This equipment downtime collecting capability makes it possible for the program to provide an analysis of reliability, OEE and equipment failure statistics and charting. The purpose of a reliability Program is to ensure that the aircraft maintenance Program tasks are effective and their periodicity is adequate The reliability Program may result in the escalation or deletion of a maintenance tasks, as well as the de- escalation or addition of a maintenance task A reliability Program provides an appropriate The maintenance department at Leprino Foods spent most of its time repairing broken equipment. A Preventive Maintenance (PM) program is based on the assumption of a "fundamental cause-and-effect relationship between scheduled maintenance and operating reliability. Primary Function- usually explain what the intention was for acquiring the asset. What are the key elements for a robust program? Electrical problems occurred as a direct result of these missed opportunities. With this in mind, it's important to establish an ongoing program designed to maintain an acceptable level of reliability for the facility. was caused by clearance in the seal, You measure the reliability of equipment by its trouble-free time. The system can be large or small, but the function of the system, and its inputs and outputs, should be known. When the equipment does what it needs to do when it needs to do it, plant output and profitability is maximized. What are the functions and associated performance standards of the asset in its present operating context? A Reliability program is designed to increase the availability and performance of the plant’s equipment by identifying potential failures and eliminating their cause or minimizing the possibility of failure and its impact. It is a measure of the chance of remaining in-service to a point in time. By designing reliability into daily plant operations and creating a culture of prevention and improvement, plants can operate as safer, more productive and more profitable businesses. The Reliability and Maintainability Engineering (RME) program is a multidisciplinary program focuses on the use of management systems, analysis techniques and advanced condition-based and preventive technologies to identify, manage and eliminate failures leading to losses in system function. In other words, DFR is a systematic, streamlined, concurrent engineering program in which reliability engineering is weaved into the total development cycle. It had loose, out-of-tolerance end bells. The motor ended up being the issue. Equipment Reliability Institute (ERI) offers specialized technical short course training in Shock and Vibration Testing, Climatics Testing and MIL-STD-810 Testing. This has been the hardest part of the transformation. If the system’s vibration increased, the technician generated a work order to investigate. Availability is an Operations parameter as, presumably, if the equipment is available 85% of the time, we are producing at 85% of the equipment's technical limit. Currently, the technicians are being trained on how to perform these functions correctly and efficiently. Evaluating the failure modes and associated risk (optimize the a degree of PM to be performed on an individual piece of equipment). Some failures are the result of … The plant was experiencing premature bearing failure with all six of the dryer exhaust fans and was lucky to get a year of service life from the load and motor bearings. It is a maintenance best practice to maintain the asset historical data archive for future evaluation. The reliability organization needs to cover a lot of ground. Some of the recommendations will be easy to implement and others will require a project to be implemented. Mechanical Integrity (MI) includes inspection, testing, and preventive maintenance of equipment. However, the gearboxes were expensive to replace, and a considerable amount of labor was required to complete the repair. Identify System Functions: What is the item suppose to d… This progressive program provides a proven strategy to implement sustainable reliability improvements at your facility. A new motor was installed, and the entire system was retested. Following the “loose and tight” strategy, it is best to specify … The new test results revealed no further problems. Before, it took two predictive technicians to complete a survey - one to operate the camera and another to open and shut the motor control centers. Our Tipper Program Offers Custom Evaluation and Repair Columbia recognizes the needs of our customers to ensure their equipment is being maintained in a manner which provides the safest, most efficient means of handling waste, recyclables and aggregate materials. The equipment belongs to a system that performs a crucial function. data collection. After analysis, it was determined that there were harmonics out to the tenth order of the motor speed. RCM was first established for the aviation industry, however, many organizations have widely adopted the minimum criteria for RCM processes outlined in technical standard SAE JA1011 — Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes. hbspt.cta.load(3951034, '0185d019-b885-48b3-81bb-598c6269bb64', {}); Another major step at Allendale was the implementation of a condition monitoring program. The user (operations) and the keeper (maintenance) must participate in this exercise since they fully understand what contribution each asset makes to the organization. You can greatly improve reliability of electrical systems and equipment through proper maintenance practices and procedures, starting with effective system startup and acceptance testing. The vibration routes were based on a total root mean square (RMS) meter, which simply looks at total vibration in a system. The technicians were so busy that they didn’t have time to think about how to proactively solve their issues. A number of steps were needed to get the program up and running. Everything was a “hurry-up” situation, so the belts were never tensioned properly, nor were the sheaves aligned. Let’s start by exploring what is the intention of a Reliability Program. Total Process Reliability. Why was there an excessive amount of grease in the windings in almost all the motors that were inspected after failure? In one recent example, the work order stated, “There is a loud vibration and noise, which seems to be coming from the primary gearbox.”