BY K.BABU RAO AWM/RYPS

TODAY’S GLOBAL SUBJECT

RELIABILITY ENGINEERING

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DELTA PASSENGER TRAGEDYNEAR VELIGONDA ON 29-10-2005

On 29-10-05 Train No. 319 Delta Passenger running between RAL & SC at about 3:45 Hrs Ran in to the Flash flood on a calvert near Veligonda.116 travellingPassengers along with Driver were killed and 200 were injured Loco &11 Coaches damaged . on investigation the bridge watch man GOURAIAH kept to watch the floods was absconding from spot resulting in to major discoster.

LACK OF HUMAN RELIABILITY

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TITANIC SUNK INTO THE ATLANTIC

OCEAN ON 15-04-1912

TITANIC ,The world’s prestigious luxury ship travelling from south Hampton to New York with 2228 passengers and crew sunk into the Atlantic ocean on 15-04-1912 due to ice berg collision. 1523 lives were lost. In investigation it was found that the 1 inch steel sheet ment for manufacturing of hull was containing Ph and S 4% and 2% respectively.The rivets provided at joints found slag inclusion and corrosion.The propeller failed to reverse at 24 nautical miles speed.Less number of Life boats.

MATERIAL FAILURE

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ROCKET FAILURE

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G-SAT 5P FAILURE

WEEPING BHOPAL

BHOPAL TRAGEDY

ON 02/03-12-1984 A WORST INDUSTRIAL CATASTROPHE HAPPENED AT

UNION CARBIDE INDIA LIMITED

AT BHOPAL IN M.P

UNION CARBIDE INDIA Ltd

BHOPAL GAS TRAGEDY

HOW HAPPENED (ANIMATION)

SCHEMATIC DIAGRAM FAILUR E ANALYSIS

FAULT TREE FOR FAILURE

GEOGRAPHICAL MISTAKE

MATTER BROUGHT INTO LIGHT

1. THE MIC TANK ALARM NOT WOKING FOR 4 YEARS

2. WENT GAS SCRUBBER OUT OF SERVICE FOR 5 MONTHS (Na OH)

3. TANK REFRIGERATOR REMOVED IN VIEW OF ECONAMY (FAILE 5 °C)

4. WATER WAS USED INSTEAD OF STEAM TO CLEAN THE PIPE-LINE AS

STEAM BIOLER OUT OF ORDER FOR UNKNOWN REASONS

5. SLIP BLIND PLATES WERE NOT PROVIDED AT THE TIME OF PIPE-CLEANING

TO AVOID WATER ENTER INTO THE MIC TANK

6. HIGH LEVEL WATER TANK PRESSURE WAS VERY LOW TO SPRAY ON

ESCAPE GASES TO DILUTE THE CONCENTRATION

7. PRESSURE GAUGE WAS REMOVED FOR RECTIFICATION ONE WEEK BACK

8. 610 MIC TANK JUMPER PIPE NOT OPENED TO BY-PASS THE GAS

9. MOST OF THE SAFETY SYSTEMS WRER NOT WORKING (FOR ECONOMY)

10. THE PROBLEM WAS MADE WORSE BY MUSHROOMING OF SLUMS AROUND

11. DOWN STREAM BLEEDERS WERE PARTIALLY CLOGGED

CASUALITIES ON THE DATE OF INCIDENT

1. NUMBER OF DEATHS ON THE DATE OF INCIDENT – 2259

2. NUMBER OF DEATHS WITH IN ONE WEEK – 3000

3. NUMBER OF PERMENENT DISABLEMENTS – 3900

4. NUMBER OF TEMPORARY PARTIAL DISABLEMENTS – 38478

5. NO OF PEOPLE EFFECTED WITH MINOR INJURIES – 558125

6. NO OF ANIMALS DIED ON THE DAY OF INCIDENT – 2000

7. NO OF PEOPLE TREATED IN HOSPITALS – 170000

CASUALITIES

EFFECT FROM THE DATE OF INCIDENT

21:00 Hrs - WATER CLEANING OF PIPES STARTS

22:00 Hrs - WATER ENTERS INTO 610 MIC TANK / REACTION STARTS

22:30 Hrs - GASES EMITTING FROM SCRUBBER TOWER

22-35 Hrs - FIRST COMPLENT WAS RECEIVED TO POLICE STATION

00:30 Hrs - SIREN SOUNDS AND STOPPED TO WORKERS ESCAPE

00:50 Hrs - LONG SIREN GIVEN IN UCIL PLANT PEOPLE TO ESCAPE

01:00 Hrs - POLICE ENQUIRED THE UCIL,DIRECTOR DENIES THE LEAK

04:00 Hrs - GASES ARE BROUGHT UNDER CONTROL

07:00 Hrs - “EVERY THING IS NORMAL” POLICE ANOUNCEMENT

TIME LOG ON 02/03 – 12 - 1984

CONVICTED AND SENTENCED TO TWO YEARS IMPRISONMENT AND FINE OF $2000 EACH

WARREN ANDERSON chairman and chief Executive Officer of union carbide of India limited BHOPAL

KESHUB MAHENDRA Non Executive Chairman of union carbide of India limited BHOPAL

contd

V.P.Gokhele Managing director

Kishore Kamdar Vice President

J.Mukund Works Manager

S.P.Chowdary Production Manager

K.V.Setty Plant Superintendent

S.I.Qureshi Production Assistant

All are above 70 years of age at the time of conviction

WHAT IS THE USE???

