Manufacturing Optimisation

Reliability & Maintenance

Prof. Tim. C. Claypole.
School of Engineering.

Tim. C. Claypole.

Principal Areas That May

Contribute To Reliability

Design

Manufacture

Operation

Maintenance

Tim. C. Claypole.

Reliability

Assumes
Initial Performance > Desired Performance
Otherwise fails immediately!

Failure

Performance < Desired Performance

Tim. C. Claypole.

Failure could be:

Lack of function
Manufacturing tolerances
Inadequate performance

Tim. C. Claypole.

Accessing Risk of Failure

Failure Mode and Effect Analysis

Considers individual components
In what ways can the component fail
How does the failure effect the performance

Fault Tree Analysis (FTA)

Looks at possible modes of failure
Identifies what combination of events is
required to produce failure

Tim. C. Claypole.

Sources of System
Information

Experience (direct and related)

Tests, Simulation and Confirmation

Most Accurate
Most Costly
Testing elements cheaper than testing whole
More basic the component, less valid
Results increasingly out of context

Analysis

Least accurate
Can direct testing to make it more effective

Tim. C. Claypole.

Failure Mode and Effect

Analysis (FMEA)

Applied to:
Design
Process
Planning
Maintenance (FMECA)

Tim. C. Claypole.

Failure mode, effect and criticality analysis

FMEA consists of specifying

for
each
component:
Failure
mode
How component can fail
Each component may have multiple failure modes
Each failure could have more than one effect

Cause of failure
Effect on system

Safety, downtime, repair etc.

Corrective Actions

Tim. C. Claypole.

Successful FMEA depends on

Expertise of the analyst
Management commitment

Tim. C. Claypole.

Design FMEA
Assumes all parts are correctly
manufactured
Considers only problems associated
with Design or materials specification

Tim. C. Claypole.

Design FMEA

Categories of potential failures

Tolerances beyond capability of the process
Failure to meet customer expectation
Unacceptable service life
Total failures in service
Reduce life due to corrosion
Reasonably foreseeable customer misuse
Problems of installing customers system

Tim. C. Claypole.

Current Status
t No.
ame
sue

Function or
process

Failure
Mode

Effect of
Failure

Cause of
Failure

Current
Controls

OCC

SEV

DET

RPN

1234
tom
cket
ue A

To provide
engine front
support

Buckling
failure of
bracket
vertical walls

Engine drop
(cooling fan
fouls
radiator)

Incorrectly
specified
material
thickness

Stress
Report
SR100

72

Test to TR
150

Tim. C. Claypole.

Corrosion

Gradual loss
of strength
leading to
structural
failure

Service
loads in
excess of
design loads

Not yet
established

288

Inadequate
protective
treatment
specified

Protective
treatment
& salt
spray tests
are
specified
TR 150

32

Status
Rating of 1 (lowest) to 10 (most severe)
OCC - occurrence
SEV - severity
DET - detection
RPN - Risk Priority Number

=(OCC)*(SEV)*(DET)
Highlights priorities
Estimate new RPN to justify actions

Tim. C. Claypole.

Current Status

Revised Status

t No.
ame
sue

Failure
Mode

Effect of
Failure

Cause of
Failure

OCC

SEV

DET

RPN

Recommended
Corrective
Action

Action Taken

OCC

SEV

DET

RPN

1234
tom
cket
ue A

Buckling
failure of
bracket
vertical walls

Engine drop
(cooling fan
fouls
radiator)

Incorrectly
specified
material
thickness

72

Tests to be carried
out to TR 150 to
verify stress
report SR 100

Tests to specified
load proves
adequate static
strength

32

Service
loads in
excess of
design loads

288

Verification by
road load
data/ test bed
required &
drawing controls
established

Road load/ test

data confirms
design loads are
satisfactory

48

Inadequate
protective
treatment
specified

32

Installation to be
reviewed after
road and
laboratory tests

Laboratory &
Road tests were
carried out & no
corrosion was
evident

32

Corrosion

Gradual loss
of strength
leading to
structural
failure

Tim. C. Claypole.

Process FMEA
Assumes product design is correct
Analyses failures due to planning or
operation deficiencies

Tim. C. Claypole.

Considers each stage of the

process
Acquisition of materials
Machine setting
Machining/Assembly
Handling
Inspection
Despatch

Tim. C. Claypole.

Failures due to:

Provision of incorrect material
Equipment errors
Operator errors
Contamination
Housekeeping
Handling damage

Tim. C. Claypole.

