Simply put, the Reliability Engineer will assist the company saves money through continuous monitoring and maintenance of the equipment. What is Reliability? Reviewing performance and adjusting the maintenance strategy. The opportunities for improving the reliability of equipment and production processes can be significant and is often a strong area of focus for operators. The probability that a PC in a store is up and running for eight hours without crashing is 99%; this is referred as reliability. Troubleshooting IS NOT Root Cause Analysis. 2 Introduction 3. Advantages of a reliability program include eliminating unexpected shutdowns, reducing production losses … Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. 1 EQUIPMENT RELIABILITY TRAINING SERIES LEVEL 1: AWARENESS 2. 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. If you think about how we use the word “reliable” in everyday language, you might get a hint. To a great extent you can choose how long you want between equipment failures. Every manufacturing facility wants production equipment to operate reliably. Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. How have you or your organization connected equipment reliability … What is reliability? Measurement 3. And, reliability increases stakeholder value. 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. 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. Having fully reliable equipment is a pre-requisite for meeting customer demand, on-time. Perform analysis of the assets including assets utilization, equipment effectiveness, and remaining useful life, etc. 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. The potential contribution of the equipment asset base to these goals is evaluated. Applied technology preventive maintenance. Apply value analysis for repairing/replacing, repairing / restructuring, and making / buying decisions. Knowing how equipment … Operational equipment reliability, and the resulting plant uptime, are inversely linked to the number of risks you allow your equipment and machinery to suffer. 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 OBJECTIVESOBJECTIVES MINDSETMINDSET The Business Case for improving equipment performance in today’s environment Reliability’s relationship to equipment performance … Develop and maintain the Risk Management Plan for identifying and managing all risks. 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. Equipment history makes it possible to refine preventive and predictive maintenance programs by targeting maintenance tasks to failure modes actually observed. 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. No organization wants assets to break down, to produce poor quality products, or to operate inefficiently. Overall Equipment Effectiveness (OEE). Reliability Testing can be categorized into three segments, 1. The block diagram for a simple two component parallel system is shown in Figure 10. Describe how the Purchasing Function can affect equipment reliability and the important elements for a Purchase for Reliability … 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 Establishing current performance levels and analyze gaps. Figure 10. Our technologically based society depends on machinery and equipment to keep it operating. In most organi… When you understand the behaviour of equipment over its lifetime you will understand why proactive maintenance (as opposed to repairs) is critical. Guide efforts for ensuring the reliability and maintenance of assets, products, and processes. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. Good products seek to minimize the unexpected interruptions in performance throughout the duration of the typical of customer experience. We want them to operate perfectly. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. Quality Glossary Definition: Reliability. Equipment Reliability Basics 101 for Reliability Management. Measuring Reliability. To a great extent you can choose how long you want between equipment failures. Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities … Should apply different techniques like Fault Tree Analysis, Weibull Tree Analysis, Six Sigma Methodology, Root Cause Analysis and Statistical Process Control for developing engineering solutions to repetitive failures. Technicians can extend the equipment’s availability by increasing its reliability. 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. The Equipment Reliability Process focuses the maintenance of physical asset reliability on the business goals of the company. ), safety and other factors. Our reliability engineers experts evaluate your plant mainteance program maturity,  and  develop a strategies to achieve short, middle and long terms benefits using proven world-class best practices. Operations focuses on reliable process and maintenance focuses on reliable equipment. Subjects would include: Examples of topics that might fit into this area also include: Ready to write? 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 … 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. Comply with standards and specifications defining requirements for design, construction, inspection, testing, decommissioning, and integrating new components with aging infrastructure. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. It is a top-down deductive approach used for determining the cause of failures or testing the reliability of a system. 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. the manufacturing processes and equipment reliability. 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). Cost-justifying (budget) tactics selected for implementation. This shows the need for the Reliability Engineer to participate in project design and installation phases for new resources and current asset alteration. The Becht ERP process achieves overall unit reliability for clients by: These losses are prioritized to focus efforts on the largest/most critical opportunities. This step is performed in collaboration with the production process. For instance, we often speak about a machine as reliable: “I have a reliable car.” Or, news people talk about a “usually … 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) Though reliability and availability are often used interchangeably, they are different concepts in the engineering domain. If the equipment has already been purchased, the inherent reliability is fixed but you can still impact the operational reliability and life cycle costs. Test new … 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). Reliability-centered maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company or facility. Another major trend indicator is the financial KPI of Maintenance Cost per unit Production. It is an inductive approach used for evaluating the process and its events leading to a possible accident. You can deliver high equipment reliability by ensuring the chance of incidents that cause failures 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. 4 Equipment Reliability Training Series Learning Objectives (Continued) 7. Notify management of upcoming inspections and recommendations, deficiencies in processes, and corrective actions. The first key area where Maintenance can impact on equipment reliability is by having an appropriate preventive and predictive maintenance program in place. All these considerations are highly crucial to lowering cost of ownership and achieving high maintainability of the equipment. The data collected and its The opportunities for improving the reliability of equipment and production processes can be significant and is often a strong area of focus for operators. The maintenance strategies are optimized so that the productivity of the plant is maintained using cost-effective maintenance techniques. Determining equipment and process performance expectations from the business plan. If the equipment’s inherent reliability or performance is poor, doing more maintenance will not help. This guide emphasizes concepts, not mathematics. Reliability … Political opinion polls, on the other hand, are notorious for producin… It encompasses availability, performance, and quality, and when used correctly is removing waste. Let’s explore the distinction between reliability and availability, then move into how both are calculated. It encompasses availability, performance, and quality, and when used correctly is removing waste. 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 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. Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. Some failures are the result of … 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. The Noria, for instance, is an ancient pump thought to be the world’s first sophisticated machine. That’s why it is our belief that the overall competitiveness of your organization depends on establishing stable and reliable processes and equipment. 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. Root Cause Analysis is a critical part of your equipment reliability program. Availability is, in essence, the amount of time that an item of equipment or system is able to be operated when desired. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. 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. Improvement The following formula is for calculating the probability of failure. 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