Availability P +61 (0) 402 731 563 F +61 (8) 9457 8642 E info@liftim-rliability.com How Asst aintnanc Stratgy Slction Affcts Dfct Elimination, Failur Prvntion and Equipmnt Rliability ABSTRACT: Th 20 th Cntury saw maintnanc stratgy volv from corrctiv, prdictiv and prvntiv maintnanc to rliability maximization. During th 21 st cntury maintnanc will disappar and b rplacd with risk-fr oprations whr no failurs occur. Th first stps takn by LRS Consultants toward building risk-fr businsss and risklss oprational procsss was thir invntion of th Plant Wllnss Way systm-of-rliability mthodology. Kywords: dfct limination, failur prvntion, risk-fr maintnanc stratgy Th failur pyramid shown in Figur 1 cam from rsarch into quipmnt rliability don nar th nd of th Twntith Cntury. As shown in Figur 2 for procss plant oprations, in th 20 th Cntury maintnanc stratgy volvd from rpairing to maximizing plant rliability and availability. Dfct and Failur Cost Surg 1 10 losss 6,500 rpairs Sourc: Ldt, Winston., Th anufacturing Gam, Ldt Entrpriss Inc., 2002 20,000 dfcts Figur 1 Th Equipmnt Failur Pyramid 100% Rliability + Prcision + Dfct Elimination A Prvntiv + Prdictiv + Planning and Schduling (IPOSSIBLE) 80% Ractiv (IPOSSIBLE) aintnanc Cost Figur 2 aintnanc Stratgy Dirctly Influncs Availability and aintnanc Cost B C:\Usrs\usr\Documnts\LRS\LRS thodology\how-maintnanc-stratgy-affcts-dfct-limination-quipmnt-rliability.docx
P +61 (0) 402 731 563 F +61 (8) 9457 8642 E info@liftim-rliability.com Each maintnanc and rliability stratgy usd in th Twntith Cntury had a clar purpos of addrssing a particular lvl of th failur pyramid, as notd of Figur 3. Dfct and Failur Cost Surg 1 10 losss 6,500 rpairs 20,000 dfcts istaks, Errors, Inaccuracis Figur 3 Th Causs Fding th Dfcts at th Bottom of th Failur Pyramid Fding th dfcts that caus plant maintnanc, rpairs and production failurs ar thir original mistaks, rrors and inaccuracis. At th start of th Twnty First Cntury th Plant Wllnss Way systm-of-rliability was invntd to maximis businss succss and profits by prvnting th xistnc of rrors. PWW stops mistaks, faults and inaccuracis from bing mad at vry stag of th ntrpris physical asst lif cycl. From concption, through fasibility, dtaild dsign, manufactur, warhousing, construction and opration th chanc of an rror or flaw is prvntd. Unlik dfct limination stratgy, PWW dsigns and builds rliability into procsss so dfcts that caus failurs cannot happn. You prvnt th possibility of failur by having no opportunity of a dfct. It rquirs that you gt ahad of a dfct and into th dfct cration vnts and situations and stop mistaks, rrors and inaccuracis from occurring that caus th dfct and its latr failur. Figur 4 is a modifid concpt dvlopd by Paul B. Pric, a Rliability Consultant and Condition onitoring Spcialist from th Unitd Kingdom for grading condition monitoring rsults. It shows how ach lvl in an organisation carris oprating and businss risks from th risks xprincd by its physical assts assmblis and parts. Each individual componnt gts its risks from th condition of its matrial of construction microstructur and thos risks transfr upwards through th businss. Th Plant Wllnss Way rcognizs this dpndncy hirarchy of risk xtnding from th oprating strsss and local nvironmnt affcting a componnt s microstructur, such as halthy lubricant, corrct lubricant film thicknss, propr intrfrnc fit btwn mating parts, trunss of componnt shap, finnss of surfac finish, subsurfac strss lvls, adquat load distribution, and so on, through to a catastrophic failur of th plant. Evry quipmnt failur can b tracd back to what was don to its componnts matrials of construction during thir liftims. Figur 4 shows ths dpndncy links btwn an initial Physics of Failur mchanism through to th componnt, subassmbly, assmbly, parnt asst, oprating procss, and, finally, throughout th businss systm. Th stat of halth at ach lvl of th hirarchy immdiatly causs risks at that lvl which can bcom problms in thos lvls abov it. Ultimatly, th rliability of vry physical asst, and C:\Usrs\usr\Documnts\LRS\LRS thodology\how-maintnanc-stratgy-affcts-dfct-limination-quipmnt-rliability.docx