Current Status
t No.
ame
sue

Function
or process

Failure
Mode

Effect of
Failure

Cause of
Failure

Current
Controls

OCC

1234
tom
cket
ue A

Drill holes

Holes out of
position

Difficult assy
of engine
mounting

Incorrect
location in
drill fixture

Operator &
Inspection
measurement
with vernier
on frequency
basis

Drill holes

Holes
undersize

Unable to
assemble to
engine

Incorrect drill
size used

Operator &
inspection
check with
plug gauge

Form
bracket

Incorrect
grade of
material used

Structural
failure

Poor raw
material
identification
& storage

Operator
local
knowledge

Tim. C. Claypole.

SE
V

DET

RPN

210

18

432

Current Status
t No.
ame
sue

Function
or process

Cause of
Failure

Current
Controls

OCC

1234
tom
cket
ue A

Drill holes

Incorrect
location in
drill fixture

Operator &
Inspection
measurement
with vernier
on frequency
basis

Drill holes

Incorrect drill
size used

Operator &
inspection
check with
plug gauge

Form
bracket

Poor raw
material
identification
& storage

Operator
local
knowledge

Tim. C. Claypole.

SE
V

Revised Status

DET

RPN

Recommended
Corrective
Action

Action Taken

OCC

SEV

DET

RPN

210

Positive location
on fixture & final
acceptance gauge

Fixture location
modified &
acceptance gauge
in use

28

18

First off check &

use of acceptance
gauge

Recommended
actions
implemented

12

432

Identify raw
material location
racks and colour
coding

Recommended
actions
implemented

144

Design or Process FMEA

Function or process
Failure mode
Effect of Failure
Cause of Failure
Current Controls
Current Status

OCC
SEV
DET
RPN

Tim. C. Claypole.

Recommended
corrective action
Action taken
Revised Status

OCC
SEV
DET
RPN

Fault Tree Analysis

Begins with list of hazards or undesired
events
Works backwards to develop list of
causes and origins of failures
Can be used with probability data to
access risk

Tim. C. Claypole.

Fault trees consist of

branches connected by nodes
AND - all events below node must
occur for the event above the
node to occur
OR - at least one of the events
below must occur for the event
above to occur

Tim. C. Claypole.

FTA of a brake

Cant stop!

Faulty
Master
Cylinder

Low brake fluid

Worn pads
Fluid leak

Broken
pipe
Tim. C. Claypole.

Leaking Cylinder
Loose Bleed

Example of and
Lever wont retract

No
lubricant

Tim. C. Claypole.

Weak
Springs

Do companies look after their company cars as well

as they look after their equipment?

Company car Eu 20 k Web press Eu 4 million = Equivalent 200 cars

Tim. C. Claypole.

Why Maintain?

Reliability and Availability

Customer Demands

Shorter run lengths

Shorter lead times
Consistent Quality
JIT delivery

Return on capital investment

Higher production speeds

More lost production per minute!

Less spare capacity

Tim. C. Claypole.

Men and machines

Despair or maintenance strategy?

Spiral of breakdown dispair
1: Production loss from breakdowns
& low productivity
2: Equipment worked harder to recover
lost production
3: Breakdowns increase & more time is lost
4: Increased production pressure reduces
maintenance time even further

Tim. C. Claypole.

Maintenance Costs

Expenditure in the EU approaching 5% of total

manufacturing turnover
an annual spend of between 85billion and
110billion
equivalent to the total annual industrial output of
Holland

Around 2 million people in 350,000 companies

were engaged in maintenance activities

Tim. C. Claypole.

Works Management(1991)

UK maintenance spending
5% of annual sales turnover
Twice UK trade deficit
Three times the value of new plant
investment
18% of book value

Tim. C. Claypole.

In diesel engines 70% of in service failures are due to

contamination of which 50% are due to wear related
problems
Approx 40% of rolling element bearings fail due to
improper lubrication only 10% fail at normal fatigue
limit

Tim. C. Claypole.

Courtesy of Shell

75% of gear failures are due to service problems

Incorrect lubrication
Foreign material
Corrosion
Bearing failure
Inadequate maintenance
Continuous or shock overloading

51% were wear related 49% overload related

Tim. C. Claypole.

Courtesy of Shell

What Is Failure?
A gear box operating in a continuous process plant production
line
The Safety Office

The Production Manager

Calls for immediate shut-down

Maintenance staff can carry out an inspection at the next shut down

The Maintenance Engineer

Requests brief stoppage of production to check the oil level. He will

also continue to closely monitor the condition over the next twentyfour hours

When will it be dealt with?

Tim. C. Claypole.

