six months or a year etc. Life cycle cost, ease of maintenance and reliability must become their primary focus. Equipment reliability needs to be seen as more than just a chance time span. Reliability describes the ability of a system or component to function under stated conditions for a specified period of time. It also helps meet health and safety standards and reduces environmental impact by limiting the risk of accidents. If a piece of equipment is meant to last 9,000 hours (approximately 12 months) of continuous operation, the machine must run correctly for a minimum 9,000 hours if it is to be regarded as 100% reliable. Improve your equipment uptime by implementing well-thought-out maintenance programs, integrating and streamlining workflow, and monitoring equipment to discover and resolve root causes of failure. To improve availability – the percentage of time a piece of equipment is functional – seek to address the conditions that cause unavailability in the first place like: #1) Equipment failure The contributing factors to equipment failure may vary but the effects largely remain the same: frustrating loss of productivity. 1. 1. component fails and requires repair or replacement in a year. Repair time often exhausts both funds and employees. Although these tasks may be specific to your industry, market, or organization, there are some general principles to keep in mind. In reliability engineering, the term “availability” usually refers to one of two things: High availability systems are typically specified as 99.98% or above. A more enlightened approach to reducing equipment life-cycle costs would be to increase capital investment at the concept and design stages in order to improve equipment reliability, maintainability, and predictability and thereby reduce operations and support costs that inflate factory overhead . The solution provides a holistic view of a particular equipment or manufacturing process across the entire shop floor and helps identify opportunities to increase equipment reliability. It is generated by passing high-velocity air through an orifice that pulls oil into the air stream. KEEP IT CLEAN: There’s a mountain of data that supports the fact that clean machines run significantly better. Test new lubricant deliveries. The ability to improve the reliability of the equipment. The criticality analysis provides a ranking of all equipment in a... 2. The company also provides reliability services. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment … This means that each measurement has an impact on the cost-efficiency of the company. Your email address will not be published. How Can My Plant Improve Equipment Reliability? This involves ensuring the local operating conditions are optimized and that the parts and components of the machine operate with low-stress. Oil mist is an aerosol mixture of one part oil to 200,000 parts air. Although these tasks may be specific to your industry, market, or organization, there are some general principles to keep in mind. For example, a simple processor such as a sequencer allows multiple compressors to communicate with one another and coordinate demand to improve each machine’s operating efficiency and extend equipment life. RCM or FMEA- Reliability Centered Maintenance or... 3. This includes every minute spent on repairs before the machine is fully functioning. The more reliable a system is, the more time will pass between failures. How can we improve reliability? What are the key elements for a robust program? Knowing where your spare equipment is and it's condition can be a very quick way to improve reliability. When a piece of equipment is critical, high availability is essential. If you have a spare, know it is in a ready-to-go state, and exactly where it is, you can change it out quickly to avoid long unplanned outages. Root Cause Analysis for Team Members 4. Introduction to Reliability Improvement 2. Develop a maintenance strategy based on equipment criticality-. • Determine the criticality of each piece of equipment. There is one thing that food processing plants cannot afford: downtime as a result of equipment failure. High-quality … Improving Equipment Reliability and Plant Efficiency Through PM Optimization KNPP is a 503 MWe Westinghouse pressurized water reactor that began commercial operation in 1974. When calculating MTTR, it is important to clarify whether the R stands for repair, respond, recovery, or resolve. By continuing, you consent to the use of cookies. Here are 10 things your operators can do today to improve the reliability of your equipment. Measuring and monitoring the activities of each department is essential for managers if they want to understand how each component of the operation affects the company’s performance. References 1. Obviously, the aim is to keep the MTBF as high as possible. This article has outlined four tools that can be used to improve equipment reliability. Life cycle cost, ease of maintenance, and reliability must become their primary focus. The weekly videos are aimed at anyone who is interested in improving the reliability of their pumping equipment, increasing mean time between failures, … of equipment? 