Explanation Of Series System Reliability Property 3 For Plant And Equipment Reliability Improvement
It tells us that for a small change in reliability at equipment level we can get a massive rise from that effect at business level.
An explanation of
Slide 35 – Use Series System Reliability Property 3 When You Want to Get Maximum Profits from Plant and Equipment Reliability
Series System Reliability Property 3 is amazing. The numbers in the boxes in the top reliability block diagrams on the slide tell an exciting story. They show us that changing each equipment’s reliability from 0.93 up to 0.95 is a 2.1% improvement, yet the total system-wide improvement produced is 8.9%. That is more than four units of improvement for each unit of effort—a 400% return-on-investment.
The numbers don’t lie. The system reliability formula tells us what will happen when we make a change that affects the entire system as one.
When we repeat the exercise for the reliability block diagrams at the bottom of the slide it confirms the effect. In this case our process train contains four equipment items. For a 2.1% rise in individual equipment reliability we get a positive 8.9% impact on the business. It seems that as the reliability of more equipment in the production train is improved the business gets ever greater benefits.
Using Series System Reliability Property 3
So, what are these system-wide improvements that Series System Reliability Property 3 tell us can produce massive returns-on-investment?
The improvements that fit Series System reliability improvement 3 have certain characteristics. One is that by doing them the reliability of each equipment item on which they are applied rises. A second characteristic is that they are universally applicable and can be used repeatedly in the same situations.
Examples include, Lubrication Management, Precision Maintenance, Operator up-skilling and training on their equipment. Maintainer up-skilling and training on their equipment, and the use of Standard Operating Procedures.
A third characteristic is that they are best practices. When best practices are used on equipment, and when working on equipment, they deliver higher reliability every time they are used. In Plant Wellness Way EAM we make use of Series System Reliability Property 3 everywhere there is a series system arrangement of any sort, be it production equipment or work processes.
Lifetime Reliability Solutions Are A Maintenance Consultancy Based In Perth, Western Australia, Servicing All Of The State
We are a World Class Maintenance Consultant Helping Industrial Businesses and Operations in Perth and across Western Australia
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We ensure you use modern, successful maintenance strategy and practices to deliver the six purposes of world class Asset Maintenance Management listed below. The help you get from Lifetime Reliability Solutions (LRS) Maintenance Consultants ensures your operation gets:
- Maximum Equipment Reliability
- Largest Operating Profit
- Certain Defect Elimination
- Highest Sustainable Production
- Exceptional Operating Risk Reduction
- Outstanding Failure Avoidance
Increasing your equipment productivity and achieving high production performance is critical to your business success. It needs an industrial maintenance strategy tailored to get your operation world class equipment maintenance and reliability. LRS Maintenance Consultants are expert at developing the ideal maintenance strategy for industrial operating plant and equipment.
To ensure that no detail is missed in developing a powerful maintenance strategy for your operation, we adopt a systematic approach to get you great maintenance solutions
Your LRS Maintenance Consultant analyses your existing maintenance systems, processes and practices to pinpoint both your problems and your opportunities. As world class industrial maintenance consultants you get a world class maintenance strategy and maintenance plan, that moves your operation quickly toward world-class maintenance performance and results. We can even help you with the implementation project when the time comes to make changes in your operation and maintenance practices.
When our maintenance consulting assignment is finished you’ll have the best-in-class maintenance management system, processes and methods. You’ll use the necessary disciplines and skills needed to get best practice maintenance results. You’ll get industrial maintenance management plans and methods that prevent plant and equipment failures. Your maintenance strategies will sustain excellent equipment health, proactively detect developing problems, and prevent breakdowns.
Your Maintenance Consultant ensures maintenance costs fall, production equipment reliability improvement, and you reach high plant availability for high production throughput
Our job as your professional maintenance consultant is to make sure that you achieve maintenance excellence in your operation and produce world-class maintenance and reliability results. You gain a competitive advantage by installing the right defect elimination work quality systems, using life-cycle asset management and reliability maintenance processes, and applying precision reliability skills on your plant and equipment.
