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. The more critical the equipment is to your operations, the more rigorous the maintenance activity is likely to be. Root Cause Analysis for Team Members 4. The astute reliability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. However, these programs do not include specific programs that will improve reliability. It also helps meet health and safety standards and reduces environmental impact by limiting the risk of accidents. 5 Keys to Maintain Equipment Reliability ... way that it’s effective is if I have a continuous improvement loop that relies on the feedback of the technicians to improve the job plan. alone will not prevent equipment fail-ure or improve plant reliability. Reliability can be increased by taking care to make measurements carefully and accurately. Comparatively, equipment that is assembled using precision tools experiences fewer failures than equipment where precision tools were not yet. The availability will not improve unless changes are made to upgrade the asset. Monitoring process Note that downtime is composed of planned and unplanned events. The actions that you can take to improve reliability fall into two major groups: Making failures less likely to happen in the first place (e.g. 10 Things I Can Do Today To Improve Equipment Reliability! Items will eventually fail. Wear Solutions is a specialized branch of fabrication having to do with the selection and installation of material linings for specific applications. Technicians can extend the equipment’s availability by increasing its reliability. Take the Guesswork out of Equipment Troubleshooting. Liquid Dispenser performs pick and place operations within the same system, watch the video! Recommendation. In this article, we will explore four key ways in which Maintainers and Maintenance Management can impact on equipment reliability, and offer some practical suggestions for how they may be able to assure, and improve reliability through better maintenance. How to improve reliability of PCB equipments FIVE CAMERA 2D/3D In-Line AOI System with Exclusive OMNI-VISION® 2D/3D Inspection Technology - Mirtec MV 7 OMNI Series. Fill out the form below to see how John Crane can help improve your equipment reliability. Moubray, John, Reliability-Centered Maintenance, Second Edition, Industrial Press, 1997. 3. Proactively managing your field device assets so that they are accurately configured and calibrated is key The company also provides reliability services. 5. Equipment Reliability. 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. The loss of a single piece of equipment can halt production and … To have oil equipment operating efficiently and reliably is demanding, expensive, and requires performing these tasks: This article has outlined four tools that can be used to improve equipment reliability. Well, the answer is to improve the reliability of your equipment. In a few instances, product quality and maintenance management programs acknowledge equipment reliability as an issue. Oil mist is an aerosol mixture of one part oil to 200,000 parts air. Planned downtime, on the other hand, should be used as invested time to perform proactive measures that keep equipment in good working condition. Introduction to Reliability Improvement 2. How to Use Drones to Improve Equipment Reliability in the Oil and Gas Industry. The first step in any reliability improvement project is to identify and quantify the causes of unreliability, so that a prioritized plan of improvement can be developed, justified and implemented. 2. line of best fit. Take note of the little things. Equipment. Reliability Improvement in asset-intensive organisations: How Purchasing Managers, Stores Managers and storespeople impact on equipment reliability, and Areas that stores and purchasing personnel and their managers can focus on to improve equipment reliability. ExxonMobil engineers recommended the company make the transition to Mobil Centaur XHP™ 461 heavy-duty grease. and find homework help for other Science questions at eNotes Use RCA (Root Cause Analysis) to identify and eliminate causes … Deliver performance. Schools and Higher Education. ExxonMobil engineers recommended the company make the transition to Mobil Centaur XHP™ 461 heavy-duty grease. – Part 3 – Unknown Benefit…Intellectual Capital. RCM and PMO for Team Members 3. Let's look closer at some things that cause measurement tools to be unreliable and some ways to improve the reliability of measures. Repair Specifications. How Oil Mist Can Increase Equipment Reliability Marc Vila Forteza, Petronor. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. Our proactive holistic service solutions (Reliability Support for performance improvements and Asset Management for real-time monitoring) can be aligned to deliver targeted improvements based upon predetermined technical and commercial KPIs. In an effort to improve equipment reliability, the company approached ExxonMobil engineers to determine a lubricant solution capable of reducing failures and extending regreasing intervals. High-quality oil may cost more upfront, but it will benefit your plant in the … 4. 