3 Golden rules:
- All machines degrade in many ways over time while most machines suffer from infant mortality.
- The cause of all degradations is ‘resistance’ to energy flows.
- Degradations may be monitored, slowed down and/or eliminated through innovative improvements to improve robustness, resilience and reliability of a machine.
3 Silver rules
- All degradations exhibit random, probabilistic, non-linear exponential behaviour.
- Degradations are interdependent manifestations of changes in energy flows and their interactions.
- Cause(s) and Effect(s) are usually separated by time and/or distance
3 Goals of Innovation:
3 Business Goals:
3 Types of Failure Modes :
- Early Failure Modes — due to stress, strain, pressure, flow, thermal gradients — 3 to 5% of all failures
- Random Failure Modes — related to interactions, balance and feedback loops — 80 to 90% of all failures
- Wear Out Failure Modes — due to tribological imperfections of surfaces, interfaces and materials — 5 to 7% of all failures
3 Methods of Management:
- Measure Energy Flows
- Quantify degradations, its effects and its duration in probabilistic terms.
- Improve design of energy flows to slow down degradation to desirable levels.
3 Steps in Reliability Improvement:
- Monitor, eliminate or slow down failures
- Avoid Consequences of Failures
- Follow a PDCA cycle of improvement
3 Engineering Disciplines:
- Condition Based Maintenance
- Design of Energy Flows