Reliability Maintenance Engineering 1 - 2 Max Benefits
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This document discusses reliability engineering and maximizing the benefits of maintenance activities. It covers topics like the costs of maintenance versus downtime, different maintenance approaches like reactive, preventive and predictive, and how to analyze equipment failure data to select the best maintenance strategy. The objectives are to reduce operating costs while improving productivity through strategic equipment maintenance based on analyzing failure patterns and mechanisms. Questions are provided throughout to facilitate discussion on these reliability and maintenance engineering topics.
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Reliability Maintenance Engineering 1 - 2 Max Benefits
- 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. MAXIMIZING POTENTIAL BENEFITS OF MAINTENANCE ACTIVITIES Session 2
- 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
- 6. Cost of Maintenance • Spares • Labor • Training • Diagnostic Equipment • It takes an investment
- 7. Cost of Downtime • Loss production • Restart Costs • Loss of Revenue • Opportunity Costs • Unscheduled downtime
- 8. Benefit of Operating • Revenue • Production • Efficiency • Uptime • Less downtime means More uptime and value
- 11. Reliability • Common Understanding • Function • Environment/Use • Duration • Probability
- 12. Availability • Common Understanding • Inherent – ideal • Achieved – PM & CM included • Operational – actual with all downtime
- 13. Maintainability • Two elements • Design for maintainability • Effectiveness of repairs – Good as new – Bad as old – Somewhere between
- 14. Uptime • Operating when it should be operating • Who defines and how is this defined?
- 17. Equipment Failure • Provides guide to maintenance approach • What are the results of failure? • What is known about failure modes and mechanisms?
- 18. Types of Failures • A range • Nobody cares • Degradation • Shut down
- 19. Failure Impact • A range of impacts • Nobody cares (why is the equipment here?) • Degraded operation • Major repair/restart
- 20. Failure Signs • Is there a warning? • Measured and predicted • Slow degradation of throughput or quality • Sudden and unforeseen
- 23. Reactive Consider for • Small items • Non-critical • Inconsequential • Unlikely to fail • Redundant
- 24. Preventive Consider if • Subject to wear out • Consumable replacement • Failure pattern known
- 25. Predictive Consider when • Random failure pattern • Not subject to wear • PM induce failures
- 26. Proactive Consider with • Root Cause Failure Analysis • Age Exploration • FMEA
- 29. 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
- 30. 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
- 33. Get the data • Data, Data, Data • Convert to information • Do the math • Look for Stability and Exceptions
- 34. 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
- 35. Build a program • Maintenance procedures • Tools and training • Engineering – Design, Reliability & Operations • Connect to business
- 36. Metrics • Not MTBF • Business metrics – Revenue, throughput, et c. • Time to failure – Mean Cumulative Function or Life Distributions
- 38. Summary • Value – do what adds value • Understand failure mechanisms • Time to failure & Environmental data • Breadth of Maintenance Engineering Maximize potential benefits of maintenance activities
Editor's Notes
- 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