Planning for Reliability
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Planning for Reliability - Introduction
This article is basically an explanation of my Planning for Reliability Presentation that was given at the Planning for Relaibility National Forum in June 2007 (Peter Horsburgh -7). This article can be used by people who viewed the presentaition and hopefully people that have not seen it. The presentation slides can be downloaded from: Planning for Reliability
If the slide includes a statement that is obvious, I will not include any explanation here.
To give you a feel what the presentation is about; its about designing maintenance strategies using Ron Moores Business Level FMEA with the aid of Isographs Simulation tools. Because we are all in Business, I will use a fiction business as a method of explaination. To give the thing a 'dose of fact' I throw some site stuff in.
Slide 3 - Reliability Growth Context
Ron Moore gives us model on how to improve our business. I interpret this model as we should use Planning and Scheduling, RCA and Maintenance Strategy Implementation to reduce the amount of reactive work to about 5% of our total effort. As a result of implementing these three area's Preventative Maintenance (Fixed time change out's) should reduce and Predictive (Condition Monitoring) and Proactive maintenance should increase.
Slide 5 - Business Level FMEA
This slide describes how the business level FMEA works from Ron Moore. You will see (later) is has parallels to Isographs simulation tools.
Slide 6 - Setting the Scene
Here is our fictional busines of two pumps in parallel, each with 50% capacity each. Our customer is asking us what capacity we can supply with 99.9% confidence levels, We want to avoid EPA fines (We are pumping some serious stuff here, ie. Water!). It goes without saying that we want the thing to be safe!
Slide 7 - Block Diagram
Here is what our business looks like in AVSIM (The Blue Folder icons), i.e. Our Block Diagram, or more technically a Reliability Block Diagram.
Slide 8 - Block Diagram - Real Example
This is a photograph of a whiteboard when we did our process mapping on our Ash Thickening plant ("ATP") here on site.
Slide 9 - Block Diagram - Real Example
This is a screen shot from AVSIM plus what the Ash Thickening plant looks like. NB. I have used the Equipment names from our CMMS to name the blocks (Folder thingy's). Very Important for exporting results later.
Slide 10 - System Functions
The next thing you need to do in Ron Moores, Business Level FMEA is to describe the Functional Failures of the line. OK, so another way to look at this is to describe what you want it to do, so you understand what you do not want it to do! We have already done this before when we described our business. To add to the presentation (this was not said), these things thought of as Concequences that you are trying to avoid, thus you are trying to measure them specifically. Please remember that we are trying to simulate what is going to happen, so using the classic "how can you manage it if you cannot measure it", you enter these things as "Concequences" into AVSIM+ or "Effects" in RCM Cost. They will forecast what will happen with these things as you make decisions. (More on that later!)
Slide 11 - System Functions - Real Example
Here is an example where we have done this on site with our ATP. We had 4 primary functions and two secondary functions.
Slide 12 - Block Functional Failures
OK, Back to our fictional Water Pump Business, here is a screen shot from RCM Cost that describes one water pump. RCMCost follows what Ron says, Write down the functional failures of each block, and you get to that by writing down the function first! (Opposites attract?!?). We have thought about this using the best information we have and come up with 4 failure modes in this case. To further the presentaion, Reliability is all about Failure Causes, in my RCM work, I would have Filter Blocked due to Ingress of contaminates. "Blocked" is the mode, "Ingress of contaminates" is the cause!
Lets link the functional failure to Effects as mentioned in Slide 10. The way I look at is that you use Functional Failures as a method of extracting failure causes. Each cause may have a different "Effect" on your business. Very important concept, and more on it later!
To be continued...
