Reliability optimization is an important part of plant revenue and profit. If you think about how we use the word âreliableâ in everyday language, you might get a hint. The probability that a PC in a store is up and running for eight hours without crashing is 99%; this is referred as reliability. Letâs explore the distinction between reliability and availability, then move into how both are calculated. The astute reliability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. 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. 2 Introduction 3. What is the role of an Equipment Reliability Engineer? 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). Rank the criticality of the new asset with respect to the rest of the plant. That is the exact purpose and duty of a Plant Wellness Way EAM system-of-reliability. Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities … View our submission and article guidelines and write your article. Develop and monitor an Asset Maintenance Plan for effective utilization of strategies and designed for identifying and isolating reliability problems. Reliability of capital equipment is critical to the success of any manufacturing operation, mobile fleet, facility operation or any combination thereof. 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. Describe how the Purchasing Function can affect equipment reliability and the important elements for a Purchase for Reliability ⦠Perform analysis of the assets including assets utilization, equipment effectiveness, and remaining useful life, etc. Reliability Testing. We focus on three major areas: Energy efficiency, Maintenance Cost and Equipment Reliability. Equipment reliability, and the importance of it, is something that is rarely questioned. Atlanta, GA 30339, USA, Copyright 2021 . Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. Equipment history makes it possible to refine preventive and predictive maintenance programs by targeting maintenance tasks to failure modes actually observed. … We use the term âproduction reliabilityâ to lay the foundation for the vital partnership between operations and maintenance. 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. Improvement The following formula is for calculating the probability of failure. How do you accurately go about determining equipment reliability? ALA now has two new measures for reliability. Some failures are the result of … Comply with standards and specifications defining requirements for design, construction, inspection, testing, decommissioning, and integrating new components with aging infrastructure. What is reliability? Good products seek to minimize the unexpected interruptions in performance throughout the duration of the typical of customer experience. 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 â Cause of Rotating Machinery failures Second day â Standards, condition monitoring and top-class maintenance Third day â Shafts, bearings and seals for reliability ⦠Equipment reliability is measured in terms of quality, performance, and productivity. Equipment History The use of historical repair and maintenance information is critical to continuous improvement in reliability. In most organi… 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. 2. 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. The goal of reliability engineering is to carry out an assessment as to the reliability of facility equipment and identify potential areas for improvement. Apply value analysis for repairing/replacing, repairing / restructuring, and making / buying decisions. The Becht ERP process achieves overall unit reliability for clients by: 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. 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) Society for Maintenance & Reliability Professionals, 3200 Windy Hill Rd, SE, Suite 600W Another major trend indicator is the financial KPI of Maintenance Cost per unit Production. 2. 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 ⦠Measurement 3. How have you or your organization connected equipment reliability ⦠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. The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. The Noria, for instance, is an ancient pump thought to be the world’s first sophisticated machine. Reliability-centered maintenance (RCM) is a corporate-level maintenance strategy that is implemented to optimize the maintenance program of a company or facility. Modeling 2. What is reliability? Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. Analyze and interpret reliability data and provide recommendat… If the equipmentâs inherent reliability or performance is poor, doing more maintenance will not help. Definitions of associated terms, a structured approach to the logging of data for proper evaluation are provided. We hear the term used a lot in research contexts, but what does it really mean? Improved equipment reliability can reduce maintenance costs, minimize opportunity costs associated with downtime, and can ensure products are not produced outside of acceptable specifications. This may include how to select and apply the most appropriate maintenance practices so the equipment and processes ⦠Operational equipment reliability, and the resulting plant uptime, are inversely linked to the number of risks you allow your equipment and machinery to suffer. Simple. Inventory Turns. 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 block diagram for a simple two component parallel system is shown in Figure 10. Equipment Reliability Basics 101 for Reliability Management. To develop and promote excellence in maintenance, reliability and physical asset management. 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). We can refine these definitions by considering the desired performance standards. 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. Describe the importance of incorporating condition-based monitoring (diagnostic/ predictive technologies into equipment in the design 8. Every manufacturing facility wants production equipment to operate reliably. Develop tests for acceptance and criteria for inspection. 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. These systems may be designed as active parallel systems or standby parallel systems. Thatâs what TPM does. 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. 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. 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. To perform a thorough … At the equipment level, the MTBR is measured for all … Reliability is the probability that a system performs correctly during a ⦠How have you or your organization connected equipment reliability to human safety? Cost-justifying (budget) tactics selected for implementation. 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. Measuring Reliability. A Reliability Engineer must manage and access the overall risk to achieve the strategic goals of an organization. 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. Root Cause Analysis is a critical part of your equipment reliability program. 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. 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. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. Like or follow us to stay up-to-date with SMRP. It is a top-down deductive approach used for determining the cause of failures or testing the reliability of a system. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. If the equipment has already been purchased, the inherent reliability is fixed but you can still impact the operational reliability and life cycle costs. Thatâs why it is our belief that the overall competitiveness of your organization depends on establishing stable and reliable processes and equipment. 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. Applied technology preventive maintenance. You can deliver high equipment reliability by ensuring the ⦠Reliability engineers are expected to: 1. Overall Equipment Effectiveness (OEE). Developing a maintenance strategy to ensure performance. 4. We’ve talked around it before. All these considerations are highly crucial to lowering cost of ownership and achieving high maintainability of the equipment. This shows the need for the Reliability Engineer to participate in project design and installation phases for new resources and current asset alteration. High equipment reliability is a choice and not an accident of fortune. 