asset reliability definition

Your maintenance should too. All Rights Reserved, A look at the tools that empower your maintenance team, Manage maintenance from anywhere, at any time, Track, control, and optimize asset performance, Simplify the way you create, complete, and record work, Connect your CMMS and share data across any system, Collect, analyze, and act on maintenance data, Make sure you have the right parts at the right time, AI for maintenance. The definition that follows is the definition that I prefer; it is one that has been derived from many definitions that I have seen over time:“The What is industry 4.0 and how will it affect our factories in the short term? It is possible to achieve the reliability required to sustain your process at the rate you require. Additional device description work on the next generation xDS™ for CIP™ devices also continues to move forward. This support is critical for project success. Two Nasa astronauts took the first all-female spacewalk. Safety Level Maintenance Manager at Kemira Oyj, Former Chairman of the Board of Directors of the Finnish Maintenance Society, Chair of the EurEau Committee on Economics and LEgal Affairs, expert at IGWP, the Polish Waterworks Chamber of Commerce, Director of Development, Finnish Safety and Chemicals Agency (Tukes), Malene Grouleff & Marianne A. O. Andersen. OnTrak SmartLube - Remote Bearing Monitoring and Precision Lubrication from anywhere, anytime, Acoustic emission testing: How to listen to pressure equipment, People are Key – Also in the Digital Age, Maintworld – 10 Years of Building International Connections in Industrial Maintenance. While every facility will have these ingredients, it is only by integrating them closely together that success will be achieved. Management must address the issues and state the general requirements so everyone understands. ODVA Reliability focuses on the predictability of the outcome of a process. This area is often underestimated in a huge number of companies. Changes in process introduce variability: the cause of most of our operating and business problems. Section 12.3 lists w… We’ve talked around it before. The issue of reliability is to provide an environment where: Management must also communicate the cost for failure – it can’t be a secret for those that need to make financial decisions and procedures must be established to communicate the costs of assumed values or calculated values for communicating to the organisation the high cost of certain failures. So is it reasonable to assume that the maintenance strategy of yesterday will deliver the production needs of today? This empirical model describes five stages of mastery that create a foundation of improved performance with growth potential continuing over a strategic horizon. According to Lifetime Reliability, the concept can be traced back to the 1960s. Prior to this time, it was assumed that the longer a piece of equipment was running, the more likely it was to fail. It is most often measured by using the metric Mean Time Between Failure (MTBF), which is calculated as follows: MTBF = Operating time (hours) / Number of Failures Simplistically, Reliability can be considered to be representative of the frequency of failure of the item – for how long will an item or system operate (fulfi… One definition can lead the site in a totally different direction than another. It is for this reason that a small number of initiatives should be implemented simultaneously. Is Poor Lighting Putting Workers’ Health at Risk? Emerson has introduced two new compressed air dryers designed to significantly extend maintenance intervals, minimize downtime and reduce energy costs in rail applications, including brakes and door control. Recycling plastic consumer packaging waste has long been easy and is a well-established practice for most consumers. By having a clear definition of reliability, it is easy to see how the lack of reliability of equipment or processes contributes to the different key performance indicators – e.g., overall equipment effectiveness (OEE) or cost. There is a subtle connection between the two; that is maintenance is seen as a FIXER of equipment and not an equal partner in the overall management of the asset. Concepts used throughout the world to describe improvements to production throughput are often termed “reliability”. The first few chosen should aim for a quick return and be issues that the managers drive and show a personal interest in. Rather, if carried out properly, a reliability-based approach will take many methods into account, depending on what increases reliability for any one asset. Following the “loose and tight” strategy, it is best to specify … Senior management must subscribe to and be a part of this. This move is often taken without any consideration of maintenance requirements or the impact it will have on plant reliability. Reliability practices begin in the boardroom! To me, reliability is best described as, “being able to be trusted to do what is expected or has been promised.” Here, we talk about reliable production in pulp and paper mills, so it is obvious that the term reliability cannot only focus on maintenance improvement initiatives or only predictive maintenance. The AVENTICSTM RDD (Roll-Up Desiccant Drying) and RDDmin air dryers have a service interval of eight years or 25,000 operating hours. Asset/liability management is the process of managing the use of assets and cash flows to reduce the firm’s risk of loss from not paying a liability on time. Martin Krill