Evolution of maintenance
Industrial maintenance parallels health care development
Period

Strategy

1930s

Breakdown Heart attack

Large budget, fix it when broken

1950s

Preventive

By-pass surgery

Periodic component replacement

1970s

Predictive

Disease detection

Condition monitoring, fix early

1980s

Pro-active

Cholesterol & blood

pressure monitoring
Root cause diet control

Performance monitoring
Contamination control
TPM (Total Productive Maintenance)

Tim. C. Claypole.

Human health care

Machine care

Maintenance Strategies
Breakdown
Restorative
Preventative
Condition

Monitoring
Pro-active
Tim. C. Claypole.

Strategy depends on:

Life
Impact on process
Detectability

Tim. C. Claypole.

Failure Consequences
Hidden failures
Safety and Environmental
Operational

Tim. C. Claypole.

Hidden failures

Not apparent to operators

Protective devices which do not fail safe

In themselves harmless
Can leave organisation expose to
potential catastrophe
Risk must be eliminated or minimised

If the failure doesnt have a consequence,

then what is the purpose of the part?

Tim. C. Claypole.

Safety and Environmental

Does the failure maim or kill?
Does it damage the environment
If Yes, then risk must be eliminated or
minimised

Tim. C. Claypole.

Operational Consequences

Economic decision
Loss of productivity
Loss of quality
Loss of service

Non operational Consequences

e.g. Pump failure

Stand by takes over
How long to repair?
How long is the organisation exposed to risk?

Tim. C. Claypole.

Breakdown maintenance

Repair or replace on failure

Light bulb approach

Doesnt need planning

just response procedure

Failure must have no HSE implications

How long does it take to repair?

Tim. C. Claypole.

Cost of breakdown maintenance

Loss of availability

High spares inventory

or need to maintain surplus capacity

or long down times

Need to maintain a breakdown crew

or long down time

Tim. C. Claypole.

Preventative maintenance

Change components before they fail

Planned shutdown

automotive oil change

can be integrated into work schedule

Avoids breakdowns

provided interval between component

replacement correctly calculated

Tim. C. Claypole.

For age related performance:

Initial Performance

Performance

Performance of system
Failure

Desired
Performance

Time
Tim. C. Claypole.

Age Related Failure

Progressive Failure with time

e.g. wear

Tim. C. Claypole.

of Failure

Probability

Probability of Failure Bathtub curve

Time

Tim. C. Claypole.

Regions of Bathtub curve

Initial

failures

Burn

in or infant mortality

Constant

risk

Slightly

rising probability
Normal operating region
Wear

out

Replacement

Tim. C. Claypole.

zone

Age related failures in civil

aircraft systems
4% follow bath tub curve
2% follow bath tub curve without section
1 (burn in)
5% follow section 2 only with a steady
increase in probability of failure with time
Only 11% of components show age
related failure

Tim. C. Claypole.

Probability of Failure Non age related

of Failure

Probability

Tim. C. Claypole.

Time

Non age related failure curves

Probability
7%

of systems on civil aircraft

Constant
14%

failure rate

of systems on civil aircraft

Probability
68%

Tim. C. Claypole.

rises to a constant level

fall to a constant level

of systems on civil aircraft

89% of components on civil aircraft

have non age related failures
Why?

Multiple modes of failure

More complex the units - more modes of
failure
Computers follow curve 3

Tim. C. Claypole.

initial high risk falls to constant risk

Cost of preventative maintenance

Never achieve full life of components

Over frequent replacement is throwing

money away

May not improve reliability

civil aircraft or computers

Tim. C. Claypole.

Condition Monitoring
- extraction of information from
machines to indicate their condition

Tim. C. Claypole.

Condition monitoring
Detect faults early when time & cost
to corrective is lowest

Temperature / Vibration / Oil condition / Power consumption

Tim. C. Claypole.

Condition-based Maintenance
Principal Requirements:

DETECTION

DIAGNOSIS

Onset of change from benign to active

mode
type, severity and location

DETERMINATION

what to do and when

Tim. C. Claypole.

Four basic methods

Performance monitoring
Vibration monitoring
Visual

including thermography and sensual monitoring

Lubricant monitoring
condition
chemical composition
wear debris

Tim. C. Claypole.

Performance monitoring

Pumps

Presses

pressure and power consumption

power consumption

Monitoring your utilities bill

Is the consumption excessive or increased

Tim. C. Claypole.

Vibration Monitoring

Misalignment

Looseness

gear mesh frequency

Oil whirl :

a peak at shaft speed

Gear damage

typically 1x, 2x and 3x shaft speed

Imbalance

a peak at shaft speed

between 0.42x and 0.46x shaft speed

Rolling element bearings :

high frequency (envelope analysis, kurtosis, shock pulse or spike energy)

Tim. C. Claypole.