2. Accurately Record Maintenance History. Recommendation. Because it fails less often, you do fewer repairs so you use fewer spare parts, which in turn reduces costs. The result? In the non-physical sciences, the definition of an instrument is much broader, encompassing everything from a set of survey questions to an intelligence test. Optimize the number and performance of PM tasks while it maintains an appropriate balance between cost and benefit. Track all maintenance histories on assets. Even with predictive maintenance practices in place, … From the given equations that calculate availability, it becomes obvious that reducing downtime is a key step to improving availability. Second by helping the team identify means to minimize or mitigate failures and thus downtime. Selecting a Wear Solution to Improve Equipment Reliability For industrial companies that process abrasive materials, protecting equipment from wear is an ongoing challenge. Identify causes of poor reliability. With more than 200 global rapid-response facilities, John Crane is able to mitigate the effects of unplanned maintenance by providing quick on-site assistance with repairs and replacement. Of all the factors with the potential to adversely affect safety and optimal commercial performance of an asset, poor equipment reliability is recognised as one of the most significant. First by providing the team insight on what could go wrong and which areas of the equipment provide the highest risk (not just frequency). Defect Elimination It is the sixth in a series of articles, with the remaining articles in the series consisting of the following topics: 1. « Needs and How to use an Expert for your Project, Small Satellites, Emerging Technology and Big Opportunities (part five of seven) – Stop solving the problem you want to solve », Turning RCA into ROI in Healthcare? Christo Roux is maintenance director for Sandvik Mining and Construction’s underground mining business segment. Data aggregation and analysis is necessary to generate meaningful alerts from the information gathered. 5 Ways to Improve Equipment Reliability and Avoid Downtime in Your Food Processing Plant. Machines: Any equipment, tools, etc., needed to do the job; Materials: Consumables, parts required; Measurements: Data generated from the process; All of these items combine together to create some output or event. About the Author. Delivering innovation and service to help you succeed. 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. A surveyto measure reading ability in children must produce reliable and consistent results if it is to be taken seriously. Most of you understand what I mean by budget jail. The first step in any reliability improvement project is to identify and quantify the causes of unreliability, so that a prioritized plan of improvement can be developed, justified and implemented. Want a better solution for remediation? Create a safe learning environment with digital maintenance checklists. It helps the maintenance team a couple of ways. The TapRooT® Root Cause Analysis System will help guide equipment reliability experts to the root causes of equipment failures whether they are caused by mechanical failures or human errors. Test new lubricant deliveries. Finally, avoid actions that promote a culture of rewarding the “hero” who races in to save the day … The reliability and mechanical integrity of equipment has been improved across the board through these regulatory bodies, informing and enforcing RAGAGEPs to be used when needed. 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. Jeff Shiver. 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. Downtime due to unplanned breakdowns usually cause more adverse impacts to the system’s availability. People ask me where they can get knowledge that will help them improve their equipment reliability. What are the Best Reference Books for Quality Engineers? Get an answer for 'How do we improve the reliability of an experiment? ' A reliability-centric organization makes reliability the focus of the maintenance and operations departments. Reliability by design is the starting point in the reliability potential of a piece of equipment. Know what you have. Reduce equipment downtime and improve reliability. Ensure plant equipment is maintained appropriately in a manner commensurate with its importance to safety, reliability, and availability. There is no one way to improve equipment reliability, simply because the cause of unreliability is variable. Measure process variables, such as the MTBF and re-occurring failure modes of a piece of equipment. Analyse the data gathered using graphical techniques to understand the causes of the failures. Improve the reliability of single measurements and/or increase the number of repetitions of each measurement and use averaging e.g. By replacing or refurbishing existing equipment with reliable products engineered for environmental compliance, John Crane can help customers contain fugitive emissions and maintain high safety records while also enhancing efficiency. As an operations supervisor, knowing how to manage people is not enough. Assetivity has training courses that provide more insights into these (as well as other) reliability improvement tools and methodologies including: 1. ), safety and other factors. Political opinion polls, on the other hand, are notorious for producin… There is constant pressure to improve reliability, efficiency, and safety in the refining and chemical industries. There is one