RAMS 2013 Tutorial Introduction to R & M Management

910 views
835 views

Published on

Reworked the tutorial as I've been asked to take over this one going forward

Published in: Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
910
On SlideShare
0
From Embeds
0
Number of Embeds
138
Actions
Shares
0
Downloads
0
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide
  • Describe problem, scope and timeline. What I knew and didn’t know. Just part of a larger development project.
  • When decision needs to be madeHow important is the decisionTesting resources (chambers, measurement systems)Model and failure mechanismsWhat models and testing would be acceptable (believed)?
  • 20 year product with very few or none dropping in power output by 20% or more. Buried in concrete tied to rebar in mountain road bridges, activated during and for 4 hours after snowfall.
  • First three are nearly possible to measure every day – R is not and at best only estimated. How to balance and make the appropriate decisions.Slightly different for maintained units – function, cost to maintain, time to repair, and availability
  • The cable is part of a larger system
  • Story of 50% field failure rate
  • Include key suppliers or vendors by providing them full reliability goals appropriate to their element of the product
  • Include key suppliers or vendors by providing them full reliability goals appropriate to their element of the product
  • Maricopa & Phoenix Railroad Bridge Collapse – 1902 in Tempe AZ – flood water weaken – collapsed in following dry season
  • Petroski – designers design away from failureIf it is unknown what will fail, how can the design avoid it?Current standing bridge built in 1912
  • Literature, previous field returns, root cause analysis of any failure, engineering judgment, modeling and simulations, experimentationImage is a colored wood engraving, called Universum and is from The Flammarion engraving is a wood engraving by an unknown artist, so named because its first documented appearance is in Camille Flammarion's 1888 book L'atmosphère: météorologie populaire ("The Atmosphere: Popular Meteorology")
  • Supply Chain and Manufacturing VariationOverstress conditionsWear out and related
  • Rolling stones t shirt – new employee and separating circuit boards by hand
  • Old diesel train buffer’s between cars
  • Story of one organization with 31 failure mechanisms and model used for decision making
  • Cable reliability testing and models
  • Story of study by intern on what was found and what caused field failures
  • Story of using reliability to achieve availability
  • RAMS 2013 Tutorial Introduction to R & M Management

