BIN95.com
3. Day 3 Review <ul><li>Lubrication Selection </li></ul><ul><li>Shaft Seals – Methods, Types, Designs, Process Effects </li></ul><ul><li>Vibration Prevention and Isolation </li></ul><ul><li>Strength of Materials for Shafts and Rotors </li></ul><ul><li>Horizontal and Vertical Shaft Design Issues </li></ul><ul><li>Bearing Design and Selection – Radial and Axial </li></ul><ul><li>Precision Maintenance </li></ul>Copyright 2009 Business Industrial Network www.BIN95.com
4. Today 4 Topics <ul><li>Risk Reduction Strategies in RE Design and Operation </li></ul><ul><li>Design, Operation and Cost Total Optimisation Review </li></ul><ul><li>Lifting Lifetime Reliability </li></ul><ul><li>Activity 1 – FMEA exercise </li></ul><ul><li>RE Root Cause Failure Analysis </li></ul><ul><li>Finding the Evidence </li></ul><ul><li>Applying RCFA in the Workplace </li></ul><ul><li>Activity 2 – RCFA exercise </li></ul><ul><li>Rotating Equipment Integrity Management </li></ul><ul><li>Activity 3 – Actions to Improve Your Workplace </li></ul>Copyright 2009 Business Industrial Network www.BIN95.com
5. Tuesday’s meeting starts with a new purpose... We’ll no longer talk of machinery problems and solutions Alan. From today to the end of the week we will talk about the business systems and processes that improve operating plant performance. You mentioned last week that systems are what we use to guarantee outcomes. They take people through a structured way of doing a thing so that luck and happenstance are removed. Yes, we use systems to improve the odds of getting the results we want. Without using a system we cannot monitor and control what we do, and we cannot be sure of what works and what does not. What sort of things will we cover this week? During the week we’ll introduce you to risk management, some simple reliability engineering concepts, and rotating equipment integrity management. This week we’ll finish your training Alan. It sounds like you saved the best till last. It’s been very good of you Bill to take the time to show and explain to me all these ideas and methods that we need to bring into the company. I’m glad that you have been such a willing student. Turning them into reality will not be so easy. Copyright 2009 Business Industrial Network www.BIN95.com
6. Risk Reduction Strategies in Rotating Equipment Design and Operation <ul><li>Understanding and Measuring Risk </li></ul><ul><li>Chance vs. Consequence Risk Reduction Methods </li></ul><ul><li>Applying Risk Reduction During Design </li></ul>Copyright 2009 Business Industrial Network www.BIN95.com
7. Understanding and Measuring Risk Risk ($/Yr) = Chance of Occurrence (/Yr) x Consequence of Occurrence ($) Risk is the product of probability or chance that an event will happen and the cost if it does. Operating risk is the size of the financial loss that will be incurred from a failure during operation. The risk formula is a power law. Power laws have particular properties. For example they are ‘ scale-free ’. In the case of risk this means the risk equation applies to every size of risk. They are ‘typically a signature of some process governed by strong interaction between the ‘decision-making’ agents in the system’. This implies that risk does not arise entirely randomly; rather it is affected by the ‘decision-makers’ present in a system. Situations that follow power laws have a higher number of large events occurring than those of a normal distribution. For risk this means that catastrophic events will occur more often than by pure chance. In power-law-mirrored events a few factors have huge impacts while all the numerous rest have little effect. For risk this means there are a few key factors that influence the likelihood of catastrophe. Control these factors and you increase the chance of success. They are known as the critical success factors. You identify them by asking, “What affects the ability to meet the objective?” For example, only about 3% of parts in equipment cause repeated problems. If these parts were identified and were then well treated and maintained, you would suffer far fewer forced stoppages of equipment. Copyright 2009 Business Industrial Network www.BIN95.com
8. How the Swiss Cheese Holes Line Up Hazard Consequences What barriers should be in place? What is the likely cause of holes in the barriers? -Answer two questions Copyright 2009 Business Industrial Network www.BIN95.com
9. What is a High Potential Incident? ESCALATION BARRIERS THREAT BARRIERS T H R E A T S C O N S E Q U E N C E S HAZARD ACTUAL CONSEQUENCES Event “ high potential incident” means an incident not causing loss or damage but, under different circumstances would result in an accident. Copyright 2009 Business Industrial Network www.BIN95.com
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