Reliability Maintenance Engineering 3 - 1 Measuring Availability

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Reliability Maintenance Engineering Day 3 session 1 Measuring AvailabilityThree day live course focused on reliability engineering for maintenance programs. Introductory material and discussion ranging from basic tools and techniques for data analysis to considerations when building or improving a program.

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  • Structuring a hierarchy of goals and measures
  • Balance between investment and value
  • Determining constraints and bottlenecks
  • Balance between investment and value
  • Developing five measures of availability
  • Balance between investment and value
  • Obtaining measures for critical equipment
  • Balance between investment and value
  • Embarking on structured approach to improve availability.
  • Balance between investment and value
  • Formulating a condition monitoring program
  • http://www.maintenancephoenix.com/2013/04/23/achieve-breakthrough-performance-today-optimize-production-capacity/
  • Balance between investment and value
  • Reliability Maintenance Engineering 3 - 1 Measuring Availability

    1. 1. Reliability Engineering Fred Schenkelberg fms@fmsreliability.com
    2. 2. MEASURING AVAILABILITY Day 3 Session 1
    3. 3. Objectives • Structuring a hierarchy of goals and measures • Determining constraints and bottlenecks • Developing five measures of availability • Obtaining measures for critical equipment • Embarking on structured approach to improve availability. • Formulating a condition monitoring program
    4. 4. Availability & Business • Translating business objectives into availability • Cost • Yield • Throughput • ROI • …
    5. 5. Hierarchy of Goals • Business goals to line, system, or process • Decision & budget level • Physical alignment • Process alignment
    6. 6. Actionable level • Apportionment • RBD and apportionment • Available • Reliability • Maintainability
    7. 7. Sample goal statements • Line x in plant y operates with 90% availability over each shift • Function • Environment • Probability • Duration • Compressor x on equipment y provides z pressure with 95% reliability over 5 years of continuous operation. • Replacement of compressor x occurs 90% of the time in less than 2 hours with existing equipment and diagnostics.
    8. 8. Performance Reporting Flow
    9. 9. Discussion & Questions
    10. 10. Process flow modeling • Map the process including • Physical item movement • Information movement • Transitions, decisions • Durations and gates
    11. 11. Constraints A limiting factor • Capacity • Throughput • Budgetary
    12. 12. Bottlenecks : a delay caused when one part of a process or activity is slower than the others and so hinders overall progress • Opportunity • Optimization
    13. 13. Examples • Bottling plant • Filler equipment – 600 per hour fill rate – Lowest rate of all equipment • Buffer (inventory holding area) – Limited by size or floor space
    14. 14. Discussion & Questions
    15. 15. Availability • Ratio of the expected value of uptime to the aggregate of the expected values of up and down time. A = E[Uptime] E[Uptime]+ E[Downtime]
    16. 16. Inherent Availability, Ai • The probability of satisfactory operation at given point in time under stated conditions in an ideal support environment. • Downtime only counts corrective maintenance and does not include – Logistics time – Administrative time – Preventative maintenance • Items under control of equipment designer.
    17. 17. Achieved Availability, Aa • Probability of satisfactory operation at given point in time under stated conditions in ideal support environments • Downtime only includes active preventative and corrective maintenance time (wrench time). • Does not include – Logistics time – Administrative time
    18. 18. Operational Availability, Ao • Probability of satisfactory operation at given point in time under stated conditions with actual support environment. • Downtime includes everything. Reliability/ Supportability/ Maintainability/ Design “Cause” Operational “Effect” Operation Logistics Maintenance Time to Support (TTS) Time to Maintain (TTM) Time to Failure (TTF) System Downtime
    19. 19. Time
    20. 20. Discussion & Questions
    21. 21. Critical Equipment • What to optimize? • Bottleneck equipment • Quality element • ‘Where the magic occurs’
    22. 22. Risk Minimization • Long repair times • Safety issues – Explosion – Releases • Poor Quality impact
    23. 23. What to Measure • Direct performance • Performance indicators • Quality stability • Leading indicators – Current – Pressure
    24. 24. Measurement Techniques • Product measurements • Process parameters • Process Control • Inspections and Studies
    25. 25. Discussion & Questions
    26. 26. Availability Improvement Planning • Assessment • Process mapping • Data collection • Characterize current state (and reason for current state)
    27. 27. Level of detail • Enough data to make informed decisions • Is the process stable? • What causes differences? • What is cost of downtime?
    28. 28. Focus on Value • Select improvement projects and tasks that have highest ROI – Low hanging fruit – Major return potential – Portfolio approach • Estimate value and risk before selecting tasks
    29. 29. Program Approaches • Major redesign • Incremental improvements • Process control (stability) • Backup plan
    30. 30. Discussion & Questions
    31. 31. Condition Monitoring • Regular observations or measures of indictors of impending failure. – Oil level – Current draw – vibration
    32. 32. Image from article by Ricky Smith on The Maintenance Phoenix site
    33. 33. Experiments, Models and Measures • Start measuring today • Engineering judgment and experience to starting monitoring • Design experiments to determine effective predictors
    34. 34. Considerations • Ability to detect fault indicators • Lead time requirements – Spare parts – Specialized equipment • Scheduling optimization
    35. 35. Discussion & Questions
    36. 36. Summary • Structuring a hierarchy of goals and measures • Determining constraints and bottlenecks • Developing five measures of availability • Obtaining measures for critical equipment • Embarking on structured approach to improve availability. • Formulating a condition monitoring program Measuring Availability

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