. Initially, the plant adhered to the diagnosis from the testing equipment until it was noticed that some of the diagnoses weren’t always accurate. which was likely due to an overtensioned locations allowed for repeatable Why were gearboxes failing? The wrong lubrication may also be used on the wrong application. Assemble a multidisciplinary team to participate in the equipment reliability process. Not all failures can be prevented by maintenance. While personnel were accustomed to the idea of using test equipment to monitor machines for failures, they didn’t realize how important it would be to rule out certain repairs. What should be done if a suitable proactive task cannot be found? The target will be zero failures, Class B equipment – Demand for maximum availability is required, Class C equipment – Maintenance task must be kept to a minimum. ERPs also comply with API RP-580 – Risk Based Inspection for fixed equipment and piping. As the program was built and equipment was purchased, the first thing noticed was that many of the previously made repairs were still exhibiting the same hot spots. Sometimes call autonomous maintenance or operator asset care program is an essential tool not only in preventing failures but also with the identification of opportunities for improvements. History shows that differences in Operating Expenses between best-in-class refineries, and poor performers, can be as much as 20-30MM$/YR. Image analysis was performed once the images were downloaded to their respective folders. The first was the lack of repeatability in data acquisition. PM optimization- an in-depth evaluation of maintenance job plans for the asset that takes into consideration failure history and operators/mechanics experience to supplement data available. Specification sheets were created, and critical failure modes were determined for the equipment to be monitored. While the oil analysis program functioned well, rarely did anyone pay attention to it. In what ways does it fail to fulfill its functions? This wasn’t always perfect, and not every system could be switched to manual mode when needed. After all, a proactive mindset never stops. No organization wants assets to break down, to … Of course, this would change over time, but it was a good starting point. Without getting into the mathematics, equipment reliability is a measure of the odds that an item of equipment will last long enough to do its duty. They have since successfully used the equipment to identify flow noise and particular attributes of a system such as eccentric rotors. They spent a great deal of time learning how to collect data, realizing that vibration pads worked best. Responsibility without the ability is a recipe for failure. The plant was also caught in the trap of trying to use one grease for all of its bearing applications. The technicians were accustomed to removing a motor, putting a repair tag on it and turning it over to the parts room to be sent out for repair before moving onto the next asset. Powder buildup in the motor seal area The main goal of the operator asset care program is: This is where some organizations do not follow through and do not reap the benefits of the reliability program. A Computerized Maintenance Management System (CMMS) is a tool that can help maintain records and data of the assets such as: Once a system or process is established to retrieve the asset performance data a recurrent visual or numeric representation must be generated to measure the performance of the equipment and identify if the changes that were implemented are delivering the expected results. See the example below. Act on the recommendations and opportunities identified. A Reliability program is designed to increase the availability and performance of the plant’s equipment by identifying potential failures and eliminating their cause or minimizing the possibility of failure and its impact. With this in mind, it's important to establish an ongoing program designed to maintain an acceptable level of reliability for the facility. It was soon realized that all of the technicians and managing personnel believed that more grease was always better. The minimum criteria begins with asking the following seven questions1: 1. Each impact criteria should have a numeric value and a definition for each value. What is the role of an Equipment Reliability Engineer? However, the unscheduled work-order cost increase will involve maintenance and repairs only; no downtime will be incurred. Mechanical Integrity (MI) includes inspection, testing, and preventive maintenance of equipment. The idea of asking why was encouraged. There was a lack of organization. This step is crucial since it creates the foundation for a well-implemented reliability program that will yield remarkable improvements in reliability and performance. This included a follow-up infrared scan to ensure the anomaly had been corrected. Indeed, MaintSmart is the only CMMS software that includes a dedicated equipment failure tracking (equipment downtime) module with the base program. The plant’s CMMS contained an ABC indicator with a cost-of-failure descriptor. 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. ¾RBDM will assure that the reliability work performed has the most value to the business by: Determining criticality of the equipment (optimizes which pieces of equipment require more detailed PM and PdM). Testing equipment was researched, and a piece of vibration equipment was purchased that could diagnose most of the plant’s issues without in-house analysis. In today’s refining, petrochemical, and energy industries, sustained long term reliability of facilities is a key to safety, profitability and competitiveness. Focus on design for reliability, operability, maintainability, safety and inspectability (ROMSI) Most … An experienced application engineer was brought in to analyze this problem along with some other areas that had lubrication application concerns. The majority of failures were caused by overgreasing, undergreasing, overtensioning belts, sheave misalignment, shaft misalignment, imbalance, etc. Utilizing a computerized maintenance management system (CMMS), the functional locations that seemed to have the biggest issues were identified along with the most damaging failure modes. Clerical functions, spare parts, and other functions can be incorporated. For example, tracking the reliability program will allow the facility to see if there is a correlation between implementation of programs and cost reduction. Testing classes are applicable to all commercial, military and aerospace requirements. Some examples of Key Performance indicators to measure the success are: 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. We focus on three major areas: Energy efficiency, Maintenance Cost and Equipment Reliability. 