reliability maintenance engineering 1 - 3 data and decisions
Post on 19-Dec-2014
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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
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