We’ve talked around it before. It encompasses availability, performance, and quality, and when used correctly is removing waste. Troubleshooting IS NOT Root Cause Analysis. The design, construction, maintenance, adjustment, calibration, and use of measuring and of manufacturing equipment are factors which impact on the reliability of the product. This guide emphasizes concepts, not mathematics. Root Cause Analysis is a critical part of your equipment reliability program. Measuring Reliability. But what exactly is reliability, and why is it important to understand the difference between it and other maintenance-relate… Use probability and statistic tools for risk and process hazard assessments. These systems may be designed as active parallel systems or standby parallel systems. Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities … process of identifying potential problems with your assets and determining what you should do to make sure those assets continue to produce at maximum capacity Good products seek to minimize the unexpected interruptions in performance throughout the duration of the typical of customer experience. This may include how to select and apply the most appropriate maintenance practices so the equipment and processes … This application of “guessing” as the primary tool for root cause analysis of equipment reliability and maintenance problems is probably the biggest challenge to achieving equipment reliability excellence. The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. Provide technical assistance to manufacturing, maintenance, and technical staff. Applied technology preventive maintenance. Test new … ETA’s principle is comparable to FTA’s technique with the distinction that events leading to failure are noticed in ETA, not just a failure as in the case of the FTA. Analyze and interpret reliability data and provide recommendat… Definitions of associated terms, a structured approach to the logging of data for proper evaluation are provided. What is reliability? Our technologically based society depends on machinery and equipment to keep it operating. We focus on three major areas: Energy efficiency, Maintenance Cost and Equipment Reliability. The contrary connection between equipment risk and reliability is not obvious, but it reveals itself to us when the risk equation is divided into its fundamental elements. It is a top-down deductive approach used for determining the cause of failures or testing the reliability of a system. You can deliver high equipment reliability by ensuring the … Accept Failures. The Becht ERP process achieves overall unit reliability for clients by: This step is performed in collaboration with the production process. Figure 10. Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities equipment that are subject to wear, erosion, deterioration, aging, etc., resulting in increasing breakdowns and outages. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. Guide efforts for ensuring the reliability and maintenance of assets, products, and processes. That’s why it is our belief that the overall competitiveness of your organization depends on establishing stable and reliable processes and equipment. That’s what TPM does. Reviewing performance and adjusting the maintenance strategy. Though reliability and availability are often used interchangeably, they are different concepts in the engineering domain. The equipment selected should be critical in terms of its effect on operations, its previous costs of repair, and previous costs of preventive maintenance. Rank the criticality of the new asset with respect to the rest of the plant. Develop tests for acceptance and criteria for inspection. I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be on continuous improvement. To perform a thorough … Reliability … Reliability is the probability that a system performs correctly during a … If you think about how we use the word “reliable” in everyday language, you might get a hint. How does that engineer prioritize the work? If you want world class reliability, then you will need to ensure failure-free design, manufacture, assembly, installation, operation, and maintenance is always done to your plant and equipment. We hear the term used a lot in research contexts, but what does it really mean? The first key area where Maintenance can impact on equipment reliability is by having an appropriate preventive and predictive maintenance program in place. You can deliver high equipment reliability by ensuring the chance of incidents that cause failures Operational equipment reliability, and the resulting plant uptime, are inversely linked to the number of risks you allow your equipment and machinery to suffer. Studies indicate that up to 95% of an asset’s Total Ownership Cost (TCO) or Life Cycle Cost (LCC) is determined before it is used. What is Reliability? 2 Introduction 3. It is an inductive approach used for evaluating the process and its events leading to a possible accident. Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. In other words, all of the units in a series system must succeed for the system to succeed. At the equipment level, the MTBR is measured for all … No organization wants assets to break down, to produce poor quality products, or to operate inefficiently. Every manufacturing facility wants production equipment to operate reliably. Like or follow us to stay up-to-date with SMRP. For instance, we often speak about a machine as reliable: “I have a reliable car.” Or, news people talk about a “usually … Send your article and accompanying documents and images to [email protected]. The Reliability Engineer (in full partnership with the operations team) develops a plan to eliminate or reduce the losses through root cause analysis, obtains approval of the plan and facilitates the implementation. Equipment History The use of historical repair and maintenance information is critical to continuous improvement in reliability. A reliability engineer is an individual responsible for tracking the equipment behavior to avoid any downtime that may affect company revenues. A Reliability Engineer must monitor the equipment in question, make suggestions as to when the equipment should be repaired and ensure that the equipment operates in a manner that prevents the company and its staff from being harmed. Simply put availability is a measure of the % of time the equipment is in an operable state while reliability is a measure of how long the item performs its intended function. 1.5 The analyses presented in this document are designed to identify deficiencies in equipment support resources as well as in the equipment itself. 1 EQUIPMENT RELIABILITY TRAINING SERIES LEVEL 1: AWARENESS 2. It encompasses availability, performance, and quality, and when used correctly is removing waste. Improved equipment reliability can reduce maintenance costs, minimize opportunity costs associated with downtime, and can ensure products are not produced outside of acceptable specifications. Referenced also is the well-known military handbook, MIL-HDBK-781, a comprehensive guide in developing reliability test plans and environmental test profiles for defense-related equipment; the MIL-HDBK-2164 provides further guidance on the traditional Environmental Stress Screening (ESS) process. The Equipment Reliability Process focuses the maintenance of physical asset reliability on the business goals of the company. The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. Operational equipment reliability, and the resulting plant uptime, are inversely linked to the number of risks you allow your equipment and machinery to suffer. However, it does include explanations of some statistics commonly used to describe test reliability. Equipment Reliability Basics 101 for Reliability Management. Improvement The following formula is for calculating the probability of failure. Inventory Turns. High equipment reliability is a choice and not an accident of fortune. The major components of reliability improvement include optimization of site rotating equipment availability by implementation of practical: Site reliability … … Develop and maintain the Risk Management Plan for identifying and managing all risks. In the non-physical sciences, the definition of an instrument is much broader, encompassing everything from a set of survey questions to an intelligence test. For example, one of the key factors affecting the reliability of electronic components and systems is temperature – basically the higher the temperature of the device the higher the failure rate. For equipment that is expected to be op… TapRooT® - Changing the Way the World Solves Problems. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. Simple parallel system – the system reliability is increased to 99% due to the redundancy. Work with Project Engineering to guarantee that new and altered installations are reliable and maintainable. Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. Before starting a project, the Reliability Engineer needs to be involved on what kind of equipment needs to be bought, what kind of ROI the company can expect in exchange, as well as how and where to install that piece of equipment. Society for Maintenance & Reliability Professionals, SMRP Professional Development Webinar Content Submission Form, Artificial Intelligence & Increasing Reliability of Facility Assets, Operational Excellence in the Maintenance & Reliability. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. The fundamental role of a reliability engineer is to develop a plan for monitoring equipment downtime, increasing equipment availability, reducing the production losses and maintenance costs by utilizing different techniques and tools. In other words, reliability can be seen as the probability of success and the dependability of an asset to continuously be operational, without failures, for a period of time. While a reliability engineer’s role differs from company to company, their objective is always the same: to minimize equipment downtime, lower maintenance cost, and to avoid business operations interruption. Atlanta, GA 30339, USA, Copyright 2021 . What is the role of an Equipment Reliability Engineer? Modeling 2. 4. Subjects would include: Examples of topics that might fit into this area also include: Ready to write? The Noria, for instance, is an ancient pump thought to be the world’s first sophisticated machine. Availability, also known as operational availability, is expressed as the percentage of time that an asset is operating compared to its total scheduled operation time. Developing a maintenance strategy to ensure performance. Simple. To be effective in preventing unexpected failures, the preventive maintenance program needs to, from a technical perspective, successfully deal with the underlying … No amount of maintenance can raise the inherent reliability of a design. If the equipment’s inherent reliability or performance is poor, doing more maintenance will not help. That is the exact purpose and duty of a Plant Wellness Way EAM system-of-reliability. The Reliability Engineer plays one of the most significant roles in business, particularly for a business relying on costly and big equipment or technology to operate. When the equipment does what it needs to do when it needs to do it, plant output and profitability is maximized. 4 Equipment Reliability Training Series Learning Objectives (Continued) 7. The analysis also provides useful information to determine what measures will decrease the risk for all plant assets. Reliability engineers are expected to: 1. A reliability engineer is an individual responsible for tracking the equipment behavior to avoid any downtime that may affect company revenues. If our maintenance and reliability strategies are effective and are solving the problems that cause failures in our equipment, this should show a continuous upward trend, which stabilizes at industry benchmark levels. That is the exact purpose and duty of a Plant Wellness Way EAM system-of-reliability. It uses Boolean logic for identifying the potential causes of failures before the failure occurs. The reliability of the system is the probability that unit 1 succeeds and unit 2 succeeds and all of the other units in the system succeed. Overall Equipment Effectiveness (OEE). Availability refers to the duration of time that a plant or a particular equipment is able to perform its intended task. the manufacturing processes and equipment reliability. Reliability testing can generally be looked at as any interruptions in usage or performance during the lifetime span of a product, part, material, or system. Technicians can extend the equipment’s availability by increasing its reliability. Imagine being a maintenance engineer and receiving 50 work orders during an overhaul with a limited budget, time, labor, spare parts, tools, machines, etc. 3. Equipment Reliability Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. Reliability. We can refine these definitions by considering the desired performance standards. All these considerations are highly crucial to lowering cost of ownership and achieving high maintainability of the equipment. To a great extent you can choose how long you want between equipment failures. View our submission and article guidelines and write your article. Reliability Testing can be categorized into three segments, 1. Society for Maintenance & Reliability Professionals, 3200 Windy Hill Rd, SE, Suite 600W The maintenance strategies are optimized so that the productivity of the plant is maintained using cost-effective maintenance techniques. The probability that a PC in a store is up and running for eight hours without crashing is 99%; this is referred as reliability. A Reliability Engineer must manage and access the overall risk to achieve the strategic goals of an organization. To a great extent you can choose how long you want between equipment failures. Notify management of upcoming inspections and recommendations, deficiencies in processes, and corrective actions. The largest contributors are recognized as critical assets and specific performance targets are identified. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. Let’s explore the distinction between reliability and availability, then move into how both are calculated. The final result of an RCM program is the implementation of a specific maintenance strategy on each of the assets of the facility. How have you or your organization connected equipment reliability to human safety? often affects its interrater reliability. High equipment reliability is a choice and not an accident of fortune. Perform analysis of the assets including assets utilization, equipment effectiveness, and remaining useful life, etc. If during the design stage, a project manager fails to consult a Reliability Engineer, this could result in additional maintenance costs down the line. Equipment reliability is measured in terms of quality, performance, and productivity. Not all failures can be prevented by maintenance. The origins of the field of reliability engineering, at least the demand for it, can be traced back to the point at which man began to depend upon machines for his livelihood. Some of the highly accurate balances can give false results if they are not placed upon a completely level surface, so this calibration process is the best way to avoid this. Equipment Reliability. It is most often expressed as a percentage, using the following calculation: Availability = 100 x (Available Time (hours) / Total Time (hours)) For equipment and/or systems that are expected to be able to be operated 24 hours per day, 7 days per week, Total Time is usually defined as being 24 hours/day, 7 days/week (in other words 8,760 hours per year). Utilizing hydraulic energy from the flow of a river or stream, the Noria utilized buckets to transfer water to troughs, viaducts and other distribution devices to irrigate fi… These are reliability-wise in series and a failure of any of these subsystems will cause a system failure. The astute reliability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. 