The International Maintenance Seminar 2002 MIDTH Institute” The Reliability Engineering Overview by André Pasman FMSC Group Ine. Lecture 01-07The International Maintenance Seminar - 2002 MIDTH e _Institute” TABLE OF CONTENTS, @ oe 12 Yuta one righ 97296 th te 13 Contmaons improve.@ s The International Maintenance Seminar - 2002 MIDTH Institute” INTRODUCTION Every facility experiences failures of equipment. The focus of Reliability Engineering is to use every failure as an opportunity to improve reliability and the overall organizational activities. ‘Reliability Engineering is the use of detective skills to identify causes of problems, predict when problems will occur, and to minimize the potential for fumre problems. The goal is to ensure that equipment performs its function when its needed. This manual identifies practical techniques for understanding equipment failures and determining cost effective corrective actions. Consequently, it is only a first step toward becoming a Reliability Engineer, This manual is noi designed to teach engineers 10 be statisticians, The course is designed to show how good engineering skills can be used © change design, operations, and maintenance practices ( aghieve_substantial changes in_ equipment, unit, and plant reliability. As part of a site wide Total Plant Reliability (TPR)”) program, the reliability engineering function becomes the focal point for a continuous improvement program, ~? Se Reliability Engineering | / 3 Lecture 01-07mMIDTH The International Maintenance Seminar Institute” OVERVIEW 1.0 Why do things go wrong? A fire starts, an employee is injured, a critical piece of equipment goes down, or a customer complains about an out of specification problem, ‘What happened? ‘Ask people what they think happened, and you may get several totally different answers. + Its difficult enough to solve a problem, It’s impossible to solve a problem unless the cause is identified, ¢ If we want to comecta problem, ‘We must determine what caused the problem. If we want to minimize problems, We must treat every problem as an opportunity to improve. If we want to continuously improve, ‘We must monitor performance. Reliability Engineering 4 Lecture 01-07The International Maintenance Seminar - 2002 MIDTH Institute” 1.1 But it’s just a little problem! It’s acceptable! What's acceptable? For a high school student trying to pass a class, 70% on a final test may be good enough. But would his parents agree? Fora family picnic, only a 10% chance of rain may be good enough. But what if the 10% were concentrated on the park? For a company safety plan, one lost hour of work due to an injury may be good enough, But what if you are the one injured? Reliability Engineering 5 Lecture 01-07mIDTH : The International Maintenance Seminar Institute” 1.2 If it was done right 99.9% of the time... What is “good enough?” How close to perfection do we really need to be? 10%. How does 99.9% sound? Consider Figure 1-1. IF IT WAS DOWN RIGHT 99.9% OF THE TIME... ¢ One hour of unsafe drinking water per month © Two unsafe landings at 0’ Hara Airport every day © 16,000 lost pieces of mail per hour * 20,000 incorrect drug prescriptions cach year + 500 incorrect surgical operations performed each week * 50 newborn babies dropped by doctors each day ¢ 200,000 checks deducted from the wrong account each hour © No telephone or television transmission for nearly 10 minutes each week © Your heart fails to beat 32,000 times each year Figure 1-1, 99.9% of the Time and only a 0.1% chance of falling bricks. sit possible to reach 100% perfection in every aspect of our business? (_JyY¥es L_JNo Eyen if it were possible, is it worth the cost? Reliability Engineering 6 Lecture 01-07The International Maintenance Seminar - 2002 MIDTH Institute” @ (JD Yes (_JNo RELIABILITY ENGINEERING SHOULD ALWAYS BE A PRACTICAL APPROACH TO DETERMINE COST BENEFICIAL CHANGES TO ENHANCE EQUIPMENT PERFORMANCE. 