The document outlines objectives and methods for collecting and analyzing reliability data to support decision-making in engineering. It emphasizes establishing data collection systems, creating equipment failure codes, and ensuring the quality and relevance of data. Additionally, it discusses examples and techniques for data collection and analysis to improve operational efficiency.

1. Reliability Engineering
Fred Schenkelberg
fms@fmsreliability.com

2. COLLECTING RELIABILITY DATA TO
SUPPORT EFFECTIVE DECISIONS
Day 1 Session 3

3. Objectives
• Establish field data collection systems
• Creating taxonomies and equipment failure
codes from ISO 14224
• Gathering and examining basic reliability data
• Developing analysis information for repair
• Determine cost advantages of alternative
action plans to meet requirements

5. Data Quality
• High quality data is
• Compete
• Compliance
– Reliability parameters
– Data types & formats
• Accurate

6. Obtaining Quality Data
Investigate data sources
• Define objective for data collection
• Inventory or operational data complete
• Sufficient and relevant data available
• Identify installation date, population and
operating period(s) for equipment

7. Obtaining Quality Data
Preparation of sources
• Run a pilot of collection
methods
• Plan collection process
– Schedules, milestones, seq
uence and number of
units, time period, etc.
• Training
• Collection process
assurance plan

8. Data Sources
• What do you need to
make decisions?
• Maintenance
Management System
• Prioritize according to
importance to safety
and production

9. Discussion & Questions

11. Boundary description
• Describe what is and is
not included
Needed for consistent
• Data collection
• Data compilation
• Data Analysis
• Decision making
Show on diagram
• Subunits
• Interfaces to
surroundings
• Be clear what is in and
outside boundary

13. Equipment Hierarchy
• Equipment Class

14. Equipment Hierarchy
• Equipment Class
• Equipment Unit

15. Equipment Hierarchy
• Equipment Class
• Equipment Unit
• Subunit

16. Equipment Hierarchy
• Equipment Class
• Equipment Unit
• Subunit
• Maintainable Level

18. Equipment Failure Codes
Create short list and codes
as needed
Three types
• Desired function is not
obtained
• Deviation outside limits
• Failure indication
observed

19. Combustion engines

20. Equipment Boundry

21. Equipment unit subdivision

22. Unit specific data

23. Failure modes

24. Discussion & Questions

26. Data Collection
Techniques
• Manual
• Inspection
• Automatic
• Surrogate

27. Equipment Data

28. Failure Data

29. Maintenance Data

30. Discussion & Questions

31. Example

32. Bottling Plant Example
• Data Collected

33. Bottling Plant Example
• Objective
• Improve change overs
so they start with
higher availability
0
0.25
0.5
0.75
1
1 2 3 4 5 6 7 8
CummulativeAvailability

35. Bottling Plant Example
• Analysis

36. Bottling Plant Example
• Options to consider
• FMEA
• Detailed RCA on top
early issues
• Redesign of change
over process

37. Bottling Plant Example
• Results
• Avoided adding second
line
• Improved availability
• Improved tracking
• Improved RCA and
redesign process

38. Discussion & Questions

39. Summary
• Establish field data
collection systems
• Creating taxonomies and
equipment failure codes
from ISO 14224
• Gathering and examining
basic reliability data
• Developing analysis
information for repair
• Determine cost advantages
of alternative action plans
to meet requirements
Collecting reliability data
to support effective decisions