WHAT IS THE USE IF A SHIP IS SUNK IN IT’S FIRST VOYAGE?

WHAT’S THE USE IF A MACHINE IS FAILED WITHIN ONE WEEK?

WHAT IS THE USE IF A MAN IS NOT PERFORMING HIS DUTY?

WHAT IS THE USE IF A WAGON IS FAILED WITHIN 90 DAYS?

LACK OF RELIABILITY

RELIABILTY ENGINEERING

Reliability: The ability of a system or component to perform its required functions under stated conditions for a specified period of time.

RELIABILITY IS RELATED WITH QUALITY

HISTORY OF RELIABILITY• The importance of quality and reliability was

born out of demands of modern technology and social needs.

• Up to 1961 the quality means whether the product is free from defects or not. In 1961 the national council for quality and reliability was formed with a main objective of creating an awareness of importance of achieving quality and reliability in the design , manufacturing and operation.

• Today reliability has become a catch word in the market to provide guarantee to the product to give trouble free service for a specific period.

RELIABILITY ENGINEERING IS CONCERNED WITH FOUR KEY

ELEMENTS Reliability is a probability. Reliability is predicated on "intended

function” Reliability applies to a specified period

of time Reliability is restricted to operation

under stated conditions.

BUILT IN DURING

1) DESIGN2) PRODUCTION3) DEVELOPMENT4) OPERATION

QUALITY & RELIABILITY QUALITY RELIABILITY1) PRODUCT IS FREE FROM DEFECTS.

1)HOW LONG WILL THE PRODUCT SERVE.

2) ASSOCIATE WITH MANUFACTURING.

2)ASSOCIATE WITH DESIGN.

3) DEPENDS UPON PRODUCTION PROCESS.

3) DEPENDS UPON WORKING CONDITIONS.

4) RELATED WITH ACCURACY.

4) RELATED WITH PERIOD OF SERVICE.

LACK OF EQUIPMENT KNOWLEDGE.LACK OF UNDERSTANDING OF

PROCESS.CARELESSNESS.FORGOTTENFULNESS.POOR JUDGEMENT SKILLS.ABSENCE OF CORRECT INSTRUCTIONS.PHYSICAL INABILITY.

Inspite of the designers best effort no equipment can be perfectly reliable.

Maintenance has become an importance consideration in the long term performance of any equipment.

Equipment failure might be costly in terms of money, time, some times dangers in terms of safety.

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In a in-motion weigh bridge out of 4 tracks switches 3 should work and out of 4 load cells 2 should work.

In a deisel locomotive out of 6 motors atleast 5 should work for its function.

In a eight cylinder auto mobile atleast 4 should fire for its function.

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EFFECTIVE AND CREATIVE DESIGN. USE OF QUALITY COMPONENTS. SYSTEM SIMPLIFICATION. PARTS IMPROVEMENT METHOD. STRUCTURAL REDUNDANCY. MAITAINABILITY AND REPAIRS.

CAUSES INFLUENCE HUMAN RELIABILITY (ROLE OF SUPERVISOR)

Whether the operator position is comfortable or not?

Any operations require reduction of physical effort?

Is the lighting of the work place is sufficient?Noise and vibrations within the tolerable limit?Does temperature cause any discomfort to

operator?Does the layout is comfortable to the workmen?Does the process can be further automised?

RELIABILITY MATHEMATICS

CALCULATING STRENGTH OF PRODUCT.ESTIMATE THE LIFE TIME OF PRODUCT.ESTIMATE THE UTILISATION TIME.ESTIMATE THE BREAKDOWN PERIOD OF PARTICULAR COMPONENT.DETERMINE NUMBER OF COMPONENTS.ESTIMATE REPAIR RESOURCES.ANALYSE THE UTILITY OF EQUIPMENT.

BETTER FAILURE ANALYSIS AND UNDERSTANDING.

IMPROVED MANUFACTURING TECHNOLOGIES.

CAREFUL DESIGN AND PLANNING.

PROPERLY SELECTION MATERIALS & COMPONENTS

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EQUIPMENT DOWNTIME COMPONENTS

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FAULT TREE TECHNIQUE

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FAILURE FOR EMERGENCY LIGHTING SYSTEM

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MOTOR REPAIR

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ROBO

Fig: Reliability and cost

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RESISTANCE TO RELIABELITY

COST CONSIDARATION

MANAGEMENT REGIDITY

LACK OF CLARITY OF GOALS

PEOPLE’S VALUES AND ATTITUDES

ABSENCE OF MOTIVATIONAL

FORCES

LACK OF SUPPORT FROM

CUSTOMERS

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CREATIVE DESIGNES

INNOVATIVE ACTION PLANS

WELL-DEFINED PROCEDURES

TRAININGS AND CAREER DEVELOPMENT

INCENTIVES FOR FAILURE FREE OPERATIONS

CUSTOMER SATISFACTION AND FULFILLMENT OF

THEIR REQUIREMENTS IN TERMS OF COST SAFETY,

OPERATIONAL FEASIBILITY IS ULTIMATE AIM OF

ANY ORGANIZATION.

HOW TO MOTIVATE RELIABILITY

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AUTOMATION

QUERIES PLEASE!!!

THANK YOU !!!