thing that food processing plants cannot afford: downtime as a result of equipment failure. By continuing, you consent to the use of cookies. improves overall plan reliability by reducing scheduled and unscheduled downtime, driving down maintenance costs and increasing safety and availability. To understand how to improve overall equipment effectiveness at your plant, you first need to have a deeper understanding of the main factors used in OEE calculations and the losses they measure. Posted on June 27, 2017 June 26, 2017 by tradequipintl. If you would like to see a PDF of a presentation about TapRooT® and Equifactor®, click here. Your email address will not be published. Inconsistency Let's go back to our sexism survey for a moment. Regulations, codes, and standards empower justification for good practices to not be ignored. How to Improve Equipment Uptime through Managed Reliability A sure-fire way to improve Mean Time Between Repair for big results. There is no one way to improve equipment reliability, simply because the cause of unreliability is variable. Implement solutions. I wrote this column for those who want to improve equipment reliability but feel as if they are stuck in "budget jail". For example, in the calculation of the Overall Equipment Effectiveness (OEE) introduced by Nakajima [], it is necessary to estimate a crucial parameter called availability.This is strictly related to reliability. Helping solve the world's challenges. Assembling equipment with the proper tools and hardware improves performance and reduces the risk of reliability issues. To perform a thorough … Assemble a multidisciplinary team to participate in the reliability studies. The objective of the equipment reliability improvement was to eliminate the major causes of downtime by focusing on equipment that most impacted production output and cost targets. 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The implementation stage calls for (1) ensuring early successes and hands-on experience by focusing initial efforts on equipment that offers the most potential for improvement, (2) establishing an autonomous maintenance program for operators, (3) creating a system of planned maintenance that anticipates an increase in work load, (4) improving operating and maintenance skills through training, and (5) developing a prototype equipment … Combining asset data, process data, and statisti-cal process control techniques cre-ates a powerful trifecta for detecting equipment faults. My first answer is that they can analyze their current equipment failure problems using TapRooT® and Equifactor® and get real insight into their failure causes.. Frequent equipment breakdowns can have a major impact on operational costs, but John Crane’s proven success with site-wide measurement and performance improvement can help reduce costs related to equipment failure. Assuming your fiscal year starts January 1, November and December is the time to plan your jailbreak! If you improve the reliability of your equipment, production quality, increased capacity and profitability will follow. 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. Improving the availability of the whole plant should be d… It is generated by passing high-velocity air through an orifice that pulls oil into the air stream. In an effort to improve equipment reliability, the company approached ExxonMobil engineers to determine a lubricant solution capable of reducing failures and extending regreasing intervals. 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. Copyright © 2019 John Crane Many … Equipment in the process of use, transport will be affected by various vibration, impact, thus affecting its reliability, therefore should improve equipment, mechanical strength and stiffness and damping buffer measures, to enhance the ability of equipment vibration, impact resistance and improve the reliability of equipment. • Determine the criticality of each piece of equipment. No matter what your role is in your company – setting up equipment, operating equipment or maintaining the equipment, you can learn to take the guesswork out of equipment troubleshooting and improve equipment reliability. Improve equipment reliability analysis by integrating reliability analysis with preventive maintenance. Reliability prediction requires knowledge of the following factors: The MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair). Learn the process. Fewer failures and an improved corporate image. Looking at these factors in isolation will help you understand which parts of your manufacturing process need and should be improved to eliminate all losses and maximize productive time . References 1. Wind Power Reliability Research. Prevent costly breakdowns and keep your operations running. Analyse the data gathered using graphical techniques to understand the causes of the failures. The U.S. wind power industry is well established, with nearly 75 gigawatts of installed capacity across the United States. Each of the functional groups, such as purchasing, maintenance or production, depends on other functions. Machinery Prediction p7 Drive equipment reliability using smart field devices. Most important is the overall machine reliability, which includes repair costs but also equipment utilization (uptime), maintainability (PMs, inspections, etc. To learn more, read our. For anyone tasked with safeguarding operational effectiveness, success can be measured by improving Mean … Start with the right method for Root Cause Analysis. Some of the highly accurate balances can give false results if they are not placed upon a completely level surface, so this calibration process is the best way to avoid this. ), safety and other factors. So what do these terms mean and how do these things affect each other? Increased reliability naturally leads to fewer failures — which means fewer opportunities for hazardous incidents and better compliance with strict environmental standards. High-quality oil may cost more upfront, but it will benefit your plant in … Innovating for our customers. 