Reliability Maintenance Engineering 1 - 3 Data and Decisions

Reliability Engineering

Fred Schenkelbergfms@fmsreliability.com

COLLECTING RELIABILITY DATA TO SUPPORT EFFECTIVE DECISIONS

Day 1 Session 3

Objectives

• Establish field data collection systems• Creating taxonomies and equipment failure

codes from ISO 14224• Gathering and examining basic reliability data• Developing analysis information for repair• Determine cost advantages of alternative

action plans to meet requirements

Data Quality

• High quality data is

• Compete• Compliance– Reliability parameters– Data types & formats

• Accurate

Obtaining Quality Data

Investigate data sources

• Define objective for data collection• Inventory or operational data complete• Sufficient and relevant data available• Identify installation date, population and

operating period(s) for equipment

Obtaining Quality Data

Preparation of sources

• Run a pilot of collection methods

• Plan collection process– Schedules, milestones,

sequence and number of units, time period, etc.

• Training• Collection process

assurance plan

Data Sources

• What do you need to make decisions?

• Maintenance Management System

• Prioritize according to importance to safety and production

Discussion & Questions

Boundary description

• Describe what is and is not included

Needed for consistent• Data collection• Data compilation• Data Analysis• Decision making

Show on diagram

• Subunits• Interfaces to

surroundings• Be clear what is in and

outside boundary

Equipment Hierarchy

• Equipment Class

Equipment Hierarchy

• Equipment Class

• Equipment Unit

Equipment Hierarchy

• Equipment Class

• Equipment Unit

• Subunit

Equipment Hierarchy

• Equipment Class

• Equipment Unit

• Subunit

• Maintainable Level

Equipment Failure Codes

Create short list and codes as needed

Three types

• Desired function is not obtained

• Deviation outside limits• Failure indication

observed

Combustion engines

Equipment Boundry

Equipment unit subdivision

Unit specific data

Failure modes

Discussion & Questions

Data Collection

Techniques

• Manual• Inspection• Automatic• Surrogate

Equipment Data

Failure Data

Maintenance Data

Discussion & Questions

Example

Bottling Plant Example

• Data Collected

Bottling Plant Example

• Objective

• Improve change overs so they start with higher availability

Bottling Plant Example

• Analysis

Bottling Plant Example

• Options to consider

• FMEA• Detailed RCA on top

early issues• Redesign of change

over process

Bottling Plant Example

• Results

• Avoided adding second line

• Improved availability• Improved tracking• Improved RCA and

redesign process

Discussion & Questions

Summary

• Establish field data collection systems

• Creating taxonomies and equipment failure codes from ISO 14224

• Gathering and examining basic reliability data

• Developing analysis information for repair

• Determine cost advantages of alternative action plans to meet requirements

Collecting reliability data to support effective decisions