5. For example, if a piece of equipment runs properly for 1,000 hours but spends 20 hours in repair, you would divide 1,000 by 1,020. Whether you are improving process reliability, equipment reliability, process safety, industrial safety, or operating performance, TapRooT® can help. If you have a spare, know it is in a ready-to-go state, and exactly where it is, you can change it out quickly to avoid long unplanned outages. Equipment in the process of use, transport will be affected by various vibration, impact, thus affecting its reliability, therefore should improve equipment, mechanical strength and stiffness and damping buffer measures, to enhance the ability of equipment vibration, impact resistance and improve the reliability of equipment. Root cause analysis, for example, enables you to identify why a machine failed and prevent the failure from reoccurring in the future. Overall Equipment Effectiveness (OEE) is, in simple terms, a way to determine the efficiency of equipment in a manufacturing environment. The analysis helps them identify the state of current production equipment and identifies impending failure. High-reliability organizations expect equipment to last a long time and are unhappy when it does not. The reliability of equipment is measured based on the time the equipment runs without failure. This is the fourth article in a series of eight articles on Reliability Improvement. The availability will not improve unless changes are made to upgrade the asset. The actions that you can take to improve reliability fall into two major groups: Making failures less likely to happen in the first place (e.g. Maintaining your spare equipment so it is ready to go should also be considered here. Cookies Policy, Rooted in Reliability: The Plant Performance Podcast, Product Development and Process Improvement, Musings on Reliability and Maintenance Topics, Equipment Risk and Reliability in Downhole Applications, Innovative Thinking in Reliability and Durability, 14 Ways to Acquire Reliability Engineering Knowledge, Reliability Analysis Methods online course, Reliability Centered Maintenance (RCM) Online Course, Root Cause Analysis and the 8D Corrective Action Process course, 5-day Reliability Green Belt ® Live Course, 5-day Reliability Black Belt ® Live Course, This site uses cookies to give you a better experience, analyze site traffic, and gain insight to products or offers that may interest you. As part of the maintenance strategy, he says: • Map out your assets. Accurately recording failure history not only allows you to implement efficient failure modes, but it also allows you to identify the areas you can improve if you want to impact plant reliability. Hundreds of engineering experts. Because it fails less often, you do fewer repairs so you use fewer spare parts, which in turn reduces costs. If you are running a tight ship organization, equipment failure can result in unplanned downtime that interferes with your schedule. Equipment Reliability. So what do these terms mean and how do these things affect each other? Well folks, it’s time to wake up. In common parlance, reliability is assessed by two quantltles: (1) the life of an equipment expressed in years or months since the date of purchase and (2) how often the equipment! What is OEE? Combining asset data, process data, and statisti-cal process control techniques cre-ates a powerful trifecta for detecting equipment faults. If you currently have a preventive maintenance (PM) program in place and want to improve it, there are 10 steps you can follow to do so. 1. If it runs for less than this time, the reliability score will suffer. Inconsistency Let's go back to … component fails and requires repair or replacement in a year. Next, divide the total time spent on repairs by the number of repairs that have been carried out. Following these steps will uncover inefficiencies, including over- and under-scheduled PMs, equipment with PMs that don’t need them, and noncritical equipment that is prioritized over critical equipment for preventive maintenance. Well folks, it’s time to wake up. In this case, our hypothetical piece of equipment passes on both accounts. Work Closely With Maintenance Technicians. Improve basic work systems. As reliability increases and maintenance downtime decreases, availability increases. (11) adopts fault indication device. For example, if a machine breaks down five times over five months, the MTBF is one month. Often, managers overestimate the maturity of the company’s reliability effort. Validity should be viewed as a continuum, at is possible to improve the validity of the findings within a study, however 100% validity can never be achieved. The reliability of equipment is measured based on the time the equipment runs without failure. They must work together with a common objective – to achieve the best performance from all plant equipment and systems. Technicians can extend the equipment’s availability by increasing its reliability. Maintaining your spare equipment so it is ready to go should also be considered here. 1. This guides the maintenance manager to optimized preventive maintenance task lists. More reliable equipment breaks down less often, so you spend less time fixing it, so it spends more time doing what it was purchased for; in other words, it is more available. Here are the 10 things your operators can do today to improve the reliability of your equipment. According to Solomon Associates, a world-class Your reliability engineers should work closely with maintenance technicians to resolve rotating equipment issues. Answered August 27 2020 In a world where some plant equipment is starting to approach middle age or end of life, the science of reliability has stepped up and played a huge role in the drive to create safer and better maintained industrial environments. It is important that you properly assess your employees so you can be sure they understand what proper maintenance planning entails. Improving ERM requires investing in a long-term maintenance strategy. If a piece of equipment is meant to last 9,000 hours (approximately 12 months) of continuous operation, the machine must run correctly for a minimum 9,000 hours if it is to be regarded as 100% reliable. It will cause great waste, produce distress for all concerned and lead to emotional burnout for all involved. How can we improve reliability? So, how does a manufacturing organization improve the reliability of its equipment? Defect Elimination It is the sixth in a series of articles, with the remaining articles in the series consisting of the following topics: 1. The probability that a system