pon Assmbly pon pon pon Asst Assmbly pon pon pon Assmbly pon Organizational BUSINESS Procss pon pon Assmbly pon icrostructur pon pon Asst Assmbly pon pon pon Assmbly pon pon P +61 (0) 402 731 563 F +61 (8) 9457 8642 E info@liftim-rliability.com th subsqunt risks thy caus to a businss, dpnds on how wll you liminat and prvnt th causs of Physics of Failur mchanisms throughout its parts lif cycls. Organizational BUSINESS RCFA Procss Ractiv + Corrctiv Asst Prvntiv + Prdictiv Assmbly Dfct Elimination ponnt PWW Failur Prvntion POF chanism icrostructur Sourc: Paul B. Pric, Rliability Consultant and Condition onitoring Spcialist, Unitd Kingdom, 2014 Figur 4 Hirarchy of from ponnt to Organization Last cntury s maintnanc stratgis look at th asst and assmbly lvls of th dpndncy hirarchy for problms. This maks maintnanc inffctiv at prvnting failurs bcaus it allows th ffct of microstructur failur mchanisms to bcom so svr as to b dtctabl in th C:\Usrs\usr\Documnts\LRS\LRS thodology\how-maintnanc-stratgy-affcts-dfct-limination-quipmnt-rliability.docx
World Class Prformanc Availability P +61 (0) 402 731 563 F +61 (8) 9457 8642 E info@liftim-rliability.com bhaviour of th parnt asst. So long as failur mchanisms ar prsnt in quipmnt thy triggr th risk of failur. Only whn thr is no risk at th Physics of Failur mchanism lvl of th dpndncy hirarchy can you nsur an asst has th maximum chanc of xcptionally long liftim rliability rsulting in th last risk of oprating failur and th maximum businss succss. Figurs 5 and 6 show how th Plant Wllnss Way is nginrd to stand sparat to th traditional maintnanc and rliability stratgis of th past. PPW is usd to first dsign a businss so its maintnanc costs start xtrmly low and maks sur it arrivs at world class oprational prformanc xtrmly fast. In th 21 st Cntury vry company can start from whr thy ar today and volv to b a PWW organization. 100% PLANT WELLNESS WAY Lif Cycl Long, Businsswid Systms Focus Rliability + Prcision + Dfct Elimination A Prvntiv + Prdictiv + Planning and Schduling 80% Ractiv aintnanc Cost Figur 5 Plant Wllnss Way Dsigns-in -fr Procsss and Rapid Availability B PLANT WELLNESS WAY Lif Cycl Long, Businss-wid Systms Focus 100% Rliability + Prcision + Dfct Elimination (5 TO 6 YEARS) Prvntiv + Prdictiv + Planning and Schduling (IPOSSIBLE) Ractiv (IPOSSIBLE) 5 Yars to Succss Figur 6 Spd to World Class Prformanc is a Rsult of Asst Lif Cycl Stratgy C:\Usrs\usr\Documnts\LRS\LRS thodology\how-maintnanc-stratgy-affcts-dfct-limination-quipmnt-rliability.docx
P +61 (0) 402 731 563 F +61 (8) 9457 8642 E info@liftim-rliability.com Liftim Rliability Solutions invntd th Plant Wllnss Way bcaus vry industrial company nds world class rliability. PWW is our answr to th qustion: How do you crat rliability? Onc you ask that qustion you soon ralis that you nd to build into companis a risk-fr businss systm of risklss procsss, with a failur prvnting cultur so that thy hav th right framwork to bcom world class oprations. You can find out mor dtails about th Plant Wllnss Way thodology from th plntiful, fr information and tutorials on th LRS Consultants Global wbsit. If you want to gt a full st of th 2015 PWW training cours slids dlivrd to our licnsd PWW Consultants world-wid you can buy th full st of PowrPoint prsntations, with cours book, spradsht tmplats and ducational articls from th onlin stor at wbpag Plant Wllnss Way 5-Day Training Prsntations. ik Sondalini Dirctor www.liftim-rliability.com C:\Usrs\usr\Documnts\LRS\LRS thodology\how-maintnanc-stratgy-affcts-dfct-limination-quipmnt-rliability.docx