2. The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. Reliability of capital equipment is critical to the success of any manufacturing operation, mobile fleet, facility operation or any combination thereof. ALA now has two new measures for reliability. To develop and promote excellence in maintenance, reliability and physical asset management. In most organi… ), safety and other factors. The potential contribution of the equipment asset base to these goals is evaluated. The opportunities for improving the reliability of equipment and production processes can be significant and is often a strong area of focus for operators. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. These losses are prioritized to focus efforts on the largest/most critical opportunities. Reliability Testing. Articles in this issue should cover activities used to assess the current capabilities of equipment and processes in terms of their reliability, availability, maintainability and criticality. To achieve a step change toward a culture of reliability, however, requires that all parts of the organization are involved, not just the operating areas. I prefer total effective equipment performance (TEEP) which is based on 365 days x 24 hours availability, so the focus can truly be on continuous improvement. The goal of reliability engineering is to carry out an assessment as to the reliability of facility equipment and identify potential areas for improvement. Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. A Reliability Engineer must determine the optimal maintenance strategies for different pieces of machinery, how to maintain the equipment performing its prescribed duty as intended by the user. This shows the need for the Reliability Engineer to participate in project design and installation phases for new resources and current asset alteration. A surveyto measure reading ability in children must produce reliable and consistent results if it is to be taken seriously. Effects are how such errors can result in faults or damaging results. The block diagram for a simple two component parallel system is shown in Figure 10. Overall Equipment Effectiveness (OEE). What is the criticality of the new asset? Reliability optimization is an important part of plant revenue and profit. Reliability is the ability of the equipment unit to perform its stated duty without a forced (unscheduled) outage in a given period of time. Participate in design development and implementation phase. operating the equipment beyond the design specifications (no capital to upgrade or replace the assets) excess break and lunchtime were observed across shifts; particular crews were able to consistently achieve higher performance (they were the most senior and knew the equipment and process) Reliability Testing is a software testing process that checks whether the software can perform a failure-free operation for a specified time period in a particular environment.The purpose of Reliability testing is to assure that the software product is bug free and reliable enough for its expected … Asset integrity activities range from technical meetings involving experts seeking to advance the state-of-the art in equipment design, inspection, testing, or reliability, to a plant operator on routine rounds spotting leaks, unusual noises or odors, or detecting other abnormal conditions. This may include how to select and apply the most appropriate maintenance practices so the equipment and processes continue to deliver their intended capabilities in the safest and most cost-effective manner. • Explain what “classification consistency” and “classification accuracy” are and how they are related. Reliability is defined as the probability that a product, system, or service will perform its intended function adequately for a specified period of time, or will operate in a … Only when it is clearly understood that achieving a high level of equipment reliability … Equipment reliability l1 1. How have you or your organization connected equipment reliability … Step 1: Selection of equipment for RCM analysis. Failure modes are how a process can fail. To achieve a step change toward a culture of reliability, however, requires that all parts of the organization are involved, not just the operating areas. The goal of an equipment reliability program is to effectively monitor equipment, procedures, and data covering the life of equipment. Equipment reliability, and the importance of it, is something that is rarely questioned. 3 OBJECTIVESOBJECTIVES MINDSETMINDSET The Business Case for improving equipment performance in today’s environment Reliability’s relationship to equipment performance … When you understand the behaviour of equipment over its lifetime you will understand why proactive maintenance (as opposed to repairs) is critical. Analysis of Failure Mode and Effects is intended to define, prioritize and restrict these modes of failure. Describe the importance of incorporating condition-based monitoring (diagnostic/ predictive technologies into equipment in the design 8. We use the term “production reliability” to lay the foundation for the vital partnership between operations and maintenance. 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