    1. 1. Introduction toR & M Management Fred Schenkelberg Ops A La Carte, LLC
    2. 2. Reliability Engineering & Management Consultant Fred Schenkelberg Senior Reliability Consultant Ops A La Carte, LLC (408) 710-8248 fms@opsalacarte.com 2013 RAMS – Tutorial 4A - Schenkelberg 2
    3. 3. Tutorial Objectives To introduce an outline to guide management of an effective reliability program. To make you think about how to integrate reliability engineering within an organization. 2013 RAMS – Tutorial 4A - Schenkelberg
    4. 4. First Challenge as Reliability EngineerNew heating cable designHow long will it last? 2013 RAMS – Tutorial 4A - Schenkelberg 4
    5. 5. What did I need to know?TimelineBudgetSamplesWhat else? 2013 RAMS – Tutorial 4A - Schenkelberg
    6. 6. How long1 or 5 yearIs this a should it last?problem?What is the goal?How does your organizationstatereliability goals? 2013 RAMS – Tutorial 4A - Schenkelberg 6
    7. 7. Outline of topics• Specifications• Apportionment• Feedback Mechanisms • What will fail? • When will it fail?• FRACAS• Maintenance Considerations• Value 2013 RAMS – Tutorial 4A - Schenkelberg 7
    8. 8. 2013 RAMS – Tutorial 4A - Schenkelberg
    9. 9. Reliability GoalFunctionEnvironmentDurationProbability 2013 RAMS – Tutorial 4A - Schenkelberg
    10. 10. Balance with other objectivesFeatures or functions of the productCost of the productTime to marketReliability 2013 RAMS – Tutorial 4A - Schenkelberg 10
    11. 11. •Cable, sensor, power supply,Cable part of a larger system controller, and connectors• Materials, processes, assembly, design, transportation, and installation 2013 RAMS – Tutorial 4A - Schenkelberg 11
    12. 12. Story of 50% field failure rateAll elements metreliability goal.Field data agreed 2013 RAMS – Tutorial 4A - Schenkelberg 12
    13. 13. Outline of topics• Specifications• Apportionment• Feedback Mechanisms • What will fail? • When will it fail?• FRACAS• Maintenance Considerations• Value 2013 RAMS – Tutorial 4A - Schenkelberg 13
    14. 14. Apportion the goal SysSub 1 Sub 2 Sub 3 Sub 4 Sub 5 2013 RAMS – Tutorial 4A - Schenkelberg 14
    15. 15. Apportion the goal SysSub 1 Sub 2 Sub 3 Sub 4 Sub 5With series system,product of sub system reliabilityis system reliability. 2013 RAMS – Tutorial 4A - Schenkelberg 15
    16. 16. Apportion complete goalFunctionEnvironmentDurationProbability 2013 RAMS – Tutorial 4A - Schenkelberg
    17. 17. NoStory of “you need to improve reliability” goalNo field dataNo Pareto of issuesJust make it better,as warranty expenses too –high4A - Schenkelberg 2013 RAMS Tutorial 17
    18. 18. Outline of topics• Specifications• Apportionment• Feedback Mechanisms • What will fail? • When will it fail?• FRACAS• Maintenance Considerations• Value 2013 RAMS – Tutorial 4A - Schenkelberg
    19. 19. Two basic questionsWhat will fail?When will it fail?Information to permit appropriateproduct development decisions 2013 RAMS – Tutorial 4A - Schenkelberg 19
    20. 20. Henry PetroskiDesign Paradigms 2013 RAMS – Tutorial 4A - Schenkelberg
    21. 21. Discovery 2013 RAMS – Tutorial 4A - Schenkelberg 21
    22. 22. Discovery ToolsDiscovery Tools 2013 RAMS – Tutorial 4A - Schenkelberg 22
    23. 23. Outline of topics• Specifications• Apportionment• Feedback Mechanisms • What will fail? • When will it fail?• FRACAS• Maintenance Considerations• Value 2013 RAMS – Tutorial 4A - Schenkelberg
    24. 24. When will it fail? Everything Fails at some point. 2013 RAMS – Tutorial 4A - Schenkelberg 24
    25. 25. Typical early life failuresProduct does not meetdesign specificationsMaterial or component characterizationProcess characterizationAssembly characterizationProcess control – focus on what’simportant 2013 RAMS – Tutorial 4A - Schenkelberg 25
    26. 26. Prediction of early life failuresNot commonly possibly for unknown variationDesign in some margin Derating Safety factor Determine marginIf variation is know, determine probability offailures – still difficult to know when though. 2013 RAMS – Tutorial 4A - Schenkelberg 26
    27. 27. Hit by a big hammerSome stress is too large to accommodate Lightening Vehicle accident Meteor strike HurricanePossibly foreseen or expected, and noteconomical to design the ability to withstand 2013 RAMS – Tutorial 4A - Schenkelberg 27
    28. 28. Prediction of overstressNot commonly possibly Design errors Environment Unexpected useWhen significant adverse consequence may occurexplore mitigation or fail safe approaches 2013 RAMS – Tutorial 4A - Schenkelberg 28
    29. 29. Wear out and relatedEverything fails –eventuallyUnderstand failuremechanisms andenvironmentThe race to cause a failure 2013 RAMS – Tutorial 4A - Schenkelberg
    30. 30. Prediction of wear out Guesses Estimates Predictions Previous products Models Testing 2013 RAMS – Tutorial 4A - Schenkelberg
    31. 31. Life testingStandardsSet levelsEnvironmental extremesSingle stress and model for acceleration factorDetermine the model and acceleration factorPhysics of failure modeling/testingPick one that fits risk, resources, and time 2013 RAMS – Tutorial 4A - Schenkelberg 31
    32. 32. Is it good enough?2013 RAMS – Tutorial 4A - Schenkelberg 32
    33. 33. Is it good enough? How do we know?2013 RAMS – Tutorial 4A - Schenkelberg 33
    34. 34. Is it good enough? How do we know? We understand the failure mechanisms & business objectives2013 RAMS – Tutorial 4A - Schenkelberg 34
    35. 35. Outline of topicsSpecificationsApportionmentFeedback Mechanisms What will fail? When will it fail?FRACASMaintenanceConsiderationsValue 2013 RAMS – Tutorial 4A - Schenkelberg
    36. 36. FRACASA method to keep it all together Triage Prioritization ClosureGrey area of when to stop fixing and ship 2013 RAMS – Tutorial 4A - Schenkelberg 36
    37. 37. Maintenance Considerations 2013 RAMS – Tutorial 4A - Schenkelberg 37
    38. 38. Value 2013 RAMS – Tutorial 4A - Schenkelberg 38
    39. 39. SummarySpecificationsApportionmentFeedback Mechanisms What will fail? When will it fail?FRACASMaintenanceConsiderationsValue 2013 RAMS – Tutorial 4A - Schenkelberg

    ×