The top concern is proper lubrication maintenance. Make sure to check maintenance schedules, assign responsibilities, and establish procedures. Addressing this issue will lead to significant improvements. Take advantage of the valuable suggestions already provided. Assess the expertise of maintenance personnel and ensure they receive adequate training. Identify common failure points and conduct thorough root cause analysis to prevent future issues. Stay informed by joining relevant data collection and predictive maintenance technology groups. Utilize the CMMS system to monitor equipment usage and overtime. Consider implementing a daily walk-through routine to observe equipment conditions firsthand. This proactive approach is a recommended industry practice.
I conduct at least two plant tours daily to gather valuable data on delays and efficiency. Despite having existing access to our reliability/CMMS program for the past two years, I am still uncovering areas for improvement. Recently, my supervisor, who initiated the program and possessed extensive experience, unexpectedly left, leaving me to decipher his methods without much direct interaction. I am proactively searching for the most effective strategies to streamline operations and boost productivity.
What CMMS software are you utilizing? Are you able to efficiently extract important data from it? Our preferred duo is Maximo for CMMS and Brio for data extraction, as they seamlessly integrate. By formulating precise queries, you can uncover a wealth of valuable information. J-
Our system utilizes MAINSAVER version 10.1 client connected to an SQL 2005 Database, along with Crystal Reports and custom DotNet applications for collecting customer feedback. With this setup, all Faculty and Staff members (around 4000 in total) have the ability to submit Work Orders and monitor their status online using the WEB platform.
Our utilization of Tabware allows for the extraction of quality data, while our delay information is processed through a system known as Noetix, from which I am able to retrieve useful data as well.
Confusion and frustration are common challenges faced by many companies when it comes to the role of a Reliability Engineer. The key lies in the HR level and management's expectations of the position. To excel as a Reliability Engineer, it is essential to start with a thorough process analysis. This includes assessing the plant, design capacities, production expectations, maintenance windows, and alignment of maintenance strategies with production requirements. Evaluating asset performance and the effectiveness of maintenance actions is crucial. Optimizing preventive maintenance may be necessary. It is also important to review the quality of Work Instructions, checks and balances, and Work Management KPIs. Reliability Engineering is a complex field with many aspects to consider, depending on the specific roles and responsibilities within the organization. By addressing these key areas, you can enhance reliability and performance.
Having worked as a reliability engineer for 5 years following a 12-year tenure as a maintenance and operation engineer, I have found that the reliability role suits me better. While others have already offered valuable advice, here are a few additional points to consider:
A) Continuously gather information on key engineering components such as pipes, flanges, pumps, gearboxes, mechanical seals, bolts, and torques, as well as new non-destructive testing techniques and the pros and cons of various detection methods. As you accumulate knowledge, others will come to you for insights.
B) Address small issues in collaboration with operators to establish your expertise and credibility.
C) Document failures and familiarize yourself with root cause analysis tools.
D) Look for opportunities to implement minor plant modifications that can enhance Overall Equipment Effectiveness (OEE) and reduce costs. Justify these changes through cost-benefit analysis. Even if you are not able to carry out these modifications, management may allocate resources or assign the task to another individual.
E) Participate actively in major outage activities, paying special attention to failed equipment. Engaging in support activities will help you build rapport with your colleagues and accelerate your learning curve.
Boost your knowledge and efficiency by accessing our extensive library of PDF equipment manuals. By reaching out to engineering, operations, and maintenance professionals, I have compiled a comprehensive collection of manuals from various sources including hard drives, CDs, and manufacturer websites. Simply let me know what manual you need, and I will do my best to provide it. Our organized database allows users to easily access manuals by manufacturer, equipment type, and specific equipment. This service ensures that operators and technicians have the necessary resources to maintain a reliable system. Don't miss out on this valuable resource available to all plant personnel.
