Reliability centered maintenance is a method of analyzing breakdowns to identify which maintenance methods will work best for each piece of machinery. Click this link to get free access to 14 hours of Plant Wellness Way videos. Equipment Reliability Strategies (e.g., one-time tasks, preventive maintenance (PM), predictive maintenance (PdM), etc.) In all cases those assemblies fitted one of the reliability curves from ‘A’ to ‘F’. The first step is to select the piece of equipment for reliability-centered maintenance analysis. The third maintenance strategy to lower random failures is to religiously do the preventative maintenance and keep your equipment’s internal and local environment clean and fresh. You might want to go further and only buy from manufactures and use installers that crave accuracy and live ‘quality’. “We’ve been very busy deploying our SAP plan and EAM (enterprise asset management) tools across the various plants. To get the most out an investment in construction equipment, it needs to be maintained in optimal shape. Becht Inspection Development and Execution Strategy (BIDES) is designed to address that with a suite of 76 documents that lay the technical foundation for Damage Mechanism Reviews, Integrity Operating Windows (IOW), Turnaround Risk Based Work Selection (RBWS), and Equipment Reliability Plans (ERP). When up to 70% new equipment first starts-up, the failure curves tell us that they are at much higher risk of failure than once they have been operated for some time. For example, small parts and equipment, redundant systems that are non-critical components of the equipment or facility and parts and equipment that are subject to random failure. in your web browser you consent to all cookies in Part of the answer to the question of how to reduce and lessen the impact of infant mortality can be found in the difference between the results of curve ‘F’ for the airline industry and the naval industry. And when do I need to do it? Reliability can be broadly defined as the probability that an Equipment will perform its intended functions continuously for a specified duration. Tuesday - Friday: 9 a.m. - 5 p.m. We asked three equipment management experts... Undercarriages are one of the more costly parts of an excavator to repair and replace so contractors can save a lot of money and downtime by ensuring... Construction companies are often advised to not get too cozy with suppliers. To calculate availability, use … So in a sense you should leave a well operating piece of equipment alone. The proposed modular approach, assisted by properly selected reliability-centered maintenance (RCM) software, has been proven to be effective in achieving efficiency, reducing development time and maximizing limited resource utilization. When measuring reliability, consideration must be given to the data contained in management reports. Christer Idhammar delivers a powerful presentation designed to enlighten you on how to focus on the fundamentals that guarantee results. In other words, once equipment is past its infant stage, you cannot predict when most of your equipment will fail! That allows most of the early failure causes to be fixed before the navy gets the equipment. The Solution ARMS Reliability was engaged to develop maintenance strategies for more than 300 pieces of equipment in the processing plant - such as conveyors, vibrating screens, crushers, high-pressure grinding rolls, ball mill and more. Of course you can choose to do nothing and just live life by ‘luck’ and repair things when they break! I can be contacted on the email address found in the ‘Contact Us‘ page. There was numerous navy ship assemblies tracked for their entire history. Yet, notes Michael D. Holloway, principle consultant, certified reliability leader, ALS Tribology, there are companies that underestimate the importance of equipment maintenance. Reactive Maintenance: Also known as Run to Failure, this strategy is to have equipment deliberately run until it breaks down. Do not do the maintenance and the machine will fail sooner than it would have. An air compressor is made of hundreds of parts combined into systems – the compressor, oil supply, pressure receiver, motor drive, etc. Their frequency of failure, the inverse of which is their reliability, was graphed. Increased reliability is achieved by doing maintenance well, doing it completely and doing it on time. Companies should weigh the options.”. For example the naval results came for both surface ships and submarines. New articles on maintenance strategy, engineering asset management, equipment reliability and operational excellence are regularly posted on this web site. That then is the second maintenance strategy to adopt – only accept equipment when it has been tested to full specification and duty for a good period of time. More the MTBR more is the Reliability. Precision maintenance includes balancing rotating equipment, checking shaft alignment is within close tolerance, reinstalling the equipment without stress and testing bearing vibration after the rebuild to prove the machine is running perfectly. To help you deliver greater operational effectiveness, we can implement an equipment lifecycle strategy that enables you to maximize the period between scheduled maintenance and helps increase reliability of your valves, actuators, instruments, and regulators. That is called ‘reactive maintenance’. These items offer low safety issues and minimal operation disruptions. We know that one curve cannot describe all failure patterns, but nearly all equipment reliability can be described by some combination of the three zones shown in Figure 2. The implication is that about 90% of all equipment can fail early in life. Over the years parts wear and don’t fit together properly, or components suffer cumulative stress and fatigue. Plan – With steps 1 through 3 in mind, design an action plan on a daily, weekly, monthly and yearly basis that lays out what a company, department, team or individual needs to accomplish and to successfully apply its equipment maintenance strategy. The course covers Equipment Reliability Strategy development and implementation to lead an oil & gas company to a pacesetter performance comprising of: y Knowledge and Best Practices to develop effective equipment reliability strategies (operation, design and The fifth strategy to offer you at the moment for minimising downtime at the infant mortality stage is to be sure you have access to critical spares and replacements. How much time would pass before the car would fail? I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be … Like the new design engineer mentioned above, a person new to fabrication or assembly will make more errors that one well experienced in their trade. Only 6% to 11% of equipment is certain to work right when first used. “We’ve been very busy deploying our SAP plan and EAM (enterprise asset management) tools across the various plants. “Equipment breaks and components fail,” he says. This is down through Failure Mode Effect Analysis (FMEA) and predicting when an asset might fail so that maintenance work can be planned and performed cost effectively before it becomes a breakdown. It is the nature of our early 21st