We streamline any production and manufacturing process by applying a blend of proven methodologies such as Six Sigma Lean, Overall Equipment Effectiveness (OEE)  and Total Productive Maintenance (TPM). Guide efforts for ensuring the reliability and maintenance of assets, products, and processes. Cost-justifying (budget) tactics selected for implementation. The potential contribution of the equipment asset base to these goals is evaluated. Inventory Turns. And, reliability increases stakeholder value. 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. 1 EQUIPMENT RELIABILITY TRAINING SERIES LEVEL 1: AWARENESS 2. Reliability is the probability that a system performs correctly during a … A surveyto measure reading ability in children must produce reliable and consistent results if it is to be taken seriously. 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. No organization wants assets to break down, to produce poor quality products, or to operate inefficiently. We can refine these definitions by considering the desired performance standards. Measuring Reliability. Reliability engineers are expected to: 1. Determining equipment and process performance expectations from the business plan. To improve poor reliability or performance that’s due to poor design, you need to change the design. When the equipment does what it needs to do when it needs to do it, plant output and profitability is maximized. Reviewing performance and adjusting the maintenance strategy. • Explain what “classification consistency” and “classification accuracy” are and how they are related. Reliability is the probability that a system performs correctly during a specific time duration. A reliability engineer is an individual responsible for tracking the equipment behavior to avoid any downtime that may affect company revenues. 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. How have you or your organization connected equipment reliability to human safety? 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. These systems may be designed as active parallel systems or standby parallel systems. 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. In other words, all of the units in a series system must succeed for the system to succeed. Reliability-centered maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company or facility. The term equipment reliability and maintenance (ERM) encompasses not only equipment, such as machines, tools, and fixtures, but also the technical, operational, and management activities, ranging from equipment specifications to daily operation and maintenance, required to sustain the performance of manufacturing equipment throughout its useful life. How does that engineer prioritize the work? ALA now has two new measures for reliability. Subjects would include: Examples of topics that might fit into this area also include: Ready to write? Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. Notify management of upcoming inspections and recommendations, deficiencies in processes, and corrective actions. Simply put, the Reliability Engineer will assist the company saves money through continuous monitoring and maintenance of the equipment. 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. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. Use probability and statistic tools for risk and process hazard assessments. Every manufacturing facility wants production equipment to operate reliably. Equipment Reliability. It is a top-down deductive approach used for determining the cause of failures or testing the reliability of a system. 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. 3 OBJECTIVESOBJECTIVES MINDSETMINDSET The Business Case for improving equipment performance in today’s environment Reliability’s relationship to equipment performance … Quality Glossary Definition: Reliability. But what exactly is reliability, and why is it important to understand the difference between it and other maintenance-relate… This guide emphasizes concepts, not mathematics. Like or follow us to stay up-to-date with SMRP. Developing a maintenance strategy to ensure performance. The definition that follows is the definition that I prefer; it is one that has been derived from many definitions that I have seen over time:“The 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 … This shows the need for the Reliability Engineer to participate in project design and installation phases for new resources and current asset alteration. Overall Equipment Effectiveness (OEE). Send your article and accompanying documents and images to [email protected]. The largest contributors are recognized as critical assets and specific performance targets are identified. Reliability optimization is an important part of plant revenue and profit. We focus on three major areas: Energy efficiency, Maintenance Cost and Equipment Reliability. What is reliability? Describe how the Purchasing Function can affect equipment reliability and the important elements for a Purchase for Reliability … Improvement The following formula is for calculating the probability of failure. Operational equipment reliability, and the resulting plant uptime, are inversely linked to the number of risks you allow your equipment and machinery to suffer. We’ve talked around it before. What is Reliability? 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 determine the optimal maintenance strategies for different pieces of machinery, how to maintain the equipment performing its prescribed duty as intended by the user. Reliability of capital equipment is critical to the success of any manufacturing operation, mobile fleet, facility operation or any combination thereof. Root Cause Analysis is a critical part of your equipment reliability program. This step is performed in collaboration with the production process. High equipment reliability is a choice and not an accident of fortune. The one at the plant level is the number of production incidents, no matter how small and no matter if they had any affect on supply availability. 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 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. The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. What is reliability? 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. At the equipment level, the MTBR is measured for all … Troubleshooting IS NOT Root Cause Analysis. 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. 