Thank you both for your valuable input! Vee, I really appreciate your suggestion of setting goals and making plans, but I'm unsure of where to start. I've been out of school for a year and still getting familiar with the industrial environment, so I'm not sure what a realistic goal for reliability would be. Do you have any tips for setting goals in this area? If you have an idea of your current Uptime performance and let's say your OEE is at 55%, consider how increasing it to 65% could impact your company financially. This will give you an understanding of the effort needed to reach that goal. You can also refer to Bob Hanse's book on Overall Equipment Effectiveness for more information on OEE. Additionally, if you know your performance in safety, environmental aspects, or maintenance costs, create improvement plans accordingly. Remember, reliability plays a crucial role in all three areas.
To enhance reliability, there are some steps you can take. Firstly, focus on the basics such as keeping equipment clean, properly lubricated, and well-maintained. This alone can resolve majority of reliability issues. Secondly, address defects systematically through a structured Root Cause Analysis process. Encourage teamwork among operators and maintainers as machinery thrives on proper care. Ensure accurate data is inputted into your CMMS and utilize analytical tools like Pareto analysis to pinpoint key areas for improvement. Provide access to updated drawings and documentation for employees and regularly measure and report progress.
Reliability, like Safety, is a mindset, so it's crucial to prioritize training and awareness among your team. These initial steps are cost-effective and yield quick results. Once you've mastered this stage, consider advanced tools like RCM, RBI, IPF, and FMECA for further improvement. Another important aspect to focus on is Productivity, which hinges on effective Planning, Scheduling, and Work Preparation. Remember, productivity issues often stem from poor management practices. I hope these suggestions provide you with some valuable insight. Best of luck with your endeavors!
Similar to Wally, I have undertaken similar tasks as well. On my website, you can find valuable Predictive Maintenance (PdM) reports, engineering files, newsletters, and technical publications. I have meticulously captured photos of equipment throughout the facility and uploaded them along with drawings and crucial technical information. Explore my site for in-depth insights and resources for plant maintenance.
I think your photo concept is great. While we have captured images during maintenance and operation, we have yet to upload them for easy reference on our company's intranet site. Having visual references readily available is extremely helpful.
I value the discussions we've had as it directly impacts our operations. Currently, we are establishing a Reliability Engineering Group within our Paper Mill. One aspect that is often overlooked in these discussions is the implementation of Failure Mode and Effects Analysis (FMEA) studies. Our main consultants are steering us towards this direction to pinpoint equipment vulnerabilities not sufficiently addressed by preventive maintenance (PM), condition-based monitoring (CBM), or predictive maintenance (PdM) strategies using a standard FMEA approach. I am curious to know if this approach is common in other facilities. While it does require a considerable time investment per equipment, the initial findings have been insightful in highlighting unrecognized issues and proposing effective prevention measures. In these sessions, both operators and mechanics actively participate, providing a comprehensive and cross-functional viewpoint. Additionally, we utilize a systematic criticality assessment process to assess the actual risk of failure, aiding in prioritizing which equipment should undergo FMEA analysis. - Ron Pihl, Reliability Manager at LFPPI
I am intrigued by the extent to which in-house Reliability/Maintenance Engineering Groups incorporate FMEAs into their regular operations. It is crucial to note the emphasis on "internally operating" in this context. Many maintenance professionals, like myself, find ourselves engaging in cross-functional work. It appears that FMEAs are predominantly utilized by external consultants. Personally, I feel the need for more FMEA facilitation training. The industrial sector as a whole appears hesitant to fully embrace comprehensive FMEAs. Instead, decisions are often based on internal experience and recommendations from manufacturers, with maintenance choices made informally. However, there are organizations that refine their initial decisions over time. I am confident that there are sectors where FMEAs are implemented effectively and routinely. I am eager to learn from internal Reliability/Maintenance Engineering personnel about their processes to reaffirm the value of this approach. Recently, I learned about REM (Review of Existing Maintenance) from Vee. This methodology provides a retrospective analysis of maintenance activities, starting from PM/job plans/spare parts and moving towards equipment. As most of us work with equipment that has a history of real failure modes, understanding the operation of the machinery becomes crucial. The success of FMEAs depends on the facilitator's expertise and the skills of the maintenance team present. Given the inherent human variability, I question whether identical FMEAs conducted in the same circumstances could yield consistent results. However, I remain open-minded and optimistic. Jeff.
