Maint Speak Reliability Engineering

What is reliability engineering?

Reliability engineering is the analysis of plant maintenance work and the creation of efficient maintenance planning systems which reduce the amount of breakdown work and increase the amount of completed planned maintenance work.

Plant Reliability analysis allows the maintenance team to see where improvements are needed and where the team is improving. Allows maintenance teams to see the quality and integrity of their data, allows the company to see where they stand in their industry comparable with other plants similar to theirs. Plant Reliability Analysis drives improvement and thus efficiency and economy. Plant Reliability Analysis SAVES YOU MONEY.

Loosing production time? Find out why and fix it, get reliable!

First in the world, powerful, easy to use proactive maintenance method.

Plant Reliability analysis is an easy to use and yet powerful, proactive maintenance engineering method, which can identify potential failure modes, determine their effect on the maintenance costs, and identify actions to mitigate the failures.

The Covaris plant reliability FMEA (failure modes and effect analysis) is a quick approach, which analyses the corrective maintenance work orders from a maintenance system. It captures work orders from the Computerised Maintenance Management System (CMMS) and allocates selected work orders to defined failure modes. It also specifies, what equipment is affected by a selected failure mode, what is the total cost of the work, and what is the total amount of labour hours spent on work for each particular failure mode. This exercise is performed by analysing historic data collected by the CMMS and includes all assets captured in the system

FMEA is an effective engineering tool for analysing data from maintenance systems. The FMEA is used to identify failure modes of the maintainable equipment and the effects of these failures. FMEA analysis can be used to specify the areas where improvements can have substantial impact.

Plant reliability analysis can tell you how many hours you are spending on a particular failure mode and how much money you are spending.

Waiting for your next breakdown? Don’t wait, prevent, get reliable now!

Failing to plan maintenance is planning to fail your plant. get reliable

The principal elements of the Maintspeak Reliability Engineering software are:

• Load up tool of CMMS data, eg plant dictionary (equipment listings, location listings, asset cost information), PM
data (procedures, tasks and operations, schedules) and stores (inventory, bins and stores, spare parts
allocations, bill of materials/kit lists)
• Analysis of the plant dictionary – check for retired plant, integrity of the hierarchies and equipment allocations,
and completeness of asset information
• Failure modes and effects analysis (FMEA) – this is a comprehensive analysis capability to study failure modes
determined from reactive maintenance work order history, the costs and equipment impacted, and the time
trend in failure histories
• PM Operations and Schedule – two major areas of functionality which advise on the engineering strategy
underlying the preventative maintenance program plus the forward 18 month schedule of resources and
equipment access
• Backlog analysis – a technique used to determine what work orders can be cancelled from the back log due to
appropriate criteria such that they have aged past the point that more recently completed work on the relevant
equipment should have addressed the original requirements
• Spare parts analysis – based on issue and return transactions, this analysis identifies slow moving stock,
obsolete stock and will advise on recommended min/max holdings of inventory
• KPI reporting – a graphics module to plot a broad range of issues and performance criteria over time, across
plant to identify where risk is associated

Power of Analysis

• They tell you that maintenance is at best practice but you know something is wrong – how do you find the
problem and then prove it?
• The whole factory seems to be in breakdown mode and you need to find a way to get some early wins and
then improve the place over time.
• You have invested a lot in your maintenance system and you need to find out how things are travelling.
• You need to manage your contractors but you don’t need a confrontation – You need agreement on where
to improve.
… and if you find a problem out there, how do you start fixing it – is it maintenance, is it production, is it the machine design …

… in its first year of operation Maintspeak has analysed over thirty sites across
many types of maintenance management systems at a low cost, and its
effectiveness is improving all the time …

What has Maintspeak done for Other People?

• Identified why things are breaking down and how often – it reported our wins and it reported our problems.
• Clearly showed where our PMs are wrong, inadequate or need improvement.
• Quantified the problems we are having with operator set-ups, use of the machine or the cleaning.
• Justified where capital works were needed and what was the cost saving to be targeted from the investment.

How do you Fix the Problem?

• Identify the critical equipment and why it is failing.
• Evaluate the PM strategies – are they working.
• Find issues with operational set-up and use of the machine.
• Recommend what has to be done to the PMs, to the set-up and use and where the problems are driven by the
machine design.

Why Trust It?

• We are using the words your people use to define work so that they can start actually doing it – if your people
can understand what they write then so can we.
• If we understand the work being done, then we can measure the reliability of assets and determine what is
going wrong.
• We do not rely on special codes and data – we do not ask your people to operate at best practice in the use of
the system.
• 1 in 10 sites have been rejected as having inadequate data – only 1 in 10 sites thought they had adequate data.