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. High equipment reliability is a choice and not an accident of fortune. 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. Equipment reliability is measured in terms of quality, performance, and productivity. 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. Analyze and interpret reliability data and provide recommendat… 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 The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. Participate in design development and implementation phase. Simple. 2. The maintenance strategies are optimized so that the productivity of the plant is maintained using cost-effective maintenance techniques. Last year, we defined reliability cultureas “the overall cultural shift that’s required for an organization to fully understand the big picture when it comes to asset reliability.” More recently, we talked about the difference between maintenance and reliability, noting that reliability is a much more holistic, long-term approach to asset management than maintenance. Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. All these considerations are highly crucial to lowering cost of ownership and achieving high maintainability of the equipment. The block diagram for a simple two component parallel system is shown in Figure 10. 4. You can deliver high equipment reliability by ensuring the chance of incidents that cause failures 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. These losses are prioritized to focus efforts on the largest/most critical opportunities. This may include how to select and apply the most appropriate maintenance practices so the equipment and processes … often affects its interrater 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. 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. Advantages of a reliability program include eliminating unexpected shutdowns, reducing production losses … Though reliability and availability are often used interchangeably, they are different concepts in the engineering domain. How have you or your organization connected equipment reliability … The opportunities for improving the reliability of equipment and production processes can be significant and is often a strong area of focus for operators. That is the exact purpose and duty of a Plant Wellness Way EAM system-of-reliability. The first key area where Maintenance can impact on equipment reliability is by having an appropriate preventive and predictive maintenance program in place. Some failures are the result of … The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. 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. Figure 10. 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. For equipment that is expected to be op… The Becht ERP process achieves overall unit reliability for clients by: Definitions of associated terms, a structured approach to the logging of data for proper evaluation are provided. Develop and monitor an Asset Maintenance Plan for effective utilization of strategies and designed for identifying and isolating reliability problems. … 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. To perform a thorough … The goal of reliability engineering is to carry out an assessment as to the reliability of facility equipment and identify potential areas for improvement. Improved equipment reliability can reduce maintenance costs, minimize opportunity costs associated with downtime, and can ensure products are not produced outside of acceptable specifications. The design, construction, maintenance, adjustment, calibration, and use of measuring and of manufacturing equipment are factors which impact on the reliability of the product. The Becht ERP process achieves overall unit reliability for clients by: The Equipment Reliability Process focuses the maintenance of physical asset reliability on the business goals of the company. However, it does include explanations of some statistics commonly used to describe test reliability. Reliability Testing can be categorized into three segments, 1. If the equipment has already been purchased, the inherent reliability is fixed but you can still impact the operational reliability and life cycle costs. If during the design stage, a project manager fails to consult a Reliability Engineer, this could result in additional maintenance costs down the line. Let’s explore the distinction between reliability and availability, then move into how both are calculated. These are reliability-wise in series and a failure of any of these subsystems will cause a system failure. That’s why it is our belief that the overall competitiveness of your organization depends on establishing stable and reliable processes and equipment. We want them to operate perfectly. View our submission and article guidelines and write your article. To be effective in preventing unexpected failures, the preventive maintenance program needs to, from a technical perspective, successfully deal with the underlying … Political opinion polls, on the other hand, are notorious for producin… Assemble a multidisciplinary team to participate in the reliability studies. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. To develop and promote excellence in maintenance, reliability and physical asset management. The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. Simple parallel system – the system reliability is increased to 99% due to the redundancy. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. A Reliability Engineer must manage and access the overall risk to achieve the strategic goals of an organization. We use the term “production reliability” to lay the foundation for the vital partnership between operations and maintenance. It encompasses availability, performance, and quality, and when used correctly is removing waste. 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. 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. Overall Equipment Effectiveness (OEE). Technicians can extend the equipment’s availability by increasing its reliability. 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. Comply with standards and specifications defining requirements for design, construction, inspection, testing, decommissioning, and integrating new components with aging infrastructure. In this concept, operations and maintenance both deliver reliability as a result of their work. Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. 4 Equipment Reliability Training Series Learning Objectives (Continued) 7. 