Gene Matzan

A Reliability Centered Maintenance Presentation

What Are The Benefits?

1. Increase Productivity

2. Reduce Waste

3. Reduce inventory

4. Extend Equipment Life

5. Reduce Maintenance Expense

6. Reduce energy consumption

World Class Effectiveness >85% Manufacturing

>90% Process

Steps required in Implementing a Reliability Program?

•Need must be established

•Management needs to champion program

•A solid plan with clear goals is required

•Work force must be trained and committed

•Must contain a Continuous Improvement loop

•Only 1 in 10 programs are successful.

Why Equipment FailsASLE Bearing Workshop M.I.T. Study

Rabinowicz, 1981

Equipment FailsBecause

Obsolete15%

Surface Degrade70%

Accident15%

Wear50%

Corrosion20%

Fatigue WearDamage resulting from

Micro-cracks loading

Abrasive WearDamage resulting from

Abrasive particles betweenTwo moving surfaces

Adhesive WearDamage resulting from Metal surfaces dragging

Over each other

Caused byWater in oil, degraded oil,Process contamination,Coolant, condensation…

Caused byMisalignment, imbalance,Improper fit / assembly,

Secondary damage

Caused byAbrasive particles in oil,Dirt, secondary wear,

Process contamination

Caused byInadequate lubricationLow visc, no oil, high

temp,Excess load, slow speed..

Cost Comparison of Maintenance Strategies

Maintenance Strategy

Run toFailure

PreventiveMaintenance

PredictiveMaintenance

ProactiveMaintenance

Run to Failure Periodic component replacement

Monitoring of Equipment with technologies

FMEA RCA Investigating and correcting Causes of failure

Cost per hp per Year $18.00 $13.00 $8.00 $0.10

Throw away parts Routine Maintenance

Vibration AnalysisOil AnalysisInfrared ThermographyUltrasound

MisalignmentImbalanceContamination Design, Process

Run to Failure

No maintenance action is taken. The equipment is simply run until it fails, then repair replace.

This is an acceptable plan where the equipment is inexpensive, or can be quickly repaired, or can be quickly replaced with minimal loss of production.

Benefits

•Very low maintenance cost

Liabilities

•May require spare part inventory

•May cause unscheduled downtime

•May cause Process Control Problems

Preventive Maintenance

One of the first modern maintenance programs to reduce unscheduled downtime

The objective is to anticipate failures by studying past performance and take corrective action before the failure occurs. The term Mean Time Between Failures ( MTBF) is the predictive tool used to promote this practice.

Benefits

•Schedules routine work (Oil changes & Lube)

•Increases Wrench Time (The amount of time a mechanic is actually using tools)

•Reduces spare parts inventory as parts ordered by planning and scheduling

•Reduces Unscheduled Downtime

Liabilities

•Often used inappropriately

•Overhauls introduce unwanted affects. Need for debug & infant mortality

Predictive Maintenance

Predictive Maintenance uses modern tools such as Vibration, Oil, Motor, and Thermal Analysis to monitor and detect impending failures with sufficient warning to schedule repairs before failure.

Much improved technique over Preventive Maintenance because the data is not strictly Analytical (MTBF), but is also based on Physical conditions present in the equipment.

Benefits

•Very reliable early warning of equipment failure

•Aids in planning and scheduling maintenance activities

•Increases wrench time

•Reduces parts inventory

•Reduces Unscheduled downtime

Liabilities

•Does not address why problems happen 4

Proactive Maintenance

Proactive Maintenance uses both analytical and physical evidence to eliminate the causes of problems. The two key components are Root Cause Analysis (RCA) and Failure Mode Effects Analysis (FMEA).

FMEA is a thought process performed where every conceivable failure mode is analyzed and assessed as to Probability and Criticality. All correctable probabilities are fixed or eliminated.

RCA is a methodology where evidence is examined after failure to determine the cause of failure. Often predictive tools such as Oil Analysis and Vibration Analysis are used to explain the failure mode. Corrective action is taken to eliminate or reduce the probability of a reoccurring problem.

Reliability Centered Maintenance Program

Reliability Centered Maintenance program is all the above and more. In addition to the maintenance strategies discussed above many other functions and concerns must be addressed.

•Management Commitment

•Cultural changes

•Asset Management

•Criticality of equipment

•Prioritization decisions

•CMMS Systems

•Education and Training

•Benchmarking and Continuous improvement

Niccolo Machiavelli "The Prince" 1532 It must be remembered that there is nothing more difficult to plan, more doubtful of success, nor more dangerous to manage, than the creation of a new system. For the initiator has the enmity of all who would profit by the preservation of the old institutions and merely lukewarm defenders in those who would gain by the new ones.

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Degrees of Success and Failure