has been working for Hager Unternehmensberatung for nearly 20 years. The words “asset” and “liability” are two very common words in accounting/bookkeeping. It’s the absence of unplanned downtime.”, In its simplest terms, this definition makes perfect sense. It is also part of the plant’s culture. On the one hand we continue to unquestioningly stick to the “tried and trusted”, yet on the other hand we cannot stop equipment failing. The prevention of failure has a cost, just as repairing failures has a cost. Euromaintenance 2016 will take place in Athens at the end of May. Determine the Asset Criticality Ranking. Taking the definition of Reliability already mentioned: “The probability that a component or system will perform a required function for a given time when used under stated operating conditions.” The most important part of this statement is: “required function … given time … stated operating conditions”. Then management wonders why the new “reliability” organisation continues to function as before when the maintenance approach was fast repairs, which were considered the key to success. Asset Strategy Management (ASM) is a structured process that enables you to gain control and effectively manage asset strategies, remove inconsistencies, and ensure your assets are up and running at their full potential enterprise-wide so you can close the gap between current asset performance and where you want to be. Dictionaries describe reliability as: dependability, trustworthiness, consistency. . For many years, we have seen the evolution of technology and the acceleration of digital hybrid technologies. Elsewhere, the concept has been defined as “the probability that a component or system will perform a required function for a given time when used under stated operating conditions.”. By understanding which assets are most important (right assets), what should be done to restore or maintain the inherent reliability of those assets (right maintenance), and at what frequency those actions should be taken (right time), a maintenance organization can become more effective and more efficient — and often reduce costs significantly. Ref. We have to take some exercise, have time to relax and eat the correct foods, (maintenance), if we are to give ourselves the best chance of staying healthy (reliable). This is part of the “customer” mentality in the plant’s culture mentioned previously. If a plant decides to introduce a reliability plan, the actual steps agreed on are affected by the definitions used. Since, as we established earlier, reliability takes everything from design to organizational culture into consideration, there can be many different frameworks incorporated into a reliability-based maintenance approach. You can think of reliability the same way. A business process includes people, the materials worked on, documents, selection process, training carried out, learning achieved, and the work environment – in fact everything within a business can affect the outcome. If we are young, athletic and involved in sport our needs (maintenance) will be vastly different from someone who is retired. Management has a big role in reliability issues, which guide design of equipment and continues through maintenance of equipment and systems. In the real world many potential failures are seldom well known or well understood, which makes failure prediction a very difficult task indeed. Without reliable equipment certain business failure eventually awaits. Many companies implement APM tasks without first understanding what drives reliability task selection. The only approach that can work is to change the strategy and culture to match the requirements of now. For instance, a cloud solution may be available with an SLA commitment of 99.999 percent, but vulnerabilities to sophisticated cyber-attacks may cause IT outages beyond the control of the vendor. Who should be involved in the reliability project? Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. Section 12.2 describes the key principles and essential features of a management system for this element. He is also the Chairman of MEETA, the Irish Maintenance Society. Ensure optimal whole of life asset strategies are deployed to all your assets, identify bottlenecks, assess shutdown intervals and establish how to extend them. “We strongly believe that production owns the assets, while maintenance owns the capability of the assets. Many initiatives fail to deliver and sustain the expected results due to lack of long-term top management support. It will cause great waste, produce distress for all concerned and lead to emotional burnout for all involved. Reliability has to do with the elimination of failure modes, and the management of resources to minimise the frequency of unavoidable failures. To create a ranking of priorities, it is necessary to define the … In other words, reliability can be seen as the probability of successand the dependability of an asset to continuously be operational, without failures, for a period of time. Reliability can be used to understand how well the service will be available in context of different real-world conditions. Just as we spend money in our effort to maintain ourselves in a healthy and productive state, it is important to understand the effort and requirements needed to keep your plant and equipment in a reliable condition. Reliability projects require financial analysis so as to correctly define cash outflows. The strategy should be in place from the beginning and communicated to all, however