One important aspect to consider is the potential loss of craft expertise due to inexperience, a topic that has been widely discussed in both this forum and the magazine. It is crucial to recognize that if craft expertise is compromised by inexperience, the quality of FMEAs conducted will undoubtedly be affected. It may be necessary for the general industry to seek out consultant facilitators and expert craftsmen to ensure optimal FMEA performance in the future. This possibility is definitely worth pondering.
- 20-07-2024
- Yvonne Mitchell
When determining where to focus your efforts as a reliability engineer, it is important to let the data guide you. By analyzing your production data using a process weibull, you can uncover valuable insights. For example, if 65% of your losses are due to process variation while only 35% are due to special causes like equipment failures or changeovers, then eliminating equipment failures may not be the most effective strategy. In a real-world scenario, a weibull analysis revealed that reducing process variation and changeovers actually led to much more significant gains in profitability than solely focusing on equipment failures. In fact, equipment failures accounted for less than 10% of production losses in one area. This highlights the importance of analyzing data systematically to make informed decisions that drive improvement and increase profits.
- 20-07-2024
- Gregory Hughes
Our PdM department, established approximately two years ago, focuses on vibration analysis and infrared testing currently, with plans to incorporate ultrasound and oil analysis. I handle the infrared work, logging around 70 different readings every week. While most readings show normal conditions, anomalies can indicate potential failures – whether gradual or sudden. We inspect critical equipment monthly and less critical ones quarterly to monitor trends and identify impending failures accurately, avoiding unnecessary downtime and maintaining the trust of our maintenance department. Drawing on historical data, we can differentiate between normal conditions and potential failures, reducing false alarms. In challenging situations, I consult electrical schematics and manufacturers for solutions, yielding positive results. To further expand, we aim to think creatively and consider unconventional inspection targets that may lead to unforeseen downtime. For instance, by inspecting incoming power lines, we discovered a hot connector on a power pole – a potential hazard that could have caused a significant plant shutdown if left unchecked. Embracing a proactive approach with quarterly checks on such unforeseen risks allows us to stay ahead of potential failures and constantly seek new opportunities for improvement beyond our comfort zone.
- 20-07-2024
- Frances Fisher
The FMEA should be an integral part of a Maintenance Control Plan, especially after conducting a Criticality Analysis related to the business process. Implementing a 10-phase process for Constructing a Maintenance Control Plan can help incorporate FMEA along with practical maintenance and reliability philosophies. This discussion extends beyond RCA, FMEA, and Criticality Analysis, emphasizing the importance of a comprehensive process. To effectively support the maintenance control plan, it is crucial to establish and monitor meaningful KPIs for asset and maintenance functions. Proper setup and utilization of the CMMS is essential for supporting these KPIs. Additionally, accuracy in the production reporting system and meaningful feedback from maintenance personnel and equipment operators play a vital role. Conducting equipment and process tolerance checks is necessary for maintenance analysis and asset reliability control. Without addressing these factors, it can be challenging to achieve real control over asset reliability. Remember, maintenance is like a water pipe; any blockages can halt the flow. For further insight, attached are documents outlining the OFMEA process that have been used for previous clients. Implementing FMEA studies can help identify equipment risks that may not have been addressed through traditional maintenance measures, involving operators and mechanics in the process to gain a comprehensive perspective. Utilizing a formal criticality assessment procedure can help prioritize risks before applying FMEA.
Are you a recent graduate looking to enhance your skills in reliability engineering and management? Consider requesting training from reputable sources like www.barringer1.com or www.noria.com to broaden your knowledge. Speak to your maintenance manager about creating a training and development plan, which could demonstrate your commitment to improving reliability within the organization. If your manager is unable to provide a plan, explore the internet for sample training plans from sites like www.hydrocarbonprocessing.com and present them as a proactive solution. Take initiative by actively participating in preventive maintenance tasks alongside the maintenance team to understand the process and gather data on preventive versus corrective maintenance through cmms. Utilize resources like John Mitchell's plant KPIs to establish performance benchmarks. Engage with the operations team to gain insights into plant operations and learn about downtime and uptime issues, causes, and improvement strategies. Dedicate time outside of work to educate yourself on reliability topics by reading books like Vee's on reliability. Set a personal goal to address and resolve plant problems on site and engage with colleagues to stay informed on plant conditions and challenges through regular communication and participation in team meetings. By actively seeking out opportunities to enhance your skills and knowledge in reliability, you can position yourself as a valuable asset within the organization.
