Reliability Maintenance Engineering Day 2 Session 4 Purpose and Equipment Three day live course focused on reliability engineering for maintenance programs. Introductory material and discussion ranging from basic tools and techniques for data analysis to considerations when building or improving a program.

1. Reliability Engineering
Fred Schenkelberg
fms@fmsreliability.com

2. EQUIPMENT SELECTION AND
REVIEW
Day 2 Session 4

3. Objectives
• Examining the lifecycle process
• RAM modeling to evaluate designs
• Conducting the Maintainability Design Review
• Developing a MDR checklist

5. Lifecycle Process
Concept
Design
MFGUse
End of life

6. Concept & Design
Concept
• System Architecture
• Reliable v Available
• Goal setting
Design
• Selection of materials
• Selection of
components
• Risk identification
• Tradeoffs

7. Production & Use
Production (manufacture)
• Process variation
• Materials variation
• Shipping variation
• Installation variation
Reliability only gets worse
Use
• Operation Stress
• Environment Stress
• Maintenance Plan
• Failure Detection

8. End of life
Decommissioning
• Lessons learned
• Tear down and analysis
• Reliability Differences
with today’s model

9. Discussion & Questions

11. Reliability Modeling
• Focus on function
– Common
– Perfect product
• Focus on reliability
– Uncommon
– Imperfect product
• CAD, FEA, Simulations

12. Design Comparison
• Reliability occurs in the
design
• Selecting the most
robust options
• DOE, Stress/Strength,
Aging, Maintenance
Costs, Failure Costs

13. What if analysis
• What could go wrong?
• Explore changes to
– Environment
– Construction
– Use profile
– Materials
Good designer do this
naturally

14. System Modeling
• Simulate different
– Maintenance policies
– Maintenance practices
– Supply chain changes
• DOE to design the
experiments
• Output is cost of
ownership and
availability

15. Discussion & Questions

17. Design Reviews
• Adversarial or
Constructive
• Formal or informal
• Status update or
detailed design check
How do you approach
reviews?

18. Stages of Review
• During design
– Risk assessment
– Options and benefits
– Decisions
• During review
– Increase awareness
– Identify errors (Petroski)
– Celebrate failures
• After review
– Process improvement
– Lessons learned

19. Hosting a review
• What is the purpose?
• What decisions are
being made?
• What is desired
outcome?
Be clear on why

20. Considerations
• People
– Knowledgeable
– Stakeholder
– Perspective
• Timeline
– Time for details
– Time for action
• Meetings
– One on one
– Group

21. Discussion & Questions

23. Review checklists
• Avoid using a checklist
or database
– Detailed checks, i.e.
keepouts, sizing, etc.
– Goal is do the checklist
• Do use the approach
guided by checklist
– Higher level
– Range of stresses

24. Review guidelines
• Brainstorming
approaches
– Day in the life
– Range of stresses
– Change one thing
• Make it safe to talk
about failure
– Not personal
– No attacks
– No solutions (take
offline)

25. Checklist cautions
• Design checklists
• Testing checklists
• Review checklists
Only works if you know
everything and follow the
spirit of the checklist

26. Golden Nuggets
• An example that has
been very effective
• Identify key failure
patterns
• Review before and after
project
– What will you do?
– What did you do?

27. Discussion & Questions

28. Summary
• Examining the lifecycle
process
• RAM modeling to evaluate
designs
• Conducting the
Maintainability Design
Review
• Developing a MDR checklist
Equipment Selection & Review