The use of recorded information

1. Adjust PM task intervals & PM tasks • Assess desirability of additional PM tasks • Eliminate unnecessary (over intensive) PM tasks • Improve failure response • Redesign and Design In order to This is a continuous process! The use of recorded information to improve OEE, reliability, safely, at lowest cost by assessing: • Failure Data • Inspection findings

2. The functions of a CMMS knowledge base 1. To determine the types of failures the equipment is actually exposed to as well as their frequencies 2. To expose the consequences of each failure, ranging from direct safety hazards through serious operational consequences, high repair costs, long out-of-service times for repair, to a deferred need to correct inexpensive functional failures 3. To confirm that functions originally classified as evident (during RCM analysis) are in fact evident to operating personnel during the normal performance of duties 4. To identify the circumstances of failure in order to determine whether the failure occurred during normal operation or was due to some external factor (accidental damage) 5. To confirm that on-condition (CBM) inspections arereally measuring the reduction in resistance to a particular failure mode 6. To inform us of the actual rates of reduction in failure resistance in order that we may determine optimum inspection intervals

3. The Purpose of a Reliability-Centered Knowledge Base 7. To record the mechanism involved in certain failure modes in order to identify new forms of on-condition inspection (CBM) or parts that require design improvement, or improve diagnostic response. 8. To identify those tasks assigned originally as default actions but that do not prove applicable and effective 9. To identify maintenance packages that are generating few trouble reports and are candidates for longer interval schedules 10. To identify items that are not generating trouble reports 11. To record the working ages of assets and components at which failures occur In summary, the purpose of a Reliability-Centered Knowledge Base is to use all of the above to IMPROVE ASSET OEE AT LOWEST COST, SAFELY

4. The UML Context Diagram Unified Modeling Language

5. Data model

6. Use Case Diagram - Complete the work order form

7. The UML use case diagram • Simplified guidelines and training document, • Accessible examples, • Supervision, discussion • Support, • Evolving failure codes , • Revision and Audit capabilty

8. UML sequence diagram

9. Overlap of 142 Failure modes Failure modes “experienced” (LRUs primarily) 727 Field Experience Anticipated vs. Actual Experience • Compared failure modes in FMEA to those encountered in the field • Turbofan Engine Failure modes “anticipated” Extracted from CaseBank study published in IEEE Paper “Comparison of FMEA and Field Experience for a Turbofan Engine with Application to Case-Based Reasoning” 610 FMEA

10. ABB Real-TPI Incident 1 Function, Failure, Cause, Effects, Consequences IVARA EXP SpotLight CBR Improved maintenance policies OSISoft PI Incident 2 Function, Failure, Cause, Effects, Consequences Etc… EXAKT DLI ExpertAlert … Incident “n” KPI Quality Loss Machine Malfunction Process Linked to RCKB

11. Reliability terminology • f(t) is the probability density function(PDF). • F(t) is the cumulative distribution function (CDF) It is the area under the f(t) curve from 0 to t.. (Sometimes called unreliability or the cumulative probability of failure.) • R(t) is the survival function. (Also called the reliability function.) R(t) = 1-F(t) • h(t) is the hazard function(At various times called the hazard rate, conditional failure rate, instantaneous failure probability, instantaneous failure rate, failure rate, the inverse of failure resistance, failure risk, and risk.) h(t) = f(t)/R(t) • MTTF is the average time to failure. (Also called the mean time to failure, expected time to failure, average life.) MTTF = =

12. The effects of gradual improvement 0.4 June – August 1964 0.3 August – Oct. 1964 Conditional probability of failure for 100 hour intervals 0.2 Oct. – December 1964 0.1 January – Feb. 1966 May – July 1967 October – December 1971 0 4000 6000 8000 2000 Operating age since last shop visit (flight hours)

13. Questions • What is the optimum reliability state? • How quickly can we achieve the optimum reliability state? • What actions do we take to accelerate the process? and • How do we measure our progress to that end?

14. Decreasing failure rate 2.0 1.0 0.9 0.8 0.7 Failure rate (failures per 1000 hours) Experience 0.6 0.5 0.4 0.3 Date of forecast Forecast 0.2 0.1 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 Operating age since last shop visit (flight hours)

15. Analysis of unanticipated failures Analysis of results of scheduled tasks RCM default decisions made in the absence of information Refining the maintenance program

16. Improvement thru analysis No other way

17. Total failures FF,PF Potential failures PF Functional failures FF 0.4 0.3 Conditional probabilty of failure for 200 hour intervals 0.2 0.1 0 2000 3000 4000 1000 Operating age since last shop visit (flight hours)

18. Total failures Verified failures Unverified failures Failure mode C Failure mode B Infant mortality Failure mode A Conditional probability of failure Working age

19. CBM Effectiveness Comparison b CBM effectiveness is related, ultimately, to how "good" the condition data is.

20. Elimination of CBM 10 Start of borescope inspection, 125-cycle intervals Inspection interval reduced to 30 cycles Modification started Number of functional failures/quarter Modification completed 5 Inspection requirement removed 0 1971 1972 1973 Calendar quarters

21. 4 Acquiring Maintenance Information Using living RCM software

22. MIMS – small mod, big impact

23. Event type • FF - the ending and renewal of a component (failure mode) due to a functional failure • PF - the ending and renewal of a component (failure mode) due to having detected a potential failure in time to avoid the more dire consequences of a FF. • S - the ending and renewal of a component (failure mode) for any reason other than (functional or potential) failure. (For example preventively replacing the component.) • B - the beginning of the life of a component in the item (if not FF, PF, or S) • BSA - the beginning of a period of temporary removal (suspended animation) of a component from the item. • ESA - the return of the same component to the item after a period of suspended animation • SA - the beginning and ending of a period of suspended animation if reported on the same work order. • MR - the minor (non-rejuvinating) repair of the item. It does not renew any components. Sometimes it will impact the monitored data. For example, a calibration, a shaft alignment, an oil change, the balancing of an impeller, and so on.

24. Creating the Events table with Living RCM • Generate a report of all work orders related to the item during the sample period. • Update each work order with the significant failure mode(s) and event type • Generate the Events table using the CMMS report writer and feed it to the LRCM software. • Perform reliability analysis (e.g. Pareto, Weibull, Jackknife, EXAKT)

25. A policy agent? CBM Databases (vibration, oil analysis, control system historian) The “right” decisions CMMS and Process Databases (events, failures, replacements, minor repairs, mission requirements …) Agent

26. Decision ICHM 20/20 Agent Accelerometer Unbalanced rotor Drive Tee Ramp Spring Spring Switch Ramp Tee The demonstration Click for movie

27. 6 Deciding on CBM • Least costly • Least intrusive • Least tolerant of failure Preferred policy for 3 reasons - it is often the strategy that is the: RCM Guide

28. Decision Function Failed state Cause Effects Conseq Task • Training • Training resources Cause Effects Conseq Task Planning (one time) Cause Effects • Procurement • Stocking • Lead times • Purchasing decisions Failed state Scheduling one time Cause Effects • Labor • Skills Yearly Sched. Function Failed state • Parts • Consumables • Outside services Quarterly Sched. Monthly Sched. • Task: tools, materials, safety procedures • Task: tools, materials, safety procedures • Tools • Test equip Analysis Resourcing 1 2 3 4 5 6, 7 Equipment

29. The RCM decision algorithm favors CBM