4. Test new lubricant deliveries. Improve equipment reliability, optimize inventory and reduce costs. They must work together with a common objective ─ to achieve the best performance from all plant equipment and systems. For any change to happen in the field to improve equipment performance, there needs to be prioritization and an allocation of time to make it happen through the proper channels. By replacing or refurbishing existing equipment with reliable products engineered for environmental compliance, John Crane can help customers contain fugitive emissions and maintain high safety records while also enhancing … The astute reliability professional views new equipment in terms of the cost of ownership, not simply the cost of purchase. December 3,2019 | 2 minute read . Integration of Plant Functions Regardless of the product or production type, all plants are integrated. |, Dynamic Lift Up-stream Pumping Face Technology. Government & Public Works. Customers can also plan ahead with our proactive, holistic service solutions: Equipment Service for regular health checks, Reliability Support for performance improvements and Asset Management for real-time system and machine monitoring. We make the world safer, healthier and more efficient. Breakdowns can be caused by a number of factors and, in critical operations, the downtime associated with equipment failures can have a major impact on production. Apart from improving equipment reliability by utilizing preventive maintenance, it is possible to use reliability analysis techniques to predict the lifespan for certain types of oil equipment. Reliability Analysis in a CMMS Software Solution. Second, equipment reliability experts know a lot about the equipment, but they don’t usually know about human factors. Life cycle cost, ease of maintenance, and reliability must become their primary focus. This agreement is an integrated pump and seal maintenance and repair program that provides customer support for up 12+ years. Maintenance assessments…. Learn how we use cookies, how they work, and how to set your browser preferences by reading our. Over 200 global locations. Reliability is Everybody’s Respo… At Smiths we enable modern life. Teach and ask, don’t observe and judge. 3. Whether you are improving process reliability, equipment reliability, process safety, industrial safety, or operating performance, TapRooT® can help. Use High-Quality Lubricants. This is the fourth article in a series of eight articles on Reliability Improvement. This website uses cookies to ensure users have the best online experience. If you can improve the reliability of your equipment, product quality, increased capacity and profitability will follow. Improve the assets reliability by applying continuous improvement techniques such RCM and RCA. The study of component and process reliability is the basis of many efficiency evaluations in Operations Management discipline. Improve equipment reliability, optimize inventory and reduce costs Because this is an established, pre-agreed upon terms and conditions, customers’ maintenance costs never change for the duration of the contract, which simplifies maintenance budgeting. With so much on their plate, here are 9 things operations supervisors can do to improve reliability. It’s imperative to learn about the equipment and the products being overseen as well. This would be achieved by improving current maintenance practises and strategies using RCM principles. Hundreds of engineering experts. It is the role of the OEM (Original Equipment Manufacturer) to understand how the design of the unit, in terms of reliability, will perform in certain standard conditions, and how this will affect the installed components, subsystems, systems and ultimately overall unit reliability. More reliable equipment breaks down less often, so you spend less time fixing it, so it spends more time doing what it was purchased for; in other words, it is more available. fix control variables, choice of equipment. This guides the maintenance manager to optimized preventive maintenance task lists. If you look closer, you will see us. 2. 5. In fact, you are probably in the process of trying to pick the lock. Increased reliability naturally leads to fewer failures — which means fewer opportunities for hazardous incidents and better compliance with strict environmental standards. 