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ReliabEg 1 PDF
ReliabEg 1 PDF
Reliability Engineering
• What is Reliability Engineering?
• Role of Reliability Engineering (Technical Support)
• Reliability Engineering Activities
– Maintenance Prevention
– LCC Analysis
– Proactive Maintenance (FPA, RCFA, Specification for
New/Rebuilt Equipment, etc.)
– Capital Equipment Replacement
– Economic Evaluation/Justification Analysis in R&M
Investments
• Other Analytical Techniques for Improvement
• Elements of a Reliability Improvement System
1
What is Reliability?
Definitions
• Maintainability: The ability of an item, under stated conditions of
use, to be retained in, or restored to, a state in which it can
perform its required function(s), when maintenance is performed
under stated conditions and using prescribed procedures and
resources. Expressed as Mean Time To Repair (MTTR).
2
Inherent Availability
MTBF
Ai =
MTBF + MTTR
Diagnostics
Predictive Maintenance
Systematic planning and scheduling
Preventive Maintenance
Inspect, lubricate
3
What is Reliability Engineering?
4
Important Aspects of Reliability
Engineering (Cont.)
• Maintenance Prevention
• Optimizes equipment life-cycle costs by using life-cycle costing
(LCC) analysis
• Employs proactive techniques to extend machinery life: Failed-
part analysis (FPA) ; Root-Cause Failure Analysis (RCFA)
• Adapts Total Productive Maintenance (TPM), Reliability
Centered Maintenance (RCM) and other concepts to the
operating environment
• Provides specifications of new/rebuilt equipment
• Develops plans and analysis of capital equipment (and other
assets) replacement
• Involvement in the economic evaluation/justification of
investments in M&R 10
5
Model for Maintenance-Free Equipment Design
1. Design/Installation Stage 2. Operation/Maintenance Stage
Install Plan
Test run Inspect
equipment inspection Inspection
results
Maintenance work
procedure improvements
Fabricate Maintenance Planned Decision to
equipment Prevention Operation Maintenance modify
Maintainability &
methods improvement
Plan
Work modification
Maintenance acceptance work
free Commision-
design ing Modification
control work Work order
Studies to
Report feedback for reduce Source; TPM by Nakajima
maintenance-free design maintenance
work Maintenance data
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MTBF analysis, cost estimation
Maintenance Prevention
Equipment Management
Maintenance
Project Engineering
Engineering
Maintenance Prevention
6
MP Objectives
• Reduce the time taken from the design to stable
operation
• Accomplish the transition efficiently with minimum
labor and a balanced workload
• Ensure that equipment is designed to be highly
reliable, maintainable, economical, operable, and
safe
• Minimize future maintenance costs and deterioration
losses of new equipment
• MP design process improves equipment reliability by
investigating weaknesses in existing equipment and
feeding the information back to the designers. 13
14
7
Evaluation of equipment investment MP design Equipment
improvement
Equipment
Business Operation and
investment Early equipment
Planning maintenance
planning management
(cost planning) (cost reduction)
(cost control)
Record of
investment
Plan equipment evaluation Equipment Mtce.
investment Design and Operation output &
efficiency logs records
debug & Mtce.
Compile equipment Fabricate & standards
investment budgets debug Maintain Take
Early
& improve measures
Set specifications, Install, test equipment to
basic design, run & debug management Measurement Increase
rough cost estimate records accuracy operability
Commission
& reliability
Evaluate investment & debug Product
quality Reduce
Cost standards equipment
Design Energy breakdowns
Investment efficiency
standards Increase
evaluation criteria Production Maintain-
output ability
Equipment
Technology Rationalization measures
Outline Outside technical information
(equipment development & modifications)
15
8
Maintenance Prevention (MP)
• The team will examine possible problems at each stage of MP
design with respect to the following issues:
– Quality
– Productivity
– Operability
– Energy-saving
– Cost
– Maintainability
– Safety and environment
• Aim is to “front end” load maintenance improvements so that
troubles (repairs, inspections, adjustments, lubrication, cleaning,
tightening) during start-up and commissioning are minimized.
• Use of standard checklists at each stage
17
9
Reduction of Early Breakdowns
(Comparing Similar Types of Equipment -
Tokai Rubber Industries)
8
Breakdowns
6
Problem prevention
4 control carried out
(June - August 1980)
2
0
0 1st 2 0 40 60 3rd 80 100
month month days
Commissioning Control
days
19
Source: TPM by Productivity Press
20
10