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Ways to Measure Your                                                 Reliability Engineering Program                      ...
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Reliability Engineering Maturity Matrix


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Reliability Engineering Maturity Matrix which will help you determine your gaps as a Reliability Engineer or Reliability Technician. Metrics used by the Reliability has been developed and added into this matrix. This matrix was designed after 15 years of research in the field world wide.

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Reliability Engineering Maturity Matrix

  1. 1. Ways to Measure Your Reliability Engineering Program RE Maturity Matrix LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5 ELEMENTS NOT ENGAGED EXPERIMENTING GOOD PRACTICE BEST PRACTICE ENLIGHTENED Total Productive No operator Operators performing limited Operators performing inspections Operators performing failure Operators performing failure Maintenance (TPM) inspections performed machinery inspections on most machinery mode based inspections on >75% mode based inspections on all of the machines machineryRELIABILITY IN MAINTENANCE Failure data is tracked and All systems failures are tracked and 100% of machine failures are F.R.A.C.A.S. Failure data is analyzed on less than 25% of limited tracking at the machine level. Failures tracked and analyzed for tracked and analyzed through a not tracked. the machines Rudimentary analysis performed on ~75% of the machines. formalized system KPIs in place an ad hoc basis. for system performance. Job plans exist for a few jobs, Job plans exist for multi-craft jobs on Job plans exist for most jobs on Robust job plan library that grows Work Procedures/Job No job plans exist. but format is poor resulting in critical machines but format is poor critical machines and follow a with each passing month. Best Plans inconsistent execution. resulting in inconsistent execution. best practices format resulting in practices format in use with lots consistent execution. of input from crafts personnel. No Bill of Materials BOM exist for critical assets BOM exist for all critical assets and BOM exist for all critical assets and BOM exist for all machinery and Maintenance Materials (BOM) exist for any only but have never been some have been updated. selected other machinery and get are continuously verified for assets. checked for accuracy. occasionally updated. accuracy on a random basis. Work Orders are used Work Orders are used on most jobs Work Orders are mandatory for Work Orders are mandatory for CMMS Management No Work Orders for multi-craft jobs but and applied to the correct level of the all jobs. Some labor and materials any work completed with labor are used. not mandatory. hierarchy. information captured. and materials properly captured and failure codes populated. Equipment A rudimentary EMP based on ~50% of the EMP is failure modes ~75% of the EMP is failure modes Entire EMP is failure modes Maintenance Plan No EMP in place OEM recommendations is in based with no formal metrics or based with limited metrics and driven with meaningful metrics (EMP) Development place. review process. reviewed on an annual basis. and a formal MOC process in place. Reliability, Availability, RAMS modeling used to prove Used to prove all system design Used to prove all system design Used to prove/adjust all EMP and Maintainability, No RAMS Modeling major operational system changes and in late stages of capital changes and larger EMP operational strategy changes . and Safety (RAMS) performed design changes projects to identify potential issues. adjustments. Used in capital Fully integrated into the capital Modeling projects to optimize performance. approval process. No Life Cycle Cost No system modifications Analysis performed. LCCA using rule of thumb LCCA using RAMS modeling LCCA using RAMS modeling decisions are made without Life Cycle Cost Total Cost of guidelines performed on performed on most capital projects. performed on all capital projects and understanding Analysis (LCCA) Ownership not selected capital projects Total Cost of Ownership is a primary major changes to the EMP the through life costs of the recognized as a driver driver in capital decision making.RELIABILITY IN DESIGN in the capital process. proposed changes. Reliability Engineering RE involved in purchase RE involved in purchase RE details purchase Purchase (RE) not involved on specification details on rebuilt RE involved in most rebuild projects specification design for all rebuild specifications for all machines/ Specifications purchase specification parts where frequent failures for important equipment. projects and only large and components…both new and design have occurred expensive new purchases. rebuilt No human factors HFE performed only on jobs/ HFE performed on all accident Human Factors engineering (HFE) machines where there has related machinery and machines HFE performed on all machines and HFE performed on all machines Engineering (HFE) performed been employee injuries with frequent maintenance critical/frequent jobs only and all job procedures performed Commissioning procedures Commissioning procedures in place Commissioning procedures in place Commissioning procedures in Commissioning No commissioning in place for larger machines for all machines installed on capital for all machines installed on capital place for all capital projects and Procedures procedures in place. installed on capital projects. projects. projects and post-maintenance start- all post-maintenance start-ups. ups on most equipment. FMEA is used to validate Use of FMEA as a design verification Formal requirements in place for Failure Modes & FMEA is not used design criteria for small portions tool is used on all new projects but FMEA as a design tool is required use of FMEA as a design tool on Effects Analysis of new designs, but is not only required on about half of the on most new designs. all new systems. required. equipment. Requirements Some engineers have been Some engineers are using Used as a design tool to improve Company has standard Design Requirements documents are not trained in drafting project requirements documents to ensure reliability but the company does requirements documents Documents used at all requirements documents but asset reliability not have requirements document for design, installation and they are rarely used. standards operational performance Analysis occasionally Analysis performed on monthly Process Weibull No analysis is performed for informational Analysis performed on an Analysis performed on quarterly basis and strategy adjusted Analysis/Reliability performed purposes. No strategy annual basis and strategy adjusted basis and strategy adjusted based basedRELIABILITY IN PROCESSES Simulations adjustments are made based based on results on results. on results. on results. OEE not used as OEE targets exist for less than OEE targets exist for ~50% of OEE is tracked for nearly 75% of OEE is the top operational KPI OEE/Loss Elimination a metric. No Loss 25% of assets and the operational equipment and is assets and often used to trigger and used to drive all improvement Elimination effort is not used for loss elimination sometimes used to trigger loss major improvement initiatives. initiatives. evident. projects. elimination projects . Some basic lean tools are used Evidence of many tools in use. Continuous improvement initiatives Lean tools are utilized in all Lean Manufacturing Lean manufacturing randomly, but no system exists No formal system for execution, and use of lean tools limited to company functions. Continuous concepts not used. for spreading the use of the tracking or reporting. operational areas only. improvement is evident tools nor tracking results. throughout the organization. Used to solve one or two One part-time “belted” practitioner on Projects completed by full time Numerous “belted practitioners. Six Sigma Six Sigma methods problems per year. Problem staff. Results tracked informally. No practitioners using systematic KPI’s include Six Sigma results. not used. selection not data driven. formal project triggers. triggers and formal reporting Drives continuous improvement. systems. Exists on Critical Assets Exists on All Assets Exists on All AssetsRESULTS / SCORECARDS Asset Health Not Measured Not Measured >65% Green >75% Green >80% Green % Planned/Scheduled 0%/25% <25%/<50% <50%/<75% <75%/<90% >90%/>90% Maintenance Cost to RAV Unknown >10% >8% >5% <2.5% Reliability Index (RI) Unknown <5 5<RI<20 20<RI<50 >50 North America • Latin America • Europe • Middle East • Asia-Pacific GPAllied Europe GPAllied GPAllied Asia-Pacific Axxes Business Park World Headquarters Brisbane, Australia Guldensporenpark 21- Blok C B-9820 4360 Corporate Rd, Suite 110 o. +61 (0)7.5540.7701 Merelbeke, Belgium Charleston, SC 29405 f. +61 (0)7.5540.7702 o. +32(0) o. 888.335.8276 f. +32(0) f. 843.414.5779