Hello, I need assistance in determining the Mean Time Between Failures (MTBF) for a large quantity of pumps, totaling over 100 units. I am aware of the formula for calculating MTBF, which is MTBF = (Number of operating hours / Number of failures). However, the challenge lies in obtaining the accurate number of operating hours, as this information is not consistently recorded and we also have standby pumps (A&B) which makes it difficult to track the usage of A pumps. To determine the number of failures, I will be reviewing the SAP records for each pump notification and work order to identify instances of pump failures. If you have prior experience in calculating MTBF in a plant setting, I would greatly appreciate it if you could provide an Excel sheet with the necessary calculations. Thank you and best regards, Fahad
In order to accurately track running hours, it is crucial to establish a systematic changeover philosophy overseen by operations. Utilizing offline data collection methods will help confirm the implementation of this philosophy. Consider adopting a run until fail approach for primary units with routine preventive maintenance for standby units to simplify monitoring. This will provide precise running hour calculations. Implementing a 30-70 or 50-50 running philosophy will yield estimated running hour figures.
Hello everyone, have you come across this formula? MTBF = (start date of last failure - start date of first failure) / (number of failures - 1). Can anyone provide a source for this formula? I believe this formula could be a time-saving method for me, regardless of the changeover philosophy, assuming that the equipment is repaired and put back into service immediately after each failure. What are your thoughts on this? Let's discuss.
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To effectively manage reliability, consider the following simplifications. Start by using calender time to track reliability. For instance, if you have 100 pumps each with a spare unit installed (totaling 200), you would accumulate 100 pump-years of operation in one year. Throughout the year, any breakdowns should be counted as failures, as should pump trips and failures predicted by PdM (CBM) that result in pump repairs. Perform preventive maintenance (PM) work on pumps to prevent failures. By following a consistent method, such as the one outlined above, you can calculate Mean Time Between Failures (MTBF) and ensure optimal reliability management. While there may be minor errors in this approach, they are negligible as long as the method is consistently applied.
Vee, What significance does the number 6.67 years hold in this particular scenario?
Hi Fahad, This definitely can be a challenging task, especially when you need to track and calculate MTBF for a large number of pumps and some of them are on standby. For the operating hours, in the absence of precise tracking, you might need to make estimations based on general use patterns. For instance, look at shift schedules or typical usage rates for similar pumps in like circumstances. This won't be perfect but it's better than nothing. As for automating the calculations, it's entirely possible to set it up in an Excel sheet using formulas to calculate MTBF, but bear in mind that with inconsistent operating hours, your results may vary. Might want to think about implementing a software solution longer term, they not only record operating hours but also predict MTBF based on historical and real-time data. Hope this helps, good luck with your project!
Hi Fahad, The task of calculating MTBF can indeed be a complex one, especially in cases like yours where operating hours are not accurately recorded. However, to get around this issue, have you considered using the total available operating hours in a given time frame (for instance, one year)? This would take into account the maximum possible operating hours for all pumps, factoring in the hours of standby pumps as well. As for the Excel sheet, I suggest setting up three columns: the first for individual pump ID, another for the total number of failures for each pump, and the last with the calculated MTBF. You can utilize Excel functions like SUM to total failures and division for the calculation of MTBF. If you need further formulaic guidance, I'm happy to assist. With careful data collection and processing, I'm sure you'll be able to generate a helpful MTBF value for your plant's pumps. Best of luck in your endeavor!
Hi Fahad, calculating MTBF can definitely be tricky, especially with inconsistent operating hour records! One approach you might consider is using a combination of the runtime hours logged for the operational pumps along with a rough estimate for the standby units, based on historical usage patterns. You could also implement a simple log for any discrepancies in operating hours going forward to help with consistency. If you still need that Excel sheet, there are some templates available online that could be adapted for your specific needs, and I’d be happy to share some links if you'd like! Good luck with your analysis!
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Answer: - Answer: To calculate MTBF in such a scenario, you can review SAP records for each pump notification and work order to identify instances of pump failures.
Answer: - Answer: The formula for calculating MTBF is MTBF = (Number of operating hours / Number of failures).
Answer: - Answer: Tracking the usage of standby pumps can be challenging, but you can try to differentiate between the usage of standby pumps and the main operating pumps in your calculations.
Answer: - Answer: If you have prior experience in calculating MTBF in a plant setting, you may be able to create an Excel sheet with the necessary calculations.
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