The Industrial Maintenance Consultant for Operational Excellence Performance and World Class Maintenance and Reliability
With LRS Maintenance Consultants you protect your equipment and save production time, cost and resources. We guarantee more operating profit because you build just the right life-cycle reliability management system you need. You get the simplest asset maintenance management processes and the ideal precision reliability skills that produce the production results you want.
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If you are in Perth, or elsewhere in Western Australia, and you want the best maintenance and reliability performance from your operation, then get a quote to use LRS Maintenance Consultant services.
Plant And Equipment Wellness Way Asset Life Cycle Management Methodology Drives Endless Equipment Reliability Improvement Until You Get World Class Reliability
World class equipment reliability improvement is only possible if you follow particular paradigms, strategies, and practices—they are used exclusively in the Plant Wellness Way EAM methodology.
The following videos cover the presentation slides and explanations in the training session on the equipment reliability improvement methods used in Plant and Equipment Wellness Way EAM.
PEW/PWW EAM Course Day 1 – Foundations Session 8 – Equipment reliability improvement | How do we to Stop Problems Happening?
Duration 3:14
In the Training Course Workbook is a Table titled ‘Human Error Rates’. You will see that it confirms that the ‘human element’, the human error rate, is real and unavoidable. We do not perform well when tasks require care, and we perform especially badly under complicated non-routine conditions. Add stress into that that mix and you get disaster. To deliver equipment reliability improvement you must eliminate human error.
How often do we see managers and supervisors put their staff into stressful situations and then complain that their people are not up to standard? The Table tells us that people simply do not perform well if things get difficult. Foolish and incompetent managers expect great results regardless of prevailing conditions and the real abilities of their staff. But wise and successful managers turn complicated situations into easy and effortless routine through SOPs and training to ensure the best performance from their people. If you want to turn the tasks you do, or those done by your people, into routine simple tasks that hardly ever go wrong, simply write clear and detailed SOPs incorporating the very best failure prevention practices available in the book “Employee Training and Development with Standard Operating Procedures” by Mike Sondalini. Then train your people to them and watch the error rate fall by 100 to 1000 times.
Journey to 6 Sigma: Minimize Variability
Duration 5:45
The slide explains the change in business and processes needed to move a company towards excellence. If nothing is done a business ‘naturally’ performs at about 2-1/2 sigma ,with about 20 errors per hundred opportunities for error. When they introduce ISO 9001 quality management, and truly live the 8 quality principles, they will see a reduction in errors. Better than that is to adopt statistical process control which requires continuous feedback from your process and its continual improvement. The best of all is the Accuracy Controlled Enterprise, which combines all the best practices of the lesser methods and asks you to use them business-wide in all the business processes.
Chance of Trouble at Each Sigma Level
Duration 0:44
Most Business make their Machines Break
Duration 6:03
It is a surprise to learn that most businesses destroy their own machines. The chart in the slide shows the history of equipment breakdowns in a plastic pipe manufacturing business. Once you create the timeline of weekly number of breakdowns ,or the weekly hours spent on breakdowns (as in the plot shown) you can see how stable the process of breakdown generation is in a business. Notice that every week there were breakdowns. Some weeks were a complete disaster, and some were not so bad – only a few lost. The results have been put into a control chart and limits placed at 3 sigma distances (The least number of breakdowns can only be zero, so the lower limit is 0). The fact that all results are within the process limits tells us that this process is stable. It has an average number of 31 hours lost weekly to breakdowns. This company makes breakdowns as one of its products!
PEW SOLUTION: “Chop out the Roots of Failure”
Duration 2:38
PEW SOLUTION: Standardised Work Limits Variability
Duration 2:19
As soon as there is work to be done the question that arises is ‘How to do it quickly and well?’. Time and quality are important, but equally important is the cost to do the work. You know from the Value Stream Concept that we only want to do activities that add value. We also know that removing ‘waste’ activities reduces the cost because time is not spent doing them. To have least cost work, done in the least time and at the right quality requires you to find the very best way to do the job that gives you all three.
Once you find that ‘best way’ of doing the job you want to make sure that it is always done the same way every time by everyone that does it. By standardising work you intend to produce a repeatable outcome every time it is done regardless of who does the task. Standardised work is a work quality control and quality assurance strategy to deliver equipment reliability improvement.