2 Introduction 3. 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. Test new … No amount of maintenance can raise the inherent reliability of a design. Analysis of Failure Mode and Effects is intended to define, prioritize and restrict these modes of failure. Effects are how such errors can result in faults or damaging results. If the equipment’s inherent reliability or performance is poor, doing more maintenance will not help. the manufacturing processes and equipment reliability. Knowing how equipment … Equipment reliability, and the importance of it, is something that is rarely questioned. TapRooT® was built (and is continuously improved) to help your company meet the ever increasing demands for reliable equipment, process reliability, improved safety, environmental … 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. Perform analysis of the assets including assets utilization, equipment effectiveness, and remaining useful life, etc. It encompasses availability, performance, and quality, and when used correctly is removing waste. Availability refers to the duration of time that a plant or a particular equipment is able to perform its intended task. For instance, we often speak about a machine as reliable: “I have a reliable car.” Or, news people talk about a “usually … Reliability is the ability of the equipment unit to perform its stated duty without a forced (unscheduled) outage in a given period of time. Reliability quantifies the likelihood of equipment to operate as intended without disruptions or downtime. Measurement 3. ), safety and other factors. Equipment History The use of historical repair and maintenance information is critical to continuous improvement in reliability. 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. 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. TapRooT® - Changing the Way the World Solves Problems. Rank the criticality of the new asset with respect to the rest of the plant. 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). ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. Only when it is clearly understood that achieving a high level of equipment reliability … Failure modes are how a process can fail. That’s what TPM does. The opportunities for improving the reliability of equipment and production processes can be significant and is often a strong area of focus for operators. Another major trend indicator is the financial KPI of Maintenance Cost per unit Production. What is the criticality of the new asset? The astute reliability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. Reliability engineers call these parallel systems. Step 1: Selection of equipment for RCM analysis. 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. Rotating Machinery Health Management and Rotating Equipment Maintenance and Reliability Training Course Content Course Content Day 1 - Machinery Health and Reliability Excellence - Introduction COURSE OVERVIEW First day – Cause of Rotating Machinery failures Second day – Standards, condition monitoring and top-class maintenance Third day – Shafts, bearings and seals for reliability … 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 calculate availability, use the formula of MTBF divided by (MTBF + MTTR). Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities … To a great extent you can choose how long you want between equipment failures. The downtime that is associated with equipment failures will depend both on the equipment reliability (the number of equipment failure events) and the length of time that it takes to restore the functionality of the equipment each time one of these events occurs (typically measured by Mean Time to Repair - MTTR). How do you accurately go about determining equipment reliability? Reliability engineering focuses on costs of failure caused by system downtime, which includes cost of spare parts, equipment repair, equipment overhaul, personnel and equipment warranty. We hear the term used a lot in research contexts, but what does it really mean? Provide technical assistance to manufacturing, maintenance, and technical staff. If you think about how we use the word “reliable” in everyday language, you might get a hint. Good products seek to minimize the unexpected interruptions in performance throughout the duration of the typical of customer experience. Operational equipment reliability, and the resulting plant uptime, are inversely linked to the number of risks you allow your equipment and machinery to suffer. Prerequisite Knowledge . 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. 3. 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. A reliability engineer uses the following tools for identifying and reducing risks: It is a tool used for prioritizing the maintenance work and identifying the most critical assets. Develop and maintain the Risk Management Plan for identifying and managing all risks. 1.5 The analyses presented in this document are designed to identify deficiencies in equipment support resources as well as in the equipment itself. Equipment history makes it possible to refine preventive and predictive maintenance programs by targeting maintenance tasks to failure modes actually observed. The goal of an equipment reliability program is to effectively monitor equipment, procedures, and data covering the life of equipment. You can deliver high equipment reliability by ensuring the … Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. The data collected and its The first step is to select the piece of equipment for reliability centred maintenance analysis. One of the fundamental roles of the Reliability Engineer is to track the production losses and abnormally high maintenance cost assets, then find ways to reduce those losses or high costs. In other words, reliability of a system will be high at its initial state of operation and gradually reduce to its lowest magnitude over time. The major components of reliability improvement include optimization of site rotating equipment availability by implementation of practical: Site reliability … That is the exact purpose and duty of a Plant Wellness Way EAM system-of-reliability. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. 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 … In most organi… 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. Work with Project Engineering to guarantee that new and altered installations are reliable and maintainable. 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