Reliability Maintenance Engineering 1 - 2 Max Benefits

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Reliability Maintenance Engineering Day 1 Session 2 Max Benefits
Three 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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  • Value iamge – intro to each task has to create value – tied to that idea,
  • Balance between investment and value
  • Background intro to terms and concepts
  • Balance between investment and value
  • Analysis of equipment failure as preparation for different types of maintenance programs
  • Balance between investment and value
  • Image to open Maintenance approaches
  • Balance between investment and value
  • Image for maintenance approaches
  • How to build a program
  • Balance between investment and value
  • Balance between investment and value
  • Reliability Maintenance Engineering 1 - 2 Max Benefits

    1. 1. Reliability Engineering Fred Schenkelberg fms@fmsreliability.com
    2. 2. Introduction • Reliability is about time to failure • Maintenance is about restoring equipment and processes to operation • Engineering is finding the right balance between cost and action
    3. 3. MAXIMIZING POTENTIAL BENEFITS OF MAINTENANCE ACTIVITIES Session 2
    4. 4. Objectives • Reduce operating cost while boosting productivity though equipment maintenance • Analyzing equipment failures for proactive, predictive & preventative maintenance • Selecting the appropriate maintenance approach • Developing a maintenance program
    5. 5. Cost of Maintenance • Spares • Labor • Training • Diagnostic Equipment • It takes an investment
    6. 6. Cost of Downtime • Loss production • Restart Costs • Loss of Revenue • Opportunity Costs • Unscheduled downtime
    7. 7. Benefit of Operating • Revenue • Production • Efficiency • Uptime • Less downtime means More uptime and value
    8. 8. Discussion & Questions
    9. 9. Reliability • Common Understanding • Function • Environment/Use • Duration • Probability
    10. 10. Availability • Common Understanding • Inherent – ideal • Achieved – PM & CM included • Operational – actual with all downtime
    11. 11. Maintainability • Two elements • Design for maintainability • Effectiveness of repairs – Good as new – Bad as old – Somewhere between
    12. 12. Uptime • Operating when it should be operating • Who defines and how is this defined?
    13. 13. Discussion & Questions
    14. 14. Equipment Failure • Provides guide to maintenance approach • What are the results of failure? • What is known about failure modes and mechanisms?
    15. 15. Types of Failures • A range • Nobody cares • Degradation • Shut down
    16. 16. Failure Impact • A range of impacts • Nobody cares (why is the equipment here?) • Degraded operation • Major repair/restart
    17. 17. Failure Signs • Is there a warning? • Measured and predicted • Slow degradation of throughput or quality • Sudden and unforeseen
    18. 18. Discussion & Questions
    19. 19. Reactive Consider for • Small items • Non-critical • Inconsequential • Unlikely to fail • Redundant
    20. 20. Preventive Consider if • Subject to wear out • Consumable replacement • Failure pattern known
    21. 21. Predictive Consider when • Random failure pattern • Not subject to wear • PM induce failures
    22. 22. Proactive Consider with • Root Cause Failure Analysis • Age Exploration • FMEA
    23. 23. Discussion & Questions
    24. 24. Interval v. Conditional Interval or time based • Fixed schedule • Assumes wear or predictable time to failure • Easy to manage and plan Condition based • Focus on failure mechanisms • Consider cost of failure • May require health monitoring • Cost effective
    25. 25. How to decide an approach Ask these questions: • Nature of failures? • Able to detect ? • Predictable? • Indicators? • Cost of failure? • Cost of maintenance? Approaches • Reactive • Preventive • Predictive • Proactive
    26. 26. Discussion & Questions
    27. 27. Get the data • Data, Data, Data • Convert to information • Do the math • Look for Stability and Exceptions
    28. 28. Where to start • Use data you have to start – build case for better data collection • Run experiments to get better data • Next focus on high value areas
    29. 29. Build a program • Maintenance procedures • Tools and training • Engineering – Design, Reliability & Operations • Connect to business
    30. 30. Metrics • Not MTBF • Business metrics – Revenue, throughput, et c. • Time to failure – Mean Cumulative Function or Life Distributions
    31. 31. Discussion & Questions
    32. 32. Summary • Value – do what adds value • Understand failure mechanisms • Time to failure & Environmental data • Breadth of Maintenance Engineering Maximize potential benefits of maintenance activities

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