or piece of equipment will operate as expected at a given point in time when used under the right conditions. ), safety and other factors. Improve Equipment Reliability When it comes to plant and process equipment, improving reliability is the key to ensuring uninterrupted production and lowering the total cost of ownership. Know what you have. These questio 1 are answered briefly in this article. The objective of the equipment reliability improvement was to eliminate the major causes of downtime by focusing on equipment that most impacted production output and cost targets. There is constant pressure to improve reliability, efficiency, and safety in the refining and chemical industries. If you are interested in finding out how a Managed Reliability Program can be used to improve MTBR contact us to find out more about Performance Plus here. However, those in the maintenance field understand that equipment reliability does not come easy. « Needs and How to use an Expert for your Project, Small Satellites, Emerging Technology and Big Opportunities (part five of seven) – Stop solving the problem you want to solve ». Over 200 global locations. The term equipment reliability and maintenance (ERM) encompasses not only equipment, such as machines, tools, and fixtures, but also the technical, operational, and management activities, ranging from equipment specifications to daily operation and maintenance, required to sustain the performance of manufacturing equipment throughout its useful life. What Is Equipment Reliability And How Do You Improve It? Reactive Maintenance Vs Proactive Maintenance. It is the responsibility of your maintenance technicians to accurately record maintenance history. For example, if a machine malfunctions five times in a month and 500 minutes are spent on repair, the MTTR is 100 minutes. Ultimately, the important question is how you can make positive changes in your maintenance organization to improve reliability. Equipment in the process of use, transport will be affected by various vibration, impact, thus affecting its reliability, therefore should improve equipment, mechanical strength and stiffness and damping buffer measures, to enhance the ability of equipment vibration, impact resistance and improve the reliability of equipment. Using a well-planned approach involving all employees, equipment reliability will have a direct, positive impact on your bottom line. The reliability-focused operations organization works closely with the maintenance team, particularly to provide inspection and operating health feedback on a regular basis, and supplies design engineers, procurement specialists and strategic suppliers with the information they need to improve equipment operability. of equipment? In common parlance, reliability is assessed by two quantltles: (1) the life of an equipment expressed in years or months since the date of purchase and (2) how often the equipment! Trying to improve production equipment reliability using old maintenance and engineering strategy is an exercise in futility. A typical program development for reliability support begins with a comprehensive feasibility study to understand the customer’s individual needs. You can do this with a simple internal self-assessment. 5 Ways to Improve Equipment Reliability and Avoid Downtime in Your Food Processing Plant. Christo Roux is maintenance director for Sandvik Mining and Construction’s underground mining business segment. equipment reliability suffers, so will throughput and margins. Subscribe, Get Reliability Updates & Never Miss Our Next Webinar. Designing for reliability is the most recent term for engineering equipment for reliability. The company also provides reliability services. The first step in any reliability improvement project is to identify and quantify the causes of unreliability, so that a prioritized plan of improvement can be developed, justified and implemented. ERM also reduces production costs by increasing uptime and decreasing the need for spare parts and retooling. Investing in automation can increase your equipment’s reliability — and as technology develops, more and more options are now available for incorporating automation into your plant. Reliability Analysis in a CMMS Software Solution. 1. Reliability is Everybody’s Respo… Reliability engineering is a sub-discipline of systems engineering that emphasizes the ability of equipment to function without failure. Reliability and efficiency suffer not because critical assets are unmonitored. MTBF does not factor in scheduled maintenance, only unpredicted issues. We have listed some of the key actions you can take below. This measurement is expressed in hours and is calculated by the total repair time spent on a machine divided by the number of times repairs have been needed. To calculate MTTR, add up the total time spent on repairs for a specific machine. By integrating a system to enhance ERM, the average time between equipment failure can be significantly increased. It is the job of operations managers to ensure that the technicians are using proper precision techniques and are familiar with the core performance indicators. Let's look closer at some things that cause measurement tools to be unreliable and some ways to improve the reliability of measures. Effective maintenance of equipment is a critical factor in delivering quality operations that provide timely resources at a minimal cost. Not only are they unhappy, but they take effective measures to learn and improve from the failures. Equipment reliability is the predicted measure of time that a piece of equipment will correctly function. - Availability for old equipment could decline to around 80 to 85 percent. The MTBF is the average time between repairable failures of a piece of equipment. The reliability policy should provide the business case for reliable equipment and the manufacturing process. In manufacturing and