integrating reliability engineering concepts
DESCRIPTION
A presentation from MARCON 2009 on how to integrate Reliability Engineering concepts into capital projectsTRANSCRIPT
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Integrating Reliability Engineering Concepts into Capital Projects:
Lessons Learned in a Case Study
Dan DeGrendel, Boehringer-Ingelheim RoxaneBob DiFrancesco, ARMS Reliability Engineering
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Agenda
• Introduction• Top 10 List• Maintenance Program Inputs• Defining the Maintenance Program• Spare Parts• Maintenance Program Outputs• Lessons Learned
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Introduction
How do you define a successful project?• Old definition: on time + within budget• New definition:
on time + within budget + reliable operations
• The reliability function must be incorporated into project teams and aligned with the site’s Reliability Team
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Top 10 hints that your new equipment may be in trouble
1.Commissioning = the motors start2.I thought you were going to enter information
into the CMMS3.Scheduled maintenance is set up as
equipment fails4.The vendor documents are in the library - as a
10,000 page pdf file5.The contractors do routine maintenance until
the project is completed
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Top 10 hints that your new equipment may be in trouble
1.What does RCM mean again?2.The new pump is walking off its pad3.Spare parts? What spare parts?4.I wondered what that equipment looked like5.Hey, does that bearing need to be greased?
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Case Study Equipment
Process Air
Clean-In-Place
Spray Dryer
Cyclone Bag House Exhaust Air
Solution Delivery
Compressed Air
Chilled Water
Heating WaterWaste Neutralization
Product Collection
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Equipment Database:Typical Situation
• Each project sub-team tracks information that is important to them
• Disadvantages:o Information is duplicated between project sub-
teamso Extra effort to obtain and update informationo Sub-teams do not have easy access to all
project information
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Equipment Database:Ideal Arrangement
• One database for all equipment information• Benefits:
o Minimize information management efforto Everyone accesses the most current informationo Avoid duplication of informationo Capture information when it is obtainedo Track equipment status throughout the projecto Define information to capture early in the project
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Equipment Database:What Do You Want To Capture?
• Equipment make/model/serial #• Procurement information• Status from design to customer acceptance• Equipment location• Equipment documentation• Capital asset information• Maintenance strategy
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Equipment Criticality
Match the maintenance strategy to the equipment criticality:• Low: Production is not impacted• Medium: Production is temporarily stopped
or capacity is limited• High: No production
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Useful Equipment Information
• Maintenance history of similar equipmento Failure modeso Failure frequencieso Scheduled maintenance taskso Spare parts consumption
• Equipment Documentationo Operating and Maintenance manualso Recommended spare parts listso Troubleshooting guideso Drawings
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Equipment Hierarchy
• Organize equipment into systems, sub-systems and components
• Use functional relationships vs. locations• Structure for FMEA and RCM efforts• Organize documentation as it is received• Assign spare parts to hierarchy levels
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
The Maintenance Program:Low Priority Equipment
• Review OEM recommendations• Maintenance history for similar equipment• Simplified FMEA• Can enter information into RCM software
(without analysis) for zero based budgeting
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
The Maintenance Program:Medium Priority Equipment
• Review OEM recommendations• Maintenance history for similar equipment• Full FMEA
o Divide the equipment into sub-systems or components
o Define sub-system or component boundarieso Describe what crosses the boundarieso Work horizontally to complete the FMEAo Cost/risk analysis of proactive work
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
The Maintenance Program:High Priority Equipment
• Review OEM recommendations• Maintenance history for similar equipment• Full FMEA – basis for the RCM• RCM assessment
o Run to failure scenarioo Evaluate re-design alternativeso Optimized maintenance program =
minimize total operating costso Forecast spare parts consumptiono Forecast life-cycle costs
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
RCM Cost Contribution Report
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
RCM Optimized Maintenance
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Other Uses For FMEA Information
• Troubleshooting guides• Work Order fault-trend analysis
o Problem codeso Failure codeso Cause codeso Action codes
• Commissioning tasks
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Spare Parts
• FMEA and RCM determine the recommended spare parts
• Vendor part list = wear parts• Bill of Material (BOM) = a list of all components• Stock parts that wear or could fail and cause
downtime
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Prioritizing Spare Parts
• Low priority• Medium priority• High priority
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Low Priority Spare Parts
• Part does not impact downtime• Can tolerate out of stock conditions• Adjust re-order point and re-order quantity to
minimize costs• Manage inventory turns
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Medium Priority Spare Parts
• Part can impact downtime• Part cost > downtime cost• Business risk if the part is not stocked• Get the end–user’s agreement if do not
stock the part
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
High Priority Spare Parts
• Part can impact downtime• Part cost < downtime cost• Part is an insurance policy – keep it on the
shelf!
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
ROP and ROQ Calculations
• Re-order point (ROP)o Safety stock levelo Based on a probability of not running out of stock
• Re-order quantity (ROQ)o Procurement costso Holding costs
• The stock room should calculate ROP and ROQ with the mechanics’ input
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Procuring Spare Parts
• Part already in stock?o Assign to new equipmento Adjust ROP and ROQ if required
• Source from a local supplier or OEM if possible
• Source from the equipment supplier if you have to
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Equipment Documentation
• Plan the library early in the project• Use the equipment hierarchy• File and organize documentation as they are
received• File documents electronically
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
CMMS Data
• Define what will be entered into the CMMS early in the project
• Define roles and responsibilities for entering data
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Commissioning Support
• Incorporate FMEA results into commissioning activitieso Base line Predictive Maintenance
measurementso Verify proper alignment of rotating equipmento Resolve potential infant mortality failures
• Use maintenance personnel for commissioning tasks
• Maintenance takes responsibility for equipment as it is commissioned
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Zero Based Budget
• Time based PM’s• Condition based PM’s• Predictive maintenance• Corrective maintenance• Spare parts and supplies• Resources• Use information to justify budget increases
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Lessons Learned
• One comprehensive equipment list• Match the effort to create the maintenance
program to the equipment’s criticality• Create a library of potential failures,
consequences and related data for FMEA’s and RCM’s
• Use P&ID numbers in the FMEA’s and RCM’s
• Review RCM content in the FMEA format
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Lessons Learned – con’t
• FMEA’s and RCM’s drive recommended spare parts
• Get detailed BOM information from the equipment suppliers
• Set ROP and ROQ values objectively• Clearly define roles and responsibilities• Get everyone’s full commitment to reliability
engineering/capital project integration
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Summary
• Smooth start-up and reliable operation of new equipment is feasible
• Need cooperation and commitment from all project stakeholders
MARCON 2009 Integrating Reliability Engineering Concepts into Capital Projects
Thank You!
Questions?