it is important to keep working on the culturechange as it is this change that will bring about the full realisation of benefits. Fiix Solutions Engineer Stuart Fergusson remembers a boss he had at a former job describing reliability like this: “What is darkness? The long answers to these questions will vary from facility to facility, however the driving factor will always be to reduce costs. Typically, air dryers have an average service interval of fewer than two years. Many businesses still use processes and practices long believed to be suitable, not comprehending that these processes naturally contain inherent volatility that make their equipment fail. Last year, we defined reliability culture as “the overall cultural shift that’s required for an organization to fully understand the big picture when it comes to asset reliability.”. Let’s take a car for example. Asset integrity, the RBPS element that helps ensure that equipment is properly designed, installed in accordance with specifications, and remains fit for use until it is retired, is one of nine elements in the RBPS pillar of managing risk. This provides style but no substance, as tools and approaches for reliability and maintenance are as different as night and day. successful transition – model keeps in step with a changing world. These systems have been proven to drive down inspection, maintenance and repair costs while improving plant reliability and operational safety. "opportunity gap." »»Who is John Coleman? Maintenance is only part of reliability and reliability is not asset management, it is only part of asset management and asset management is more than managing assets. These successes will help drive the culture change as it goes through the normal phases. But what exactly is reliability, and why is it important to understand the difference between it and other maintenance-related concepts? Euromaintenance is known as the summit for all involved in maintenance across Europe, it’s the place to be. Successful implementation of RCM will lead to increase in cost effectiveness, reliability, machine uptime, and a greater understanding of the level of risk that the organization is managing. So began the idea of condition-based maintenance, wherein failures were linked to a change in the condition of an asset, rather than its age. The definition that follows is the definition that I prefer; it is one that has been derived from many definitions that I have seen over time: “The probability that a component or system will perform a required function for a given time when used under stated operating conditions.”. You have some control over it. Over time, experts have come to understand that design, operation, technology, and organizational culture all significantly impact reliability. Before we dive deeper into what reliability is, let’s take a quick moment to clarify what it isn’t. Maintenance disasters caused by unexpected events, generally called “black swan” events, may be prevented by the development of Industrial AI (IAI), given its ability to find “invisible” insight in data. Leaders need to have a clear view of how their organisations conduct maintenance. Reliability technology predicts failures and with the use of longer-range tools reduces the cost of failures. Since availability does account for repairs and repair time, it’s really just a function of reliability. Copyright © 2020. Data on its own is useless; it must be refined into information if it is to be of any real benefit. To achieve the required result we must match the exercise and diet to our lifestyle. Assets are defined as resources that help generate profit in your business. Liability is defined as obligations that your business needs to … The result is 300 operating hours. “If age doesn’t cause machines to break down, we should monitor an asset’s condition”, “What’s the real reason a piece of equipment is failing?”, “Failure is due to a number of different factors, and many frameworks can contribute to maximizing reliability”. Asset integrity, or asset integrity management systems (AIMS) is the term for an asset’s capacity to run effectively and accurately, whilst also protecting the wellbeing of all personnel and equipment with which it interacts – as well as the measures in place to assure the asset’s life cycle. This means that important terms like “asset” reflect the new definition in the ISO 55000 standard which is “something that has potential or actual value to an organisation” rather than a previous definition. Responsiveness: The speed at which tasks are performed. Thus both reliability and maintenance activities are ruled by finance just as improvement decisions are always about finance and alternatives. It is important to understand clearly, for example, whether it is maintenance costs that need to be decreased, or should it be a reduction in the maintenance costs per unit produced. Maintworld - Building International Connections in Industrial Maintenance. Asset Management Proper asset management allows organizations the ability to make educated decisions at the right time. If reliability issues are identified, a reliability engineering team may, also, require a redesign. So to define asset management in one word is difficult, but a two-word definition is: OPERATING PHILOSOPHY. What does asset integrity mean for the oil and gas industry? Competency Requirements for Future Engineers, Taking Control of Plant Data with PlantSight Digital Twins, To Transform or Tinker, That is the Question, Connectivity is Key for Comprehensive Maintenance Strategy, Diagnosing Mechanical and Electrical Faults Using Ultrasound Spectrum Analysis, Management of Ultrasonic Data in a Power Plant, Industry 4.0 … A Practical Maintenance Perspective and Significant Impacts on Our Maintenance. If an inspection frequency that is too short, equipment will be over maintained, and resources are wasted. 