Reliability-Based Industrial Maintenance Guide
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ScribdTranslationsReliability-Based Industrial Maintenance Guide
Translated by
ScribdTranslationsINDUSTRIAL MAINTENANCE MANAGEMENT
MODULE:
INDUSTRIAL MAINTENANCE
& OPERATIONAL SAFETY
[Link]. A
Cours 3:
Maintenance based on the
reliability
2
Reliability-based maintenance
Objective:
Define what is MBF: Reliability-based maintenance
Understanding the MBF process: Case study
Understanding how to improve from the MBF
How to develop the various maintenance activities in the
workshop (preventive, inspection, greasing, replacement)?
What methodology to apply?
What information to rely on?
Use of the MBF to answer these questions!
What is the objective of the MBF?
Ensure the highest equipment availability rate
production: Challenge 0 sudden stop.
La MBF quels outils ?
Decomposition of the workshop into a multi-level hierarchy:
line, equipment, sub-assembly, components
Definition of equipment criticality and classification
•Analysis of equipment (FMEA)
Definition of a maintenance plan ensuring reliability
operational of the equipment according to its class
The MBF: a process of continuous improvement
Définir Establish the criticality
the hierarchy equipment
Define the modes of
Implementation of plans of
failures of
maintenance recording of
components and their
the history of breakdowns
criticality
Development of Define a plan of
operating modes maintenance according to the class
and the file the equipment and the criticality
machine failures
Definition of the equipment hierarchy: example
Elements
maintainable
Line 1
…..
Unit 1
FACTORY Line 2
Unit 2 Line 1 …
Determination of critical equipment
. What criteria can be studied?
to define the equipment
critiques?
Determination of critical equipment
•The families of criteria for establishing the criticality of equipment:
Risks to users and passengers
Environmental risks
Unavailability
Redundancy
Indirect shutdown costs
•…
Determination of critical equipment
Development of a criticality analysis taking into account 2 related factors
to potential equipment failures:
The probability of failure
The consequence of the failure
Classification into categories based on the result at each level
Probability level:
The probability of failure is calculated by taking into account the following criteria:
The frequency of the occurrence of this failure (F)
The complexity of the system (C)
Level of consequence:
The consequence is calculated by taking several criteria into account, for example:
Impact on humans (IH)
Impact on the environment (IE)
The impact on costs (direct and indirect) (IC)
The quotation
For each criterion, a rating is made according to the RETEX/History, e.g.:
Quotation 1 3 5 7 9
F Rare failures 1 time/year 1 time/6 months once a month 1 time/week
Simple conception Little conception Repair
Conception impossible
C Simple conception with little complex with PDR
complex (level 4/5) (change of
repair available
the installation)
Quotation P = F + C
The quotation
For each criterion, a rating is made according to the feedback and the scope, e.g.:
Quotation Consequence = IH + IE + IC
Cotation 1 3 5 7 9
Accident serious until the
Incident with hospitalization mortal
IH Aucun impact Minor Incident Incident with prolonged stop
light
Long-term deadly rejection
IE No impact Occasional harmful rejection (1 Moderately harmful waste
Minor non-harmful rejection times/month daily
IC (D/IND) None 1 MAD /month <10 MAD /month <50 MAD /month 100 MAD /month
The classification
Depending on the rating of each criterion, it is possible to define a
classification of equipment from most critical to least critical
C B A
D C B
D D C
1 and 8 9 and 17 18 et 27
Consequence
The maintenance strategy
Define availability and reliability objectives for the equipment based on their
criticality (A;B;C;D)
Maintenance efforts will be focused on the most critical equipment (A then B)
What parameters will influence
on the availability of the equipment?
The maintenance strategy
•Les paramètres influençant la disponibilité de l’équipement :
The failure rate
Repair times
Reduction of the failure rate:
Improve the reliability of the equipment through preventive maintenance
Redesign equipment to reduce the severity of failures
Reduce downtime
Ensure the availability of spare parts
The good technical knowledge of the equipment
Detailed and informed operating procedures
The maintenance strategy
According to the criticality (A;B;C;D) of the equipment, the monitoring is:
Highly advanced equipment A, and if possible B
Complete documentation
PDR stock,
complete preventive maintenance
Less pressure on class C and D equipment
Minimum maintenance framework
Limited documentation to that of the manufacturer
less strict stock PDR
•Maintenance N1 and N2, rarely the other levels
The maintenance strategy
Example to be put in place
Criticality Type of maintenance Complementary types
Class A and B Systematic maintenance Online monitoring (vibrations,
Conditional maintenance analyze of oil,
Frequency at least once if possible thermography, …
•Maintenance predective
Class C Maintenance systematic•Routine maintenance and
lightened inspection
Maintenance conditional
with reduced frequency
Class D Maintenance systematic
just necessary
Round maintenance
Development of the maintenance plan
Definition: A structured set of tasks that includes the activities,
procedures, the resources, and the time required to execute the
maintenance
How to define the plan of
preventive maintenance of a
equipment?
Development of the maintenance plan
To establish a maintenance plan, it is necessary to:
•Analyser les défaillances potentielles ou vécues par l’équipement
Identify the causes and effects of these failures
Define maintenance activities to prevent the occurrence of failures
Estimate the correct frequency of interventions reducing the risk of failure
Set up detection systems to prevent failure
Method?
Development of the maintenance plan
To establish a maintenance plan, it is necessary to:
Analyze the potential or experienced failures of the equipment.
Identify the causes and effects of these failures
Define maintenance activities to prevent failures from occurring.
Estimate the right frequency of interventions reducing the risk of failure
Implement detection systems to prevent failure
It is the FMEA method: Failure Mode and Effects Analysis
and their criticalities
Development of the maintenance plan
For this FMEA work, it is necessary to have:
•The manufacturer's documentation (PDR, wear parts, lubrication plan, lockout,
security, dismantling procedure
•Maintenance recommendations (manufacturer, central services, hygiene and
security, regulation
•A nomenclature => Functional decomposition of the equipment
Feedback from operators and repairers
•The history of failures of the equipment or a similar equipment
•The conditions of use (environment, usage rate...)
Need to form a group for equipment evaluation
Development of the maintenance plan
The maintenance plan for equipment includes:
The subset or relevant component
The state of the equipment (running or stopping necessary)
•La tache à effectuer et son type (systématique, conditionnel, inspection…)
The periodicity of the spot
The allocated resources (material/tools/human)
The need for spare parts
The necessity of a standard operating procedure
The reference documents for the intervention
Elaboration
the maintenance plan
Creation of the Machine folder
The machine file includes:
An equipment file (designation, functions) and its breakdown (subassemblies..)
Plans and diagrams of the equipment
Notice to manufacturers