Reliability Engineering

Fred Schenkelbergfms@fmsreliability.com

MEASURING AND IMPROVING MAINTAINABILITY

Day 2 Session 3

Objectives

• Defining maintainability and metrics• Discussing reliability & maintainability• Mastering maintainability techniques• Maintaining simplicity• Increasing maintainability though design• Restoring and optimizing maintainability

Metrics

• Purpose of metrics– Making decisions– Monitoring– Comparison

• What are common metrics?

Establishing Metrics

• Business requirements

• Process markers

• Technically possible

Cascade of metrics

• Profit

• Throughput

• Quality & Yield

• Vessel Pressure

Metric Cautions

• We always have measured this

• Technology changes

• Business requirements change

• Customer expectations change

Discussion & Questions

How do you talk about R&M

• Reliability

• Availability

• Maintenance

• Systems, programs, people?

Related Metrics

• Safety

• Reliability

• Quality

• Profit

Poor examples

• Lack of measure

• Lack of resolution

• Not useful for decision

• Others….

A good metric

• Actionable

• Meaningful

• Accurate

• Repeatable

Discussion & Questions

Mastering R&M Techniques

• Awareness & Practice

1. Unconscious incompleteness

2. Conscious incompleteness

3. Unconscious completeness

4. Unconscious completeness

Mastery

Sources for Knowledge

• Reading

• Conferences

• Training

• University Programs

• Webinars reliabilitycalendar.org

Experiments & Curiosity

• An experiment a day

• Failures are chance to learn

• How to do this safely?

Novice to Expert

• Individual effort

• Team effort

• Hierarchy of internal support

Discussion & Questions

Decision focused

• If task not related to a decision or value

– Why?– What can be learned?– Process improvement

• Each task should have value attached

KISS Principle

• Example of simple solutions

• Review fixes and patches for ways to simply entire process

• It takes work to be simple

Always ask why

• Why is this being done

• Why is this important

• Why now?

• Why does this work?

Even the paperwork

• Forms, checklists, and incentives

• Story of repair center and repair action form

• Story of prototype process

Discussion & Questions

Design for Reliability

• Set of tools to improve reliability

• Systematic, streamlined, concurrent engineering program

• Balance of function, cost, time to market, and reliability

DFR Example

• Derating story

• Best Practices– Environmental Testing– Stress/strength– Process control

Design for Maintainability

A design strategy, involving both the designer and end user, with the following objective:• Identify and prioritize

maintenance requirements.• Increase product availability

and decrease maintenance time.

• Increase customer satisfaction.

• Decrease logistics burden and Life Cycle Costs.

DFM Example

• High speed printer story

http://plant-maintenance.com/benchmarking.shtml

Discussion & Questions

Restoring

• Good as new

• Bad as old

• Somewhere between

Balance cost downtime uptime

• Redundancy and cost

• Cost of rapid repair

• Finding the balance

Maintaining

• Sustainable

• Issues with routine

• Prioritization methods

• What works for you?

Reliability Management

• Business objectives

• Morale of workforce

• Alignment of purpose

Discussion & Questions

Summary

• Defining maintainability and metrics

• Discussing reliability & maintainability

• Mastering maintainability techniques

• Maintaining simplicity• Increasing maintainability

though design• Restoring and optimizing

maintainability

Measuring &Improving Maintainability