2 Reference Sources Table 1 lists the sources used to collect terms and definitions related to reliability… But just what does the term really mean? This concept focuses on making maintenance decisions based on maximizing overall machine reliability over a period of time. defines availability as “the probability that a system is not failed or undergoing a repair action when it needs to be used.”. The conference, with the support of the EFNMS, is the only commercially independent conference covering the topics we deal with in the maintenance world. Just because you can show a documented procedure is not surety it will produce the required result. Reliability-centered maintenance (RCM) is a concept of maintenance planning to ensure that systems continue to do what their user require in their present operating context. Strategic Asset Management Inc. 2 Our approach is based on the Operational Reliability Maturity Continuum. Define Asset Reliability program: The Asset Reliability Approach is established on the most effective Preventive Maintenance strategies for each piece of equipment, considering its criticality, availability, and operating environment. Bryan Christiansen is the founder and CEO at Limble CMMS. Eight questions shaping the future of maintenance. Unless the senior managers are sold on the fact that these processes are critical to achieving the objectives, little focus will be put on them and they will ultimately become discredited and not fully implemented. Now most sites have many systems for gathering data, so much data in fact that they do not know what they have. However, additional specialized resources are typically still required to achieve high reliability. People often confuse reliability and availability or use the two terms interchangeably. “Prevent the event” is smart maintenance of yourself or that critical piece of production equipment more commonly referred to as “proactive maintenance”. How maintenance is misunderstood. The site strategy needs to emphasise the few variables where the focus should be kept. This relies on predictions from reliability engineers for the mode of failure also provides information about failure severity. The cost of failures must also include gross margin losses from production outages and lost opportunity production—this is particularly true for continuous process operations when the production is sold beyond the current manufacturing level. Asset Reliability CWA's ASSET (Assessment, Sustainability, Safety, Enhancement, and Testing) Reliability Division provides responsive asset management services to prolong the service life and enable the safe operation of equipment and infrastructure. How did we come to this modern understanding of reliability? However, this healthy lifestyle has a cost in terms of time and what we might eat and drink. If 89% of failures were occurring for reasons other than the equipment simply being old, what were those reasons? By that it is possible to find a way forward: Reliability policies must integrate safety, quality, risk, and financial requirements for the company to achieve the business objectives. In many facilities manufacturing is seen as the customer of maintenance – this thinking will, in my opinion, work against the overall objective – the only customers that exist in reality are those who purchase the end product, and delivering a quality product to the customer is key for survival. Fiix® is a registered trademark of Fiix Inc. A reliable piece of equipment performs like it’s supposed to every time you use it. Once reliability is adopted as a measure of overall business loss, it becomes much easier to get management support for reliability initiatives. In recent years, reliability-centered maintenance has gained popularity. In the current economic climate, managers of manufacturing facilities are under a constant battle to increase profitability and minimise costs. The world has changed. Reliability is defined as the ability of an item to perform as required, without failure, for a given time interval, under given conditions ( One of the key issues is the difficulty in defining a reliability problem. Asset Integrity management improves plant reliability and safety whilst reducing unplanned maintenance and repair costs. Success will breed success and commitment. If the definitions are not well thought through a high degree of confusion is likely to occur. Any strategy requires four critical success factors: People, Process (management), Technology and Information. Thirty-five years after the Russian cosmonaut Svetlana Savitskaya was the first woman to take a spacewalk, a new historical event took place above our heads on 18 October 2019. Subscribe to our newsletter for the latest bulletin on the world of Maintenance. Join over 14,000 maintenance professionals who get monthly CMMS tips, industry news, and updates. Sure, the main point is to produce effectively and to reduce unnecessary costs, but is maintenance really part of the costs that are unnecessary? In the previous article on Reliability in Design, we noted that “Inherent Reliability” (the level of reliability of an asset, as determined by its fundamental design and