- 20-07-2024
- Wesley Jenkins
Engaging discussion surrounding the integration of FMEAs into the daily maintenance routine of in house RCM personnel. Despite efforts to implement a sustaining FMEA program, challenges persist in moving beyond the training phase. With maintenance staffing meeting operational needs at 80% wrench time, finding room for improvement remains a priority amidst management's push for efficiency. The virtual FMEA initiative appears to have stalled, raising questions about its future progress. In the midst of agreement troubles on a fan unit, the complexity of FMEAs for equipment like Chromatography skids is highlighted. Is it more feasible to adhere to manufacturer recommendations and leverage internal expertise to streamline maintenance processes, rather than focusing on exhaustive FMEA analysis? The quest for success in the realm of FMEAs continues, particularly in regulated environments. Jeff reflects on the progress achieved in RCM implementation thus far, with aspirations to elevate the program to new heights.
In considering maintenance strategies, it may be more efficient and cost-effective to follow the manufacturer's recommendations and tailor them to fit the specific needs of your equipment. Manufacturers possess valuable insights on potential failure modes based on their Design FMEAs and limited testing. However, real-world operating conditions can vary significantly from these controlled tests, impacting failure rates. To effectively manage critical equipment, a proactive RCM approach is recommended. While published RCM results may not be readily available, industries with high safety risks have successfully utilized this method to enhance performance and safety measures. In my experience, RCM has proven to be highly effective compared to traditional FMEA methods. It's important to understand the differences between FMEA, FMECA, and RCM to make informed maintenance decisions that ensure optimal equipment performance and longevity.
- 20-07-2024
- Penelope James
Congratulations on holding the position of a "Reliability Engineer," which is considered to be one of the most dynamic and rewarding roles in the industrial sector. I believe that the field of reliability engineering is a game-changer in management, with "Reliability Engineers" being likened to the strategists directing operations on the ground.
In my experience across various organizations, one recurring challenge is the lack of clarity in defining and communicating job roles effectively. As a "Reliability Engineer," you may have encountered this issue, but it presents a valuable opportunity for you. Seize the chance to establish a clear definition of the Reliability Engineer role within your company. Embracing this opportunity could make you the go-to person at your facility, and you will relish every moment of this role.
Analogous to a field general, a pivotal task for Reliability Engineers is to assess the strengths of the adversaries and weaknesses of their own forces. This information must be communicated effectively to headquarters to ensure the necessary resources are allocated for achieving success. A key aspect of this assessment process is measuring and quantifying various parameters.
To excel in your role, consider the following:
1. Assess your facility's weaknesses to determine the need for reliability.
2. Evaluate your department's strengths and weaknesses to gauge your capabilities in meeting reliability requirements.
3. Quantify your successes to secure the resources needed to sustain the revolution of reliability.
One essential aspect is measuring reliability, which influences the level of support and recognition your efforts receive. A recommended metric for this purpose is Operating Equipment Effectiveness (OEE), which provides a comprehensive view of operational efficiency. Additionally, Mean Time Between Failures (MTBF) is essential for targeting areas of improvement within your operations.
In addition to these primary measurements, it's crucial to focus on lubrication, predictive technologies, root cause failure analysis, Reliability Centered Maintenance (RCM), and Preventive Maintenance Optimization (PMO). These strategies can significantly enhance equipment reliability and operational efficiency in the long run.
By prioritizing these initiatives and fostering a culture of reliability within your organization, you can drive substantial improvements and mitigate future operational challenges effectively. Embrace the role of a Reliability Engineer with dedication and expertise, and you will witness transformative changes in your facility.
Sincerely, Mike.
Mike, I received great feedback on my recent post about the future plans for our company after spending two months in the plant. I outlined key areas for improvement such as downtime tracking, CMMS utilization, equipment assessment, failure analysis, scheduling, store room management, and quality assurance. However, the first response I got was questioning the reliability of a specific process/equipment and how it fits into our overall plan for improvement.