How can you design for reliability using reliability engineering principles?

Spent 24 years in direct mechanical reliability positions. In my opinion, while using statistical methods may assist in identifying reliability issues at plants, you need to have knowledgeable and/or eager to learn people with the passion and fortitude to tackle reliability problems in the field. That’s is the fundamental requirement for a successful reliability program. Reliability is certainly not probability!

As It's difficult to completely eliminate all failures, a certain amount of failure should be tolerated. The ability of an item/equipment to perform a required function under specified conditions for a certain time interval as mentioned in its manufacturer's statement notes is referred to as its reliability. What reliability is all about is: - What is the equipment's minimal acceptable failure rate? - How likely is it to perform on demand? Quality is major part of reliability, as high as the quality, high level of integrity is considered. Quality roles started during manufacturering and constructing. Many approaches are considering to garantee the reliability of equipment in operation through regular inspection activities.

I agree with Abdul. Metrics don't define reliability.... they provide information for its deployment in defined areas. The definition above is a discussion point at best, for the use of metrics will pinpoint lifecycles/clues/upgrading of parts to provide a higher reliability in systems and the parts that make them work. Don't use reliability as a means for your next 4-letter report in a Tier Meeting to justify your value to the company. Use reliability to improve all systems in your facility for a longer and fully predictive life cycle.

I agree with some and not all, as MTBF and MTTR will be specific to particular issues and vary dramatically with fleet to fleet and model to model. Also the MTTR will depend on the resource availability, so a actual benchmark of machine performance against OEM in regards to power output at rated design capacity. AVAILABILITY may be used as an the indication of the fleets current condition.

Begin by creating a master/key asset register that includes all equipment, loops, and subsystems. Following that, a failure mode based on the worst-case scenario for each specified item from equipment is assessed. The anticipated consequences and severity of the failure, as well as the likelihood of occurrence, are next identified. Then, each registered item will be assigned a tag level based on its criticality ranking (high, medium, or low). Finally, safeguards and assurance tasks, such as inspection/maintenance program, spare parts availability and redundancy strategy, are established according.

One thing to add to this is again estimation of operational life limits and maintenance intervals through physics of failure analysis is key in estimating reliability metrics, and in corollary the cost aspects as well

By using RBD (Reliability Block Diagram) modelling of a system, we can simulate a system based on defined reliability target. The system reliability analysis is then able to define which equipment in our system is the weakest (bad actor), or define the optimum operational philosophy (by standby/spare units). Furthermore, if we combine RBD and facility throughput (using Monte Carlo or Maros software, etc), it will become RAM analysis. We can define the predicted output of the system and think what we should do to achieve the target (production, injection rate, etc).

In essence reliability testing is divided into 3. 1. Infant mortality failures- detected through ESS/HASS/Burn in testing 2. Random Failures- Detected through Operating limit and Durability testing 3. Wearout Failures- Detected through Stress Testing, ALT and Endurance testing

The fundamental goal of the reliability regular assurance task and inspection is to find failures early on. A sudden breakdown while in operation or on demand could have disastrous consequences. Reliability measures ensure that failures are detected early in the development stage. Replacement and repair plans discussed in advance, including safely shutting down the entire system if necessary, based on the findings and inspection results.

To design for reliability, you can apply principles of reliability engineering, such as identifying potential failure modes, conducting reliability analyses (FMEA, FMECA), selecting appropriate materials and processes, and implementing preventive and predictive maintenance strategies.

Measure it to manage it, because optimization is all about effective management. A solid planning tool is essential to measure, control, and optimize reliability activities. CMMS plays a significant and effective role in planning, organizing, and storing historical data, allowing for extensive optimization. It is also worth noting that adopting condition monitoring tools is quite useful and beneficial. Lube oil analyzers, infrared/thermo-cameras, vibration detectors, drone ultrasonic testers, smart pipe pigging tools, and so on are all considered excellent tools for substantially optimizing and increasing reliability.

When you are in the client's position, it is important to determine what level of performance you are requiring for that system. This needs to be clearly documented, and people in the organization must have those accessible. Many issues the operational sites faces are related to operating/maintaining an equipment beyond the design constrains. It is essential to align the strategy around what the equipment can actually deliver, instead of pursuing unreasonable expectations. What is the OEE, MTBF, MTTR or availability that you require to deliver the expected results? Answering this question can drive effective operational strategy, maintenance requirements, or CAPEX plans (in case the of limitations being found within your current system).