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Articles: Reliability-Centered Maintenance

The Elusive P-F Curve

J. Moubray coined the phrase  “P-F interval”. He used it to highlight two pre-requisites of CBM, namely:

The Introduction of the I-P Interval

Moving Back On the P-F Curve to Maximize Maintenance Effectiveness

Douglas J. Plucknette
RCM Discipline Leader – Allied Reliability

My first introduction to equipment reliability came in 1988 at Eastman Kodak Company in Rochester New York. Jerry Haggerty one of the founding members of SMRP (Society of Maintenance and Reliability Professionals) had begun to assemble a steering committee of Kodak Maintenance professionals who would begin working together sharing information on equipment reliability. As a member of this team I remember well the emphasis Jerry put on understanding the P-F curve and the P-F interval. Jerry knew that if we could get our managers to understand the P-F curve we could begin to make the transition into predictive technologies and reduce the amount of reactive maintenance being performed at our plants.

The Maintenance Effectiveness Review

Abstract: One of the more common tools utilized as part of a Condition-Based Maintenance (CBM) program is Reliability-Centered Maintenance (RCM). The RCM process is a front-end program designed to develop a maintenance program to provide the right maintenance, on the right equipment, at the right time and for the right reasons. Unfortunately, most RCM programs do not contain a continuous improvement aspect as many assume that the rigorous process will provide accurate and sustainable results. However, with this process, errors do occur and changes to technology, or the identification of improved tests and inspections not identified during the process, may change the best practice maintenance identified through the process. With the implementation of a program developed within the military, the Maintenance Effectiveness Review, a continuous improvement process can be implemented.

The Reality of Failure

Failure Curves

The Responsible Custodianship of Physical Assets

1 A Maintenance Mission

What exactly is the purpose of the maintenance function? In a world of growing expectations, increasingly onerous regulatory constraints, shifting technological paradigms and endless reorganisations - all of which must be dealt with urgently - it is easy to get lost.

The Swagelok Reliability Journey

Swagelok has been in business for over 60 years, manufacturing the highest quality valves and tube fittings. We are also a privately held company with sales distributors and warehouses throughout the world that supply excellent support and service. Swagelok has been a successful company as viewed by its end-customers, having the highest quality products on the market.

Our manufacturing model is machining, processing and assembly, with over 1000 different work centers. Over the years we have been able to utilize redundancy of equipment to mask our downtime issues. Unlike a process plant, we have many options with this redundancy to make or assemble a specific product. As we started to implement Lean Manufacturing throughout our supply chain we made good progress in reducing our costs and the number of touch points. However, when we started to measure overall equipment effectiveness (OEE) on our machines we realized we had some major issues with machine downtime. A decision was made as part of our overall Lean initiative to create and implement a new maintenance program that would address our machine deficiencies. We researched different types of approaches to improve our maintenance programs. After some benchmarking and interviewing different consultants, we felt that the Reliability Excellence approach offered by Life Cycle Engineering (LCE) met our requirements. We felt that their methods and best practices would fit in best with our culture and our Lean journey. LCE came to Swagelok in 2007 and did an assessment of where we were in regards to maintenance - basically how reactive were we? The results of the audit were that we were on the high end of a reactive or emerging maintenance program scoring 353 out of a possible 1000.

When and How to Template An RCM Analysis

RCM Blitz is a Reliability Tool designed to develop a complete maintenance strategy for a process or piece of equipment. When implemented this maintenance strategy will help to ensure the inherent designed reliability of any process or asset. Performing an RCM analysis takes an investment in time and resources to complete so I always advise my clients to follow the RCM Blitz process to ensure the equipment they have selected to analyze will show a return on their investment dollars.

When does it pay to use Reliability Centered Maintenance

Originally presented at Reliability 2.0

Paul Dufresne, CMRP, CPMM, Trico Corp.

When does it pay to use Reliability Centered Maintenance? Maintenance practices have long focused on time based "preventive maintenance" techniques and non‐value added PMs. The availability condition of a production facility makes notable impact to the productivity. The results of having no clear strategic approach to preventive maintenance lead to many undesirable consequences. The reliability‐centered maintenance (RCM) considerations underlie the identification of equipment monitoring requirements and help establish the need for, the type of, and the frequencies of preventive and predictive maintenance. This presentation is a case study in how one paper company utilized the RCM methodology to identify the most cost effective, value added preventive and predictive maintenance tasks to improve equipment reliability and machine availability within the Neenah Cold Spring Facility.

Why Managers Don’t Endorse Reliability Initiatives

Don Kuenzli, as a plant manager, successfully transformed two oil refineries to highly reliable and sustainable performance by creating a culture of Continuous Improvement through defect elimination. He had a vision to create "a world class facility with pacesetter performance" for these refineries. When Don shared his vision with his boss at one of these sites, he was told that they could not afford to create this level of performance. Managers often make the assumption that the best performance is gained by paying a high price. There are many benchmark studies that demonstrate quite the opposite.

Why Remediation of CMMS Data is Essential to Reliability-Centered Maintenance

by Scott Weston, CMRP, Reliability Engineer, Global Knowledge Management, Inc.

In my experience, companies tend to install and commission operating equipment quickly so that it may contribute to the bottom line as soon as possible. Some do a better job than others of analyzing the equipment and determining the preventive and predictive maintenance activities necessary to get the most out of the equipment. Once these activities are determined, they tend to continue on in perpetuity. Equipment/instrument and spare parts data are loaded as well, and are rarely updated. As the equipment ages and changes are made, change management systems may or may not capture updated data. This causes more work for the crafts persons, less efficiency in maintenance activities, and decision making with outdated or incorrect data.

 

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