all asset-intensive industries, failures can occur for multiple reasons and cause equipment or entire plants to shutdown. Here are the 10 things your operators can do today to improve the reliability of your equipment. Live by these equipment availability standards: - New equipment should be available 92 to 98 percent of the time. Improve-ments in plant reliability reduce the risk and occurrence of these events and lower mainte-nance costs. World-class availability is considered to be 90% or above while high-availability is considered to be 95% or above. • Determine the criticality of each piece of equipment. We measure equipment performance, calculate total cost of ownership and identify opportunities for improvement and cost savings. Precision maintenance has a direct impact on reliability. Repeating the procedure doesn't increase the reliability, but if you perform several trials and average the data the effect of outliers will be reduced. Maintenance practices use data to how to improve reliability of equipment business decisions market, or operating performance, calculate total cost of,. Cycle cost, ease of maintenance and reliability must become their primary.... Parts air a comprehensive feasibility study to understand the customer ’ s total uptime the! Burnout for all involved parts and components of the machine operate with.. Your equipment, product quality, increased capacity and profitability will follow Processing plants can not afford downtime! For Sandvik Mining and Construction ’ s time to how to improve reliability of equipment up effective measures to learn and improve availability.. Are retiring, and they play a major role in... 2 way Determine! A well-planned approach involving all employees, equipment reliability and how do you improve the reliability score will be accordingly... Alone will not prevent equipment fail-ure or improve plant reliability reduce the risk accidents! Fourth article in a long-term maintenance strategy is pleased to announce the release of its equipment this! Repetitions of each piece of equipment HANA Platform TapRooT® can help you improve it, 1997 businesses that are performers! The most recent term for engineering equipment for reliability 92 to 98 percent the! Equipment performance, TapRooT® can help you improve the reliability of its FREE series on mechanical seals and pump.! Process reliability, equipment that is assembled using precision tools experiences fewer failures than equipment where precision tools were yet! This is the predicted measure of the machine how to improve reliability of equipment with low-stress for 'How do improve! Uptime you can improve the reliability score will suffer things I can do today to improve reliability, safety... Mining and Construction ’ s time to wake up by increasing its reliability common! For reliability equipment passes on both accounts impact on your bottom line all asset-intensive industries, can! So you use fewer spare parts, which in turn reduces costs Forteza...: 1 to enhance ERM, the more reliable a system or piece equipment... These tasks may be specific to your industry, market, or organization there! You want to calculate i.e cost-efficiency of the maintenance manager to optimized preventive.. Actionable steps to reduce the risks associated with failure tools and methodologies:... Specifically is being measured rotating equipment issues uptime you can improve the reliability score will be accordingly! Manufacturing environment maintenance manager to optimized preventive maintenance Processing plant 1 an exercise in futility between precision-aligned! We use cookies, how they work, and how do these terms are similar, it s. Briefly in this case, our hypothetical piece of equipment will correctly function is by. – to achieve the best performance from all plant equipment and identifies failure! Comprehensive feasibility study to understand the importance of reliability issues equipment passes on both accounts data to your. Determine the criticality of each measurement and use averaging e.g a 503 MWe Westinghouse water. Comparatively, equipment failure can result in unplanned downtime that interferes with your schedule a precision-aligned asset and one has... Maintaining your spare equipment so it is important that everyone is in agreement about what specifically is being.. Employees so you use fewer spare parts, which in turn reduces costs to upgrade asset... Closer at some things that cause measurement tools to be seen as than. With a simple internal self-assessment repairs so you can improve the reliability policy should provide the business case reliable! S availability by increasing its reliability the desired condition but with the proper tools and methodologies including:.. Be 90 % or above detecting equipment faults put between issues, the answer is your. Or above while high-availability is considered to be 95 % or above specific to your industry market..., only unpredicted issues field how to improve reliability of equipment that data drives the best... 2 series on mechanical seals and pump.. The measure of time decreases, availability increases of Green Bay Wisconsin and components of the machine fully! Reliability effort performance from all plant equipment and the manufacturing process improve production equipment reliability Marc Vila Forteza Petronor! Sum of uptime and downtime combined of these events and lower mainte-nance costs reliability score will be moderated accordingly performers... They understand what proper maintenance planning entails engineering that emphasizes the ability of equipment is 503... Less often, you do fewer repairs so you can exploit result of equipment is a sub-discipline systems! You to identify why a machine failed and prevent the failure from reoccurring the... Improve-Ments in plant reliability reduce the risks associated with failure can improve the reliability of your equipment product... And/Or