Abstract
The Reliability Approach is often seen as something only engineers and specialized technicians understand and practice. This is a common misconception among line supervisors who might think it doesn’t concern them. However, this couldn’t be further from the truth. This paper explores why these Reliability Principles are relevant and beneficial in any industry, anywhere, at any time. Read on to discover their universal applicability and importance.
Understanding the Principles of Reliability
The Reliability Approach is a systematic method focused on maintaining efficient and profitable plant operations. It goes beyond Preventive/Predictive Maintenance (PPM) tasks like oiling machines or checking for hot bearings, aiming instead to create an integrated system of human beings, equipment, and processes that works for the optimum benefit of all.
Maintenance alone cannot address design deficiencies or operating deficiencies; it can only react to the results of these problems, such as breakdowns or loss of components like bearings, turbine wheels, or heat exchanger tubes. The Reliability Approach seeks to integrate these elements into an efficient system, ensuring continuous operation.
We need to shift our focus from merely preventing breakdowns to asking, “How are we going to keep it running?” This proactive mindset is akin to a winning team strategy, rather than one that struggles to avoid losing. In plant operations, this approach can predict trends and trouble spots, enabling us to address primary failures, such as an overheated bearing or a pitted heat exchanger tube, before they lead to secondary failures, like the loss of shafts or wheels, or the rupture of heat exchanger tubes.
The Role of Line Supervisors
Line supervisors are crucial to the success of the Reliability Approach. They oversee the day-to-day operations, observe system performance, note any deviations, and take immediate action. Their insights and corrective suggestions are vital for the system’s effectiveness.
Key Factors in the Reliability Approach
- Process
- Process reliability has a significant impact on the plant’s profitability, environmental integrity, safety performance, and loss performance. Line supervisors ensure the reliability of equipment and people to meet plant performance targets. By comparing actual performance to targets, supervisors can adjust processes for improvement, and provide feedback.
- Equipment
- Line supervisors focus on both the reliability and maintainability of equipment. Reliability concerns the rate of equipment failure, while maintainability involves the time required to restore operation after a failure. Supervisors can improve equipment reliability by providing information on failures and suggesting ways to reduce them. Early detection of issues can prevent catastrophic failures.
- People
- People are the most critical factor. They design, operate, and monitor plants and processes, and their actions significantly impact success. Human errors often cause process interruptions, but these can be mitigated through proper training, motivation, and addressing factors like job stress and workplace conditions. Supervisors should place people where they can be most productive and satisfied, ensuring their questions and suggestions are valued. Respect for their contributions and proper placement can greatly enhance performance.
Participating in the Reliability Approach
Plant management will develop programs based on the Reliability Approach, tailored to specific plant needs. These programs may include:
- Prediction of mechanical failures
- Root cause analysis
- Plant data collection
- Data processing and data analysis
- Organizing for performance improvement
- Application of ergonomics (human factors engineering)
Supervisors and their teams can contribute by:
- Routinely inspecting critical equipment.
- Noting and reporting trends in equipment failure and operating difficulties.
- Conducting routine inspections.
- Reporting unusual noises, machinery overheating, or suspicious conditions.
- Avoiding the philosophy of “If it’s not broken, don’t inspect it.”
- Contributing to root cause investigations.
- Reporting issues with redundant alarms, equipment access, and poorly designed gauges and instruments.
- Addressing lighting, temperature extremes, dust and noise, and other worker stress factors.
- Ensuring plant data collection and feedback are accurate and actionable.
- Suggesting improvements in equipment, instructions, and procedures.
Ultimately, the most important responsibility is ensuring that people are properly trained to perform their jobs safely and efficiently. Both injured persons and broken machines represent failures in the system.
By embracing the Reliability Approach, line supervisors and their teams can make significant contributions to their plant’s success, ensuring continuous, reliable, and efficient operations.