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. 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. Here are the 10 things your operators can do today to improve the reliability of your equipment. However, those in the maintenance field understand that equipment reliability does not come easy. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. 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. 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! Use high-quality lubricants. 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. MTTR (Mean Time To Recovery, Repair, Respond, or Resolve), How Disparate Systems Can Impact Operations Without Integrations, Deferred Maintenance | Effective Means of Reducing Deferred Maintenance Costs, CMMS System Integration: Increase ROI & Efficiency In Maintenance. six months or a year etc. By maintaining the equipment properly or fitting more reliable equipment) Making changes such that the overall system continues to function satisfactorily even when a failure occurs (e.g. Effective maintenance of equipment is a critical factor in delivering quality operations that provide timely resources at a minimal cost. Data aggregation and analysis is necessary to generate meaningful alerts from the information gathered. Begin using data to support your cause – The best maintenance organizations understand that data drives the best... 2. Improve equipment reliability analysis by integrating reliability analysis with preventive maintenance. Equipment reliability is the predicted measure of time that a piece of equipment will correctly function. Subscribe, Get Reliability Updates & Never Miss Our Next Webinar. 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. If you improve the reliability of your equipment, production quality, increased capacity and profitability will follow. It is generated by passing high-velocity air through an orifice that pulls oil into the air stream. Life cycle cost, ease of maintenance, and reliability must become their primary focus. By continuing, you consent to the use of cookies. How can we improve reliability? How to test: Repeat single measurements and … If you can improve the reliability of your equipment, product quality, increased capacity and profitability will follow. If you can reduce external factors that cause failure, you can increase the time your equipment operates at full capacity. The criticality analysis provides a ranking of all equipment in a... 2. ERM also reduces production costs by increasing uptime and decreasing the need for spare parts and retooling. This includes every minute spent on repairs before the machine is fully functioning. If you are running a tight ship organization, equipment failure can result in unplanned downtime that interferes with your schedule. 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. Often, managers overestimate the maturity of the company’s reliability effort. It should include guidelines for maintenance and reliability, focus areas for improvement, a set of measures, and a time horizon in which to see the effort’s benefits. Optimize performance of critical equipment What is OEE? 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. By integrating a system to enhance ERM, the average time between equipment failure can be significantly increased. 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. The weekly videos are aimed at anyone who is interested in improving the reliability of their pumping equipment, increasing mean time between failures, … MTBF does not factor in scheduled maintenance, only unpredicted issues. Although these tasks may be specific to your industry, market, or organization, there are some general principles to keep in mind. Hundreds of engineering experts. 10 Things I Can Do Today To Improve Equipment Reliability! Combining asset data, process data, and statisti-cal process control techniques cre-ates a powerful trifecta for detecting equipment faults. It also helps meet health and safety standards and reduces environmental impact by limiting the risk of accidents. Obviously, the aim is to keep the MTBF as high as possible. component fails and requires repair or replacement in a year. (11) adopts fault indication device. Your employees operate your machinery on a daily basis, and they play a major role in... 2. Practical assessments are designed to test your practical skills: how well you can design and carry out an experiment and analyse results, but also your understanding of the purpose of the experiment and its limitations.One aspect of this is the reliability, validity, and accuracy of the experiment. Improve the reliability of single measurements and/or increase the number of repetitions of each measurement and use averaging e.g. A typical program development for reliability support begins with a comprehensive feasibility study to understand the customer’s individual needs. Reactive Maintenance Vs Proactive Maintenance. What are the key elements for a robust program? In reliability engineering, the term “availability” usually refers to one of two things: High availability systems are typically specified as 99.98% or above. The reliability of equipment is measured based on the time the equipment runs without failure. KEEP IT CLEAN: There’s a mountain of data that supports the fact that clean machines run significantly better. Technical measures to improve the reliability of PCB equipment: plan selection, circuit design, circuit board design, structural design, component selection, manufacturing process and other aspects, the specific measures are as follows: (1) Simplify scheme design. line of best fit. When normal acceptance and start-up testing isn't performed (usually to save a … If you can improve the reliability of your equipment, product quality, increased capacity and profitability will follow. 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 . Inconsistency Let's go back to … Develop a maintenance strategy based on equipment criticality-. How Can My Plant Improve Equipment Reliability? This article has outlined four tools that can be used to improve equipment reliability. Improve basic work systems. Ensuring that there are no hard-to-reach points that require the equipment to be shut down to service will increase maintainability and, as such, will achieve reliability right out of the gate. The reliability policy should provide the business case for reliable equipment and the manufacturing process. Ultimately, the important question is how you can make positive changes in your maintenance organization to improve reliability. component fails and requires repair or replacement in a year. Even if you don’t have a reliability engineer in your organization, you can implement a few basic reliability engineering techniques to make a sustainable difference in your operation. If it runs for less than this time, the reliability score will suffer. Assembling equipment with the proper tools and hardware improves performance and reduces the risk of reliability issues. Moubray, John, Reliability-Centered Maintenance, Second Edition, Industrial Press, 1997. The plant is located on Lake Michigan, about 30 miles South-east of Green Bay Wisconsin. Fred, with his years of experience, was able to provide some great insights to the role of reliability engineering, and what those in the maintenance department can do to improve reliability. They must work together with a common objective – to achieve the best performance from all plant equipment and systems. 1. of equipment? It will cause great waste, produce distress for all concerned and lead to emotional burnout for all involved. The availability will not improve unless changes are made to upgrade the asset. 5 Ways to Improve Equipment Reliability and Avoid Downtime in Your Food Processing Plant. There is constant pressure to improve reliability, efficiency, and safety in the refining and chemical industries. RCM or FMEA- Reliability Centered Maintenance or... 3. To this end, the mechanical strength and stiffness of the equipment should be improved, and vibration damping measures should be taken to strengthen the equipment's resistance to vibration and shock. Increase Equipment Reliability by reducing downtime leveraging Cognizant’s OEE Analytics Cloud Solution built upon HANA Platform. Although these terms are similar, it is important that everyone is in agreement about what specifically is being measured. How Oil Mist Can Increase Equipment Reliability Marc Vila Forteza, Petronor. And identify opportunities for improvement and cost savings Solution built upon HANA Platform its equipment reducing downtime Cognizant! Of Green Bay Wisconsin program development for reliability is Everybody ’ s total uptime by sum! 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