1. Three Primary Steps in Maintenance Reliability Engineering by Jim Taylor, CPE, CPMM Director of Operations, Machinery Management Solutions, Inc. www.machineryhealthcare.com

2. Key Takeaway: Reliability Engineering can be done by the average maintenance professional michaelcardus

3. You work in a small to medium size facility or plant. California Cthulhu

4. You’re a Maintenance professional: an Engineer, a Maintenance Manager, Supervisor, Planner, or Crafts Person. theakshay .

5. Low availability and repeat failures on your HVAC equipment is affecting your production and customer service. mlinksva

6. You want to either remove or detect failure causes to manage the failures . Goal Managed Avoided Surprise Managed Avoided Surprise

7. Reliability Engineering principles provide a way to do that. Measure Availability Find Bad Actors Perform Failure Analysis Develop Job Plan Data Collection Implement Job Plan Repeat

8. One of your primary duties is to improve Availability (Ao). MTBF MTTR MLDT FRACAS

9. What is A o ? Availability is the proportion of time a system is in a functioning condition

10. To do that you must increase Mean Time Between Failures (MTBF) Czarcats

11. What is MTBF? Average elapsed time between failures of an operating system

12. How do you calculate it? Timeline from Wikipedia

13. How can you use it? High MTBF can result from: Design Lack of training Lack of proper tools Lack of documentation Lack of proper equipment Lack of proper maintenance Lack of proper parts

14. You also must reduce Mean Time To Repair (MTTR) B Rosen

15. What is MTTR? Average time required to repair a failed component or system. A measure of maintainability

16. How do you calculate it?

17. How can you use it? High MTTR can result from: Design Lack of training Lack of proper tools Lack of documentation Lack of proper equipment

18. You also must reduce Mean Logistics Delay Time (MLDT) zyphbear

19. What is It? Average time a system is awaiting maintenance

20. How do you calculate it? Total delay time does not include active maintenance time

21. How do you use it? High MLDT can result from: Time for locating parts and tools Delivery time Locating, setting up, or calibrating test equipment Dispatching personnel Reviewing technical manuals Awaiting transportation

22. To keep track of it all you need a Failure Reporting, Analysis, and Corrective Action Reporting System (FRACAS). English106

23. You must capture the details of the failure in enough detail to do effective failure analysis. As found condition Failed components Operating parameters Sequence of events Fluid levels Signs of over temperature or pressure

24. You must capture the times involved in order to calculate MTBF, MTTR and Ao. Loading time = total time – planned downtime Planned downtime = scheduled maintenance time + management time Operation time = loading time – Unplanned downtime Unplanned downtime = logistics delay time + active repair time

25. The data you capture must be stored in a way to make analysis as easy as possible. fo.ol

26. After you have started collecting the data, you are in a position to do Root Cause Failure Analysis (RCFA). www.isixsigma.com

27. For each problem, you will find the cause, the cost, and a solution.

28. Determine the failure cause or causes? brendan.wood

29. Define the effects of the failure and their costs. Julia Manzerova Unhappy Customer

30. Then rank the causes. www.sixsigmaspc.com

31. Finally apply Reliability Centered Maintenance (RCM) principles to develop a corrective action.

32. You can use the RCM decision tree to decide on the correct procedure.

33. Start at the top of the tree, assuming that the failure has occurred.

34. As you can see, the decision tree is biased towards Condition Assessment.

35. You may find redesign is best option in some cases.

36. Make sure the procedure is both effective and applicable.

37. An Applicable procedure actually improves the situation.

38. An Effective procedure costs less to do the procedure than to suffer the failure.

39. Develop a corrective action plan in enough detail to enable effective application.

40. The Job plan should have step by step actions.

41. Make sure you include all safety information.

42. Estimate all the resources needed. Skills Tools Parts Consumables Equipment

43. You now have a Job Plan that should either eliminate the cause of the failures or give you enough lead time to manage the failure.

44. We started with a piece of HVAC equipment that was causing problems. mlinksva

45. We applied some basic RE principles to find the cause and develop a solution. Measure Availability Find Bad Actors Perform Failure Analysis Develop Job Plan Data Collection Implement Job Plan Repeat

46. We now must put that Job Plan into action and track the results.

47. We should see an increase in Ao and a decrease in costs. Goal Managed Avoided Surprise Managed Avoided Surprise

48. Key Takeaway: You can perform this kind of analysis. theakshay .

49. Do it and you’ll avoid surprises, and you’ll have a happy customer. Muffet

50. Within the next week pick a problem machine; Estimate the MTBF, MTTR, MLDT and availability, based on either history or subjective analysis. Pick a failure that is causing problems and perform a RCFA. Develop a way to manage that failure using RCM principles. Make sure the solution is both applicable and effective. Write and implement a Job Plan to correct the problem. I’ll be glad to review your project if you’d like. Your Next Step (Homework)

51. Questions? Comments? Jim Taylor, CPE, CPMM [email_address] 765-366-4285 http://blog.machineryhealthcare.com