Reliability Maintenance Engineering 2 - 4 Purpose and Equipment

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Reliability Maintenance Engineering Day 2 Session 4 Purpose and Equipment
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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  • Examining the lifecycle process
  • Balance between investment and value
  • RAM modeling to evaluate designs
  • Balance between investment and value
  • Conducting the Maintainability Design Review
  • Balance between investment and value
  • Developing a MDR checklist
  • Balance between investment and value
  • Reliability Maintenance Engineering 2 - 4 Purpose and Equipment

    1. 1. Reliability Engineering Fred Schenkelberg fms@fmsreliability.com
    2. 2. EQUIPMENT SELECTION AND REVIEW Day 2 Session 4
    3. 3. Objectives • Examining the lifecycle process • RAM modeling to evaluate designs • Conducting the Maintainability Design Review • Developing a MDR checklist
    4. 4. Lifecycle Process Concept Design MFGUse End of life
    5. 5. Concept & Design Concept • System Architecture • Reliable v Available • Goal setting Design • Selection of materials • Selection of components • Risk identification • Tradeoffs
    6. 6. Production & Use Production (manufacture) • Process variation • Materials variation • Shipping variation • Installation variation Reliability only gets worse Use • Operation Stress • Environment Stress • Maintenance Plan • Failure Detection
    7. 7. End of life Decommissioning • Lessons learned • Tear down and analysis • Reliability Differences with today’s model
    8. 8. Discussion & Questions
    9. 9. Reliability Modeling • Focus on function – Common – Perfect product • Focus on reliability – Uncommon – Imperfect product • CAD, FEA, Simulations
    10. 10. Design Comparison • Reliability occurs in the design • Selecting the most robust options • DOE, Stress/Strength, Aging, Maintenance Costs, Failure Costs
    11. 11. What if analysis • What could go wrong? • Explore changes to – Environment – Construction – Use profile – Materials Good designer do this naturally
    12. 12. System Modeling • Simulate different – Maintenance policies – Maintenance practices – Supply chain changes • DOE to design the experiments • Output is cost of ownership and availability
    13. 13. Discussion & Questions
    14. 14. Design Reviews • Adversarial or Constructive • Formal or informal • Status update or detailed design check How do you approach reviews?
    15. 15. Stages of Review • During design – Risk assessment – Options and benefits – Decisions • During review – Increase awareness – Identify errors (Petroski) – Celebrate failures • After review – Process improvement – Lessons learned
    16. 16. Hosting a review • What is the purpose? • What decisions are being made? • What is desired outcome? Be clear on why
    17. 17. Considerations • People – Knowledgeable – Stakeholder – Perspective • Timeline – Time for details – Time for action • Meetings – One on one – Group
    18. 18. Discussion & Questions
    19. 19. Review checklists • Avoid using a checklist or database – Detailed checks, i.e. keepouts, sizing, etc. – Goal is do the checklist • Do use the approach guided by checklist – Higher level – Range of stresses
    20. 20. Review guidelines • Brainstorming approaches – Day in the life – Range of stresses – Change one thing • Make it safe to talk about failure – Not personal – No attacks – No solutions (take offline)
    21. 21. Checklist cautions • Design checklists • Testing checklists • Review checklists Only works if you know everything and follow the spirit of the checklist
    22. 22. Golden Nuggets • An example that has been very effective • Identify key failure patterns • Review before and after project – What will you do? – What did you do?
    23. 23. Discussion & Questions
    24. 24. Summary • Examining the lifecycle process • RAM modeling to evaluate designs • Conducting the Maintainability Design Review • Developing a MDR checklist Equipment Selection & Review

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