Thermal imaging

NEC Thermo Tracer

TH7102

General thermal traces

-200C to 2500C
Hot spots in systems
Influence of cooling,
drying etc ..

Condition monitoring

Hot bearing
Failing systems

Tim. C. Claypole.

Lubricant Analysis
Lubricant properties :
Form a fluid film between loaded surfaces
Act as a coolant
Carry away contaminants (solid, liquid
and gaseous)
Act as a hydraulic medium
Protect against rust and corrosion

Tim. C. Claypole.

Simple Sensory Tests

Tim. C. Claypole.

COST
COSTBENEFIT
BENEFITANALYSES
ANALYSES
Case
Casestudy
study11
1992
1992--US
USAir
AirForce
Forceoil
oilanalysis
analysisprogram
program
reported
reported190
190serious
seriousproblems
problemsin
inaircraft
aircraftcomponents
components
prior
priorto
tofailure.
failure.Five
Fivefindings
findingsresulted
resultedin
inremoval
removalof
of
engines
enginesfrom
fromF-16
F-16aircraft
aircraftprior
priorto
toserious
seriousengine
engine
damage
damage--total
totalcost
costavoidance:
avoidance:$15,000,000.
$15,000,000.
Case
Casestudy
study22
US
USnavy
navyoil
oilanalysis
analysisevaluation
evaluationconcluded
concludedthat
that
just
justthree
threeaircraft
aircraftsystems
systemsresulted
resultedin
inaareturn
returnon
on
investment
investmentof
ofmore
morethan
than178%
178%over
overoil
oilmonitoring
monitoring
costs
costs

Tim. C. Claypole.

Wear And Wear Debris Characteristics

Size Distribution
Re-entrained
Wear Debris

W
U1
U2

Foreign Debris
(Contaminated)

SEM
Elemental Analysis
Composition
Material

Tim. C. Claypole.

Wear and Debris

Production Rate
(concentration)_

Wear Debris
Morphology vs.
Wear Mode

Severe Sliding Scuffing

Pitting Fatigue

Pitting
Fatigue

Time

Idealised Representation Of Wear Progression

Wear Debris
Production
Rate

Active Wear
(decreasing)

Reactive
Zone

Proactive Zone
Trend monitoring
and diagnostic
capability

Reactive
Zone

Diagnostic capability
requirement
Benign Wear

Active Wear
(increasing)
Time

OIL & WEAR DEBRIS ANALYSIS

Trend Monitoring: Detection and measurement of wear products
Diagnosis: Oil Analysis
Morphological analysis of wear products

Tim. C. Claypole.

Particle Features Vs. Wear Characteristics

Tim. C. Claypole.

Spectrographic oil analysis

Monitoring traces of chemical composition

Source can be identified

e.g. copper from bearing surfaces

deterioration related to increased traces
important if lubricant circulates around several surfaces

Used by

Municipal bus operators

North sea oil rigs

Tim. C. Claypole.

Courtesy Swansea Laboratory Services

Magnetic Detector Plug

Wipes

Tim. C. Claypole.

Representative Debris - RB 199 Engine

Tim. C. Claypole.

Wear Particle Morphological

Descriptors
Particle
Type

Description

Mild or
Rubbing

Particles < 20 mm chord dimension and approx. 1 mm thick. Results

from flaking of pieces from the shear-mixed layer

Cutting

Swarf-life chips of fine wire coils. Cause by abrasive cutting tool

action

Laminar

Thin, bright, free metal particles, typically 1mm thick, 20 50 mm

chord width, with holes in surface and even edge profile emanates
from mainly gear/rolling element bearing wear, associated with
fatigue action

Fatigue

Chunky, several microns thick; e.g., 20 50 mm chord width

Spheres

Typically ferrous, 1 > 50 mm diameter; generated from micro-cracks

under rolling contact conditions

Severe
Sliding

Large, 50 mm chord width, several microns thick. Surface heavily

striated with long straight edges. Typically occurs in gear wear.

Tim. C. Claypole.

Pro-active maintenence

Identifying and eliminating causes of

failure
similar to FMEA
e.g. rather than monitor a bearing for wear
caused by ingression of contaminating
particles, eliminate the contamination
before it causes wear

Tim. C. Claypole.

Cost of maintenance

Item and consequential damage

Downtime by unscheduled failure

Early replacement

Periodic component replacement

Monitor

Production loss
Maintenance team on stand by

Cost of equipment

Monitoring

Personnel, training etc.

Tim. C. Claypole.

Changing maintenance profