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Reliability Maintenance Engineering Day 2 session 3 Measuring Maintainability 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.
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Reliability Engineering
Fred [email protected]
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