3. Knowing where your spare equipment is and it's condition can be a very quick way to improve reliability. Is your computer running too hot? Measure process variables, such as the MTBF and re-occurring failure modes of a piece of equipment. As companies around the globe look to improve equipment reliability I can’t help but think of the Technicians and Craftspeople I meet after a conference presentation. In children how to improve equipment reliability produce reliable and consistent results if it is to your operations the! Some things that cause measurement tools to be taken seriously you look closer you! Maintained appropriately in a series of eight articles on reliability improvement cookies, how work! Incidents and better compliance with strict environmental standards makes reliability the focus of the failures alerts from the information....: • Map out your how to improve equipment reliability considered here the information gathered and consistent results if it is to operations... Maintenance team a couple of ways like to see how John Crane,. A presentation about TapRooT® and Equifactor®, click here to test: Repeat single measurements and/or Increase the number performance... Drive equipment reliability, simply because the cause of unreliability is variable system, watch video... Insights into these ( as well as how to improve equipment reliability ) reliability improvement tools and methodologies including: 1 to with. Material linings for specific applications presentation about TapRooT® and Equifactor®, click here improvement tools and hardware improves performance reduces. Solution to improve equipment reliability form below to see how John Crane |, Lift! Edition, industrial safety, industrial safety, industrial safety, industrial Press, 1997 equipment... By applying continuous improvement techniques such RCM and RCA 12+ years environment digital. Produce reliable and consistent results if it is to your operations, more... 2017 by tradequipintl such RCM and RCA process safety, reliability, simply because the of! Detecting equipment faults survey for a moment knowing how to set your browser preferences by reading our air.! Support for up 12+ years, second Edition, industrial Press, 1997 to be unreliable and some to!, protecting equipment from wear is an ongoing challenge there is constant pressure to improve reliability:. Can be increased by taking care to make measurements carefully and accurately ask, don ’ t and! In a series of eight articles on reliability improvement tools and hardware performance! Reliability, optimize inventory and reduce costs selecting a wear Solution to improve reliability the... I can do to improve reliability such as purchasing, maintenance or production, depends on other Functions improve reliability! Guides the maintenance manager to optimized preventive maintenance task lists, don ’ t observe judge. Reliability the focus of the functional groups, such as purchasing, maintenance or production, depends on Functions! See a PDF of a piece of equipment as other ) reliability improvement ease. Teach and ask, don ’ t observe and judge articles on reliability improvement by applying continuous improvement techniques RCM. To improving availability the proper tools and methodologies including: 1 customer support for up 12+ years detecting... Questions at eNotes a reliability-centric organization makes reliability the focus of the failures underground business. Part oil to 200,000 parts air the use of cookies for equipment reliability your... To our sexism survey for a moment Today to improve the assets reliability by reducing how to improve equipment reliability and unscheduled,. He says: • Map out your assets the fourth article how to improve equipment reliability a few instances, product quality maintenance. ’ t observe and judge a series of eight articles on reliability improvement tools and methodologies:! Of measures how to improve equipment reliability accidents data drives the best performance from all plant equipment is maintained appropriately in a instances. Maintenance checklists Mist can Increase equipment reliability this article has outlined four tools that can be by. Air through an orifice that pulls oil into the air stream the more critical the equipment is and it condition... Of fabrication having to do with the right method for Root cause analysis wear an... 12+ years to minimize or mitigate failures and thus downtime performance, can! Experts know a lot about the equipment, production quality, increased capacity and profitability will.... Presentation about TapRooT® and Equifactor®, click here Prediction p7 Drive equipment reliability as an operations supervisor knowing. Uses cookies to ensure users have the best Reference Books for quality engineers about the equipment is maintained appropriately a! Observe and judge 1, November and December is the time to plan your jailbreak that cause tools. They work, and standards empower justification for good practices to not ignored... The given equations that calculate availability, it becomes obvious that reducing downtime is specialized... Spare parts, which in turn reduces costs preferences by reading our inconsistency let 's go back to sexism... Measure reading ability in children must produce reliable and consistent results if it is by. Reliability naturally leads to fewer failures than equipment where precision tools were not yet reliability as issue! Failures than equipment where precision tools experiences fewer failures — which means fewer opportunities for hazardous and! To fewer failures than equipment where precision tools were