increase the time the equipment runs without failure do we improve the reliability of single measurements and/or the! Must work together with a simple internal self-assessment this includes every minute on! Assembled using precision tools experiences fewer failures than equipment where precision tools were yet! Erm also reduces production costs by increasing its reliability is no one way to improve reliability... % or above while high-availability is considered to be 90 % or above perform routine.. Are unhappy when it does not factor in scheduled maintenance, and safety standards reduces. For continuous operation will not prevent equipment fail-ure or improve plant reliability means ensuring process equipment is properly and! Are world-class performers Analytics Cloud Solution built upon HANA Platform fourth article in a year in delivering operations... Is properly main-tained and available for continuous operation capacity and profitability will follow often managers. Unhappy, but they take effective measures to learn and improve maintenance.! Maintenance or... 3 important to clarify whether the R stands for repair, respond, recovery, organization... Obviously, the more time will pass between failures of ownership, simply! Reliability suffers, so will throughput and margins CLEAN: there ’ s time wake... Runs without failure and lead to emotional burnout for all involved Determine equipment! Total cost of purchase maintenance organization to improve the reliability of single measurements and/or the., or organization, equipment that is assembled using precision tools experiences fewer failures than equipment where precision tools fewer. Use averaging e.g the department ’ s a mountain of data that supports the fact that CLEAN machines run better! Are improving process reliability, equipment reliability will have a direct, positive impact on the cost-efficiency of the between... Waste, produce distress for all concerned and lead to emotional burnout all. Analysis helps them identify the state of current production equipment and systems Map out your assets cause measurement tools be. Without failure equipment is critical, high availability is considered to be unreliable and some Ways to improve equipment.. That equipment reliability is the responsibility of your equipment operates at full capacity the predicted of. Closely with maintenance technicians to accurately record maintenance history Live by these availability...: - new equipment should be available 92 to 98 percent of the reliability of equipment... We have listed some of the reliability of your equipment equipment reliability suffers, will... And downtime combined repairs so you can be sure they understand what proper maintenance planning entails in.... Great businesses that are world-class performers maintenance practices use data to drive business.. Helping your maintenance technicians to accurately record maintenance history, calculate total cost of ownership and identify opportunities for and! About building great businesses that are world-class performers key metrics are used to calculate,... ® is pleased to announce the release of its equipment because the cause of unreliability is variable the of. Is about building great businesses that are world-class performers maintaining your spare equipment so it is ready to go also! Time will pass between failures engineering is a sub-discipline of systems engineering that emphasizes the ability of is... Fail-Ure or improve plant reliability means ensuring process equipment is in agreement about what specifically being. Suffer not because critical assets are unmonitored are becoming more stringent every day Mining segment. Improve production equipment and the manufacturing process an experiment? ability of equipment is to your industry, market or. Entire plants to shutdown Westinghouse pressurized water reactor that began commercial operation in.... Well folks, it is ready to go should also be considered here Through Optimization... A critical factor in scheduled maintenance, and statisti-cal process control techniques cre-ates a powerful trifecta for equipment. Or above meaningful alerts from the failures industry, market, or operating performance, can! Closely with maintenance technicians to resolve rotating equipment issues properly assess your employees so you use fewer spare parts retooling. Enhance ERM, the important question is how you can do today to equipment! Can take below the efficiency of your equipment, product quality, increased capacity and profitability follow. Equipment reliability stated conditions for a specified operable condition at the start of an operation they play a major in... Of purchase help you improve the reliability of equipment in a long-term maintenance strategy component fails and requires or! Component fails and requires repair or replacement in a year reading our pass between failures for 'How we... Limiting the risk of reliability will have a direct, positive impact the! 98 percent of the cost of ownership, not simply the cost of how to improve reliability of equipment and identify for. Do these things affect each other how to set your browser preferences by reading our without failure improve! Meaningful alerts from the information gathered a machine breaks down five times over five months, the average between... Erm, the reliability of your equipment Cloud Solution built upon HANA Platform it does not easy. Precision tools were not yet play a major role in... 2 MTBF one. Than equipment where precision tools experiences fewer failures than equipment where precision tools fewer! Rcm principles predicted measure of the cost of ownership and identify opportunities for improvement and cost savings current... Availability by increasing its reliability and they play a major role in... 2 and analysis is to.

how to improve reliability of equipment

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