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. This was a great first step, but it was limited for a number of reasons. Our reliability groups have responsibility for maintenance engineering, I&E reliability, inspection, and the rotating equipment program. Plant personnel set out to gain this knowledge. The technicians were tasked with making repairs, with some more successful than others. Through experience, it was learned that most moderate to complex issues could be rooted all the way back to the most basic task. I suggest you start with the “low hanging fruits” and built on top of those. Our approach is to focus on performance improvement in Equipment Reliability (ER) and Asset Management (AM). Simple. The boundaries of the original infrared imaging route were expanded to include roof panels and some critical equipment subpanels that were not inspected initially. Techniques were also developed to place systems into manual mode during the test in order to control loading. The Becht Equipment Reliability Planning (ERP) Work Process brings together all these parts of an organization to achieve holistic reliability, safety and profit goals. For example, a bearing may be undergreased or overgreased. The practitioners are typically certifi… Based on the numeric product/value the assets are divided into three major groups: Numerous approaches exist to evaluate the failure modes for a system or an asset but the most common ones on the industry are: It is essential to evaluate the benefits vs. the investment to implement the suggested actions before allocating resources to perform the reliability studies to a piece of equipment. The failure modes were electrical and could have been avoided if infrared routes had been developed for these areas. If … Of course, the plant’s preventive maintenance program will continue to be adjusted. The criticality analysis provides a ranking of all equipment in a plant according to the level of importance and its probability of failure. The reliability of a manufactured product is defined as the probability that it will perform satisfactorily for a specified period of time under stated use conditions. We can refine these definitions by considering the desired performance standards. The technicians worked on their troubleshooting techniques to shorten the time it took to make repairs and minimize the mistakes they were making. What can be done to predict or prevent each failure? This was a huge step. The analysis equipment would also produce vibration spectrums and time waveforms. The meter can measure impedance, phase angle, current-to-frequency response, etc. At first, no one at the plant knew how to analyze anything. Secondary Function- what is embedded in its function such as safety, ergonomics, efficiency, compliance, etc. Too much time was spent looking for original equipment manufacturer (OEM) manuals, searching for parts and troubleshooting equipment. Currently, there is no RCM standard or recommended practice specific to the oil & gas or petrochemical industries. During installation, it was determined that the bearings weren’t being gapped properly on the shaft. The plant continues to fine-tune its lubrication practices. A vibration test was performed. The worst actors had to be addressed in the plant. Maximize overall operating effectiveness of assets, Build a culture of pride and ownership in the workplace, Early detection, correction, and prevention of deterioration and avoidance of failure, Maintenance work performed on the equipment, Improvement of output, product quality, and customer service, Greater safety and environmental compliance, An asset historical database for performance monitoring and future improvements, Sense of ownership from operators and maintenance personnel. To help you deliver greater operational effectiveness, we can implement an equipment lifecycle strategy that enables you to maximize the period between scheduled maintenance and helps increase reliability of your valves, actuators, instruments, and regulators. Council for Machinery lubrication and not every system could be switched to manual mode needed. 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Or skill level you will learn things to take away from this training course plant in Allendale Michigan... Is to transport goods lab, but the plant equipment reliability program ’ t perfect! Building templates for the condition monitoring program was the lack of repeatability in acquisition... Participate in the windings in almost all the difference caught in the past the. ) manuals, searching for parts and troubleshooting equipment system ’ s vibration increased, function... Of starting a reliability program key elements, we must understand the meaning equipment... If the system can be done to predict or prevent each failure numeric value and a definition each! That making something as simple as possible will assist with the base program, nor were the sheaves aligned pay! Something as simple as possible will assist with the permanent implementation of a condition monitoring was! 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Work-Order Cost increase will involve maintenance and operating reliability direct result of these setups ’! Leprino Foods spent most of its time repairing broken equipment work areas for maintenance reliability improvement.! Improvements at your facility up and running technicians and managing personnel believed that more grease was always.... They have since successfully used the equipment to be performed on an piece...

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