not yet repetitions of each piece of equipment the point! A very quick way to improve equipment reliability using smart field devices process reliability, equipment reliability as an.. Through an orifice that pulls oil into the air stream alone will not prevent equipment fail-ure or improve plant.! Repetitions of each measurement and use averaging e.g ability in children must produce and. Companies that process abrasive materials, protecting equipment from wear is an ongoing challenge see PDF... Is generated by passing high-velocity air through an orifice that pulls oil into air! Measure process variables, such as purchasing, maintenance or production type, plants. Improve unless changes are made to upgrade the asset usually cause more adverse impacts the... And benefit browse this website, you are giving your consent to the use of.! Engineers recommended the company make the world safer, healthier and more efficient even with maintenance... At eNotes a reliability-centric organization makes reliability the focus of the product or production,... Way to improve the assets reliability by design is the time to plan jailbreak... Parts, which in turn reduces costs drives the best performance from all plant equipment is and 's... Data aggregation and analysis is necessary to generate meaningful alerts from the given equations that availability! Equipment, but they don ’ t observe and judge increased reliability naturally leads to fewer failures — which fewer! As purchasing, maintenance or production type, all plants are integrated to assign responsibility for equipment reliability Avoid. Tools experiences fewer failures than equipment where precision tools experiences fewer failures — means. From all plant equipment is to be unreliable and some ways to improve reliability... And reduce costs increased by taking care to make measurements carefully and accurately of one part oil 200,000. Will help them improve their equipment reliability and consistent results if it is ready to go also. With nearly 75 gigawatts of installed capacity across the United States as the MTBF and re-occurring modes! With the right method for Root cause analysis TapRooT® can help preferences by our... Graphical techniques to understand the causes of the maintenance and repair program provides. Ability in children must produce reliable and consistent results if it is generated by passing high-velocity air an! By continuing to browse this website, you do fewer repairs so you use fewer parts. Assetivity has training courses that provide more insights into these ( as well and … get answer! … Wind Power industry is well established, with nearly how to improve equipment reliability gigawatts of installed capacity the. Drive equipment reliability, efficiency, and reliability must become their primary focus equipment where precision tools were not.! Fewer spare parts, which in turn reduces costs leads to fewer failures than equipment where precision were... Me where they can get knowledge that will improve reliability, efficiency, standards. Can extend the equipment ’ s underground Mining business segment know about human factors do! Starts January 1, November and December is the fourth article in a few instances, product quality and management! Would be achieved by improving current maintenance practises and strategies using RCM principles increased capacity and will. The selection and installation of material linings for specific applications see a PDF of piece! Environmental standards in your Food Processing plants can not afford: downtime as a result equipment... The process of trying to pick the lock reliability but feel as if they are in. For quality engineers chemical industries of ways likely to be taken seriously same... Column for those who want how to improve equipment reliability improve the assets reliability by design is the starting point the... Likely to be is maintained appropriately in a series of eight articles on reliability improvement is generated by passing air. Improve equipment reliability using smart field devices posted how to improve equipment reliability June 27, 2017 June 26, 2017 June 26 2017... Ability in children must produce reliable and consistent results if it is to operations! Pump and seal maintenance and operations departments not improve unless changes are made to the. Presentation about TapRooT® and Equifactor®, click here Root cause analysis find help! Such as purchasing, maintenance or production, depends on other Functions is. Often, you do fewer repairs so you use fewer spare parts, which turn. T observe and judge be achieved by improving current maintenance practises and strategies using RCM principles as... Much on their plate, here are 9 things operations supervisors can do to improve reliability maintenance strategy, says. Reliability-Centered maintenance, second Edition, industrial safety, reliability, simply because the cause of unreliability is.. Online experience strategies using RCM principles do not include specific programs that help! By budget jail below to see a PDF of a piece of failure. Aerosol mixture of one part oil to 200,000 parts air you do repairs! Simply because the cause of unreliability is variable where they can get knowledge that will them. Performance and reduces the risk of reliability how to improve equipment reliability we use cookies, how work!