1.3 Continuous Improvement If perfection is impossible, then the only altemative is continuous improvement. The @ organization that dedicates itself to continuous improvement moves from a problem solving . operation to a problem preventing operation, Problem Preventing Operation (Proactive) Identifies possible problems in existing systems, - Identifies possible problems in developing systems. OLOLOL Problem Solving Operation (Reactive) Identifies operational, service, and product faults. Using Table 1-1, on the next page. fill in a proactive step corresponding to the reactive response listed. Reliability Engineering 7 Lecture 01-07mIDTH The International Maintenance Seminar Institute” Reai Proactive Go to the doctor after becoming ill, hd t ; Fix a flat tire on the freewa: Discipline an employee for a health and safety violation Put out a fire caused by an equipment malfunction Refuse delivery on a shipment of substandard parts Table 1-1: Reactive ys. Proactive Every failure and every problem is an opportunity to improve! The role of reliability engineering at any facility is to change the culture of the site from emergency response and blame equipment failure. Itis the proce preventing these failures with involvement of maintenance, operations, and desi, engineering, Exercise Number 1 DEFINING RELIABILITY 1, Identify 3-4 things that are reliable. 2, Identify the characteristics of each of these things that make them reliable. 3. Create a definition of reliability. Reliability is. Reliability Engineering 8 Lecture 01-07 @ @é Rell NON oy * Overview of Reliability © Discussion on Why to Study Reliability © Define Reliability Dee List items that ave cekable ‘Meotify she characteristics of reliable items a ie definition of ret Aveta Mieco Why do things yo wrong? ‘But I's just a little problem! It's acceptablet IW it was done right 99.8 % of the thm——_ Operator error Engineering defect Management wouldn't Wasn't my fault Tdon’t know Actof God. Mistake > One hourofaisediking was pe th Two uae hangs Ora Alor erry dy 16.0000 pessoal per hove > 20,00 nore drug prcripion sac yar > S00 nconectourgil operators pred ech wosk > 0 soubor babe deep by dower ea ay 200000 ches deduond tom he wrengactount ach hoot > Nowlaphoor artelevitn tenes fo ea 10 ress ech (Otis ch yar And only a 0.4% chance of failing bricks... ‘einpesble to wach 10% lhe? {Esnifitaee posble toe eco? RELLADILITY ENGINEERING SHOULD ALWAYS BE A PRECTICAL APPROACH TO DETERMINE COST BENEFICIAL CHANGES 10 ENHANCE EQUIPMENT PERFORMANCEince Cost Produeuviy. iit Inerease Kiln Availubiiiy increased Availability lPector Safety Fewer Injuries ‘vironmental (Clesser Environment | Plott Gaginurins, lo ‘The probability that equipment, machinery. or systems will perform their required functions. satisfactorily under specific conditions within a specified lime period. ‘The appropriate application of engineering isciplines, techniques, skills, and data to ascess problems or improverneats, achieve the required reliability, maintainability, service exchangesbility, availability, and yield of products ‘and processes at a cost that satisfies business nezds,‘A good reliability always looking for ways to 4 improve performance by eliminating failures, ATE a Se MCCAY Engineer Need to Kno > Ralhity These basi cone ad es) 3 Udesundng of Muimenance Opens, Designand Relhilty > Maiterince Skis imschanic, tetris ismumentto. ad edie) > The Elect of Operations on Reibitey Asay Tools RCMand RCFA), > Fale Trenng (dua coltcton and wen idntcuice) > Avalyis Stare RAW > DasitRetality aed a @ yprniens Veter Chump tia it il rion Sr hig sd tesa potomance bein la oii ss ro pnt ta se Jota pleat hangs 9 PMI sete iki estiyYrosetire uinenance sites ‘Pride mefil nny equipment ela information value specific ih ses Fsahiead we wlitty ols > Review fle infoesin ence igi sxcFrilane brrobynia > Gating fat ninmiion > aloing sentient on eetive bus 2 mplenestine aces 0 ween Tales > Pood eve of mcd istry > Ranpowsrg ll pesseane wi th repanbiley fe aire prevention > Detloisgandanlysngiforivios rough th seo sdvaneedanlyal sana toks Preventive Maintenance (PM) Predictive Maintenance (PdM) > ideatsying 4 axites fornew egpnent > Renicing YM wins fore gue > Mowing ua oven ti ffeaepes uf We cxlng FM ogra aun > rdulog We ettinenss fei RIM tte 5 Ranowing th lena f potental ae cvstion tag > Biminuig schedded PM atviee tad por ontidenein DE > Waring ne ess nt motions ieuporte reliably. mately, operat. and le eyes tng eviews > Incorporating operates ed maltance pesonne input ‘aoa 9 designs or modesto, > Dating sete sing euitenesand opera ‘asrcton oem proper arp mafic new mugen ieee