4 Equipment Reliability Training Series Learning Objectives (Continued) 7. 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. Imagine being a maintenance engineer and receiving 50 work orders during an overhaul with a limited budget, time, labor, spare parts, tools, machines, etc. For instance, we often speak about a machine as reliable: âI have a reliable car.â Or, news people talk about a âusually ⦠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. 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. But what exactly is reliability, and why is it important to understand the difference between it and other maintenance-relate… The first step is to select the piece of equipment for reliability centred maintenance analysis. Political opinion polls, on the other hand, are notorious for producin… Reliability. The analysis also provides useful information to determine what measures will decrease the risk for all plant assets. Though reliability and availability are often used interchangeably, they are different concepts in the engineering domain. To improve poor reliability or performance thatâs due to poor design, you need to change the design. Notify management of upcoming inspections and recommendations, deficiencies in processes, and corrective actions. We want them to operate perfectly. 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). Our Facilities Services main goal is to provide operating savings by proactively maintaining the premises and supporting systems in optimal conditions. 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. Most computer equipment therefore has some form of cooling, ranging from a simple fan to forced chilled air cooling. These are reliability-wise in series and a failure of any of these subsystems will cause a system failure. A surveyto measure reading ability in children must produce reliable and consistent results if it is to be taken seriously. It uses Boolean logic for identifying the potential causes of failures before the failure occurs. A reliability engineer is an individual responsible for tracking the equipment behavior to avoid any downtime that may affect company revenues. The goal of an equipment reliability program is to effectively monitor equipment, procedures, and data covering the life of equipment. 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… Availability refers to the duration of time that a plant or a particular equipment is able to perform its intended task. 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. 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. Reliability is the ability of the equipment unit to perform its stated duty without a forced (unscheduled) outage in a given period of time. TapRooT® - Changing the Way the World Solves Problems. The first key area where Maintenance can impact on equipment reliability is by having an appropriate preventive and predictive maintenance program in place. 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. Connecting the importance of human safety to the importance of equipment reliability is critical in driving an injury-free culture. 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 Only when it is clearly understood that achieving a high level of equipment reliability ⦠The probability of an injury is significantly increased with non-routine maintenance activity resulting from equipment failures. To be effective in preventing unexpected failures, the preventive maintenance program needs to, from a technical perspective, successfully deal with the underlying ⦠Availability is, in essence, the amount of time that an item of equipment or system is able to be operated when desired. The major components of reliability improvement include optimization of site rotating equipment availability by implementation of practical: Site reliability ⦠No amount of maintenance can raise the inherent reliability of a design. Use probability and statistic tools for risk and process hazard assessments. Overall Equipment Effectiveness (OEE). Reliability quantifies the likelihood of equipment to operate as intended without disruptions or downtime. 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. When you understand the behaviour of equipment over its lifetime you will understand why proactive maintenance (as opposed to repairs) is critical. Work with Project Engineering to guarantee that new and altered installations are reliable and maintainable. During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. Operations focuses on reliable process and maintenance focuses on reliable equipment. 1.5 The analyses presented in this document are designed to identify deficiencies in equipment support resources as well as in the equipment itself. To a great extent you can choose how long you want between equipment failures. 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. 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. Advantages of a reliability program include eliminating unexpected shutdowns, reducing production losses ⦠Reliability ⦠The first key area where Maintenance can impact on equipment reliability is by having an appropriate preventive and predictive maintenance program in place. Analysis of Failure Mode and Effects is intended to define, prioritize and restrict these modes of failure. The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. 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 ⦠When the equipment does what it needs to do when it needs to do it, plant output and profitability is maximized. 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. Prerequisite Knowledge . For example, one of the key factors affecting the reliability of electronic components and systems is temperature â basically the higher the temperature of the device the higher the failure rate. 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. Subjects would include: Examples of topics that might fit into this area also include: Ready to write? Provide technical assistance to manufacturing, maintenance, and technical staff. Alternatively, availability can be defined as the duration of time that a plant or a particular equipment is able to perform its intended task. Assemble a multidisciplinary team to participate in the reliability studies. Reviewing performance and adjusting the maintenance strategy. 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. Simple parallel system â the system reliability is increased to 99% due to the redundancy. If during the design stage, a project manager fails to consult a Reliability Engineer, this could result in additional maintenance costs down the line. Accept Failures. Technicians can extend the equipment’s availability by increasing its reliability. The Becht ERP process achieves overall unit reliability for clients by: This application of âguessingâ as the primary tool for root cause analysis of equipment reliability and maintenance problems is probably the biggest challenge to achieving equipment reliability excellence. ERPs also comply with API RP-580 â Risk Based Inspection for fixed equipment and piping. The largest contributors are recognized as critical assets and specific performance targets are identified. 3 OBJECTIVESOBJECTIVES MINDSETMINDSET The Business Case for improving equipment performance in todayâs environment Reliabilityâs relationship to equipment performance ⦠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. No organization wants assets to break down, to produce poor quality products, or to operate inefficiently. 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. 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. This step is performed in collaboration with the production process. Our technologically based society depends on machinery and equipment to keep it operating. 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. What is Reliability? • Explain what “classification consistency” and “classification accuracy” are and how they are related. Reliability Testing can be categorized into three segments, 1. Reliability engineers call these parallel systems. Equipment 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. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. Reliability is the probability that a system performs correctly during a specific time duration. High equipment reliability is a choice and not an accident of fortune. 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. 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. 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