installation) differs from “Operational Reliability” which is the reliability of the asset actually observed in operation. While there is no accepted industry definition for asset utilization, the definitions used by … For quantifying reliability issues it is important to know why, how, how often, and costs of failures. The purpose of a reliability gap assessment is to identify the shortcomings in achieving the asset performance management objectives so that a reliability program plan can be properly developed. Reliability-centered maintenance should not be thought of as an alternative to any one maintenance strategy. It is therefore important to challenge and agree on the definition used. MTBF is a basic measure of an asset’s reliability. Forecast expected levels of system availability and production levels, and cost / resource requirements to maintain … Asset integrity management (AIM) focuses on pressure containing vessels like pipes and tanks to ensure that these assets deliver the required functions and performance in a sustainable manner. Definition: Reliability: The ability to perform tasks as expected. safety performance and awareness is increased, production targets are consistently achieved, reduction in cost of maintenance per unit of production, continued upward trend on reliability – success breeds success, moral hugely improved – celebrate success, resistance to change – “That’s the way we have always done it”, working relationships that are counterproductive. Click here for digital Maintworld and editorial archive. Reliability issues are bound to the physics of failure mechanisms so the failure mechanisms can be mitigated. AssetWise Asset Reliability enables you to develop proactive strategies that improve long-term asset reliability and performance. In order to carry out the analysis this concept required, root cause analyses had to be carried out to try to understand where the problem occurred that caused machinery to fail. This is the language understood best in the boardroom. Kiilto brought together enthusiastic partners to pilot the recovery of HDPE packaging during the year with eight customer companies. The usual question is “will the pump deliver the flow?” – No consideration is given to how long it will sustain the increased flow for. Increasing production is often one of the options taken to decrease the unit cost. Digital Ecosystems – Because the Customer is Always Right, How to get the Block into the Supply Chain, Keeping Doors Open and Closed at the Same Time, Emerson´s New Air Dryers Quadruple Maintenance Intervals in Rail Applications, ODVA Enters into Agreements with FDT and Fieldcom Group; Continues XDS Development, Maintenance: A Necessary and Important Function in the Future, Computerized Maintenance Management System (CMMS), know where to go, but not how to get there, make changes, but no benefits – model doesn’t align with real world. They deal with: You must have a path forward to successfully achieve reliability. These companies focus as much on the enablers—the rigorous processes, role clarity, and accountability systems—as they … Key financial variables that affect the site should be identified – these are the ones that will make the largest difference to the profit margin. Asset reliability and maintenance overhead cost There is a direct, corresponding maintenance-overhead benefit derived from less maintenance labor. performance indicators that drives the wrong behaviour. A current management fad is to take a maintenance mentality organisation and change job titles to include the word reliability. Because maintenance is seen as a cost within the organisation Maintenance management is often under such high pressure to control expenditure that they are unable to carry out the work required to deliver the possible breakthrough results. Sustainability transformation: Are you ready for the change? Trying to improve production equipment reliability using old maintenance and engineering strategy is an exercise in futility. Both reliability engineering and maintenance engineering have roots in each other’s territory and thus must know about each other’s roles, responsibilities, and tools. Variability is the range of possible outcomes. Reliability requires a partnership approach – that is everybody working together for the common goal. This brought about a huge change in the way people thought about equipment failure. What work performed by a plant’s staff is considered “reliability” and how does this work actually improve the profitability of a company? Remember best performers face brutal facts. Much of the work we carry out every day in maintaining our plant and equipment is accepted by all without question – “that’s the way it has always been carried out” thus implying it must be the correct and the best way. Black Swans in Maintenance and Industrial AI: Predicting the Unpredictable? Analyze your data, find trends, and act on them fast, Explore the tools that can supercharge your CMMS, For optimizing maintenance with advanced data and security, For high-powered work, inventory, and report management, For planning and tracking maintenance with confidence, Learn how Fiix helps you maximize the value of your CMMS, Get best practices, helpful videos, and training tools, How a leader in the oil industry used Fiix to slash inventory costs, Discover guides full of practical insights and tools, Read how other maintenance teams are using Fiix, Get the latest maintenance news, tricks, and techniques.

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