Failure is not an option: Traditional Maintenance is also not an option
3 Golden rules:
- All machines degrade in many ways over time while most machines suffer from infant mortality.
- The cause of all degradations is ‘unfavourable’ energy flows and interactions
- Degradations may be monitored, slowed down and/or eliminated
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 Reliability Improvement and Sustaining it:
- Detecting the factors of deterioration
- Slowing down the ageing or deterioration process
- Maintaining a system near quasi-static equilibrium state
3 Methods of Management:
- Measure Energy Flows
- Quantify degradations, its effects and its duration in probabilistic terms.
- Improve structure that facilitates energy flows to slow down degradation to desirable levels.
3 Organisational Capabilities to achieve Excellence:
- Innovation culture
- Information and Work flow
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