Century technology that equipment parts do not last forever. We use machinery and equipment to do particular functions we need done. Send an email to info@lifetime-reliability.com, Be a Subscriber Subscribe to be at the leading edge of EAM, Maintenance and Reliability, © 2005 - 2020 Lifetime Reliability Solutions | World Class Reliability - All rights reserved, download the free 299-page Plant and Equipment Wellness PDF book and templates, get free access to 14 hours of Plant Wellness Way videos. The second observation you must make is from curve ‘D’. Reliability engineering is a strategic task concerned with predicting and avoiding failures. These failure patterns, or failure curves, are shown in Figure 1. The aim of maintenance is to control the timing of the failures so that you can select when they happen. We can see from the reliability curves that for nearly 100% of equipment in the period between run-in and wear-out, you cannot predict when a particular piece of equipment will fail. Proactive Maintenance: Also referred to as Reliability Centered Maintenance, this strategy is based on Predictive Maintenance and Condition Based Maintenance. Proactive Maintenance tries to manage failure through analytics with the embodiment of never allowing the same failure to reoccur. Holloway presented the education session – “Preventative Maintenance” – at CONEXPO-CON/AGG 2020. The range and difference of values between the airline industry and naval results, as well as within the naval results, are believed to reflect the different environments and duty requirements within the respective industry. Maintenance is cheap. “Often, a predetermined schedule for this sort of maintenance is built into the operation and changing it may produce disruptions and even be costly for the mid-term. Figure 3 shows the infant mortality zone and asks the important questions that need to be asked by every company that uses equipment. By understanding these failure, or reliability curves, and the information they contain, you can select the right maintenance strategies to deliver lifetime equipment reliability! “The foundation for any maintenance strategy,” Holloway maintains, “is to change for the better by determining what a company can do to prevent equipment from breaking, enhance safety, drive down operating costs and improve profitability by getting the most out of its people and equipment assets.”, “Although achieving such positive change is difficult,” Holloway – who has been involved in the field of failure analysis for 35 years – says “there are five basic elements that have to be tackled for increased equipment reliability.”. “The basic philosophy of Proactive Maintenance is using analysis and adding a root-cause failure to detect and pinpoint precise problems to avoid or eliminate those problems from occurring again,” he says. Root Cause Analysis is a critical part of your equipment reliability program. When your car is broken down you can’t get to where you need to be! Depending on the asset, the service could be done on an hourly or mileage basis, and can include such maintenance processes as changing engine and transmission oil, replacing filters, greasing/lubrication, brake system inspections, etc. Since you will not be stripping your equipment down until there is evidence that it is needed, it becomes important when it is stripped and rebuilt that two things happen. Equipment failures are a result of defects; therefore by eliminating defects we can improve equipment reliability. This article is an overview of the content presented. You will find that equipment designed by a novice engineer will have many more failures than equipment designed by an experienced engineer. When equipment is built you do not know the skills and abilities of the fabricators and assemblers. What is the right maintenance to do? Equipment Lifecycle Strategy for Valves, Actuators & Regulators Maximize the period between scheduled maintenance and increase the reliability of your assets with an equipment lifecycle strategy … The actual chance of failure is not fixed, it can be influenced. Predictions are based on specific information about an asset type that is a reliable predictor of imminent failure, and on real-time data gathered using various equipment condition monitoring measurements, sensors and techniques (current, voltage, temperature, vibration, lubrication, etc.) That makes it is almost pointless to overhaul a machine and replace its parts, because most of the time they are perfectly fine. First is that equipment and plant designers do not know what they don’t know. Reliability-centered maintenance (RCM) analysis provides a structured framework for analyzing the functions and potential failures of facility equipment, such as pumps, compressors, a facility processing unit, etc. Maintenance for Controlling Random Failures Once your equipment is past its early life it enters a long period of time where it suffers random failures. that lead to desired business results. We touched on it earlier – we must monitor the condition of the machine or equipment to see if it is changing. For companies and businesses who rely mostly on their equipment to do the job for them, a mishap such as this will cost the company a lot. It cannot be said that 1% of all cars are failed at some point. and compared – using analytics – against known parameters of failure. Accept Failures. All equipment will eventually fail. Competency Development – Determine the competency and skills needed to make changes and then provide the necessary training. Involve the full team. TapRooT® was built (and is continuously improved) to help your company meet the ever increasing demands for reliable equipment, process reliability, improved safety, environmental stewardship, regulatory compliance, and product quality. Figure 4 tells us that from time to time something will go wrong and the equipment fails. Focus on design for reliability, operability, maintainability, safety and inspectability (ROMSI) Most … You just want the compressed air. What are the causes of premature failure when equipment is new? But… if you put in a lot of new components and assemblies, they all start at the infant mortality stage with its associated higher failure rates! IMPLEMENTING STRATEGIC ASSET MANAGEMENT. Improve Equipment Reliability by Using TapRooT® Root Cause Analysis Equipment reliability expert Heinz Bloch helped us tailor TapRooT® Root Cause Analysis for equipment reliability professionals. Hence ‘don’t touch it till it breaks’ should become ‘why touch till it breaks’? Do the maintenance and the machine will keep working as it should for longer. Say you were to drive your family car off-road once and treat it as you would an off-road vehicle. A computer is made of hundreds of parts – the central processing unit, image processing, memory storage, monitor, key board, etc. This drives the goal to create generic equipment reliability strategies, given many different names in different organizations, such as generic maintenance strategies, equipment reliability strategies, best in class strategies, corporate strategies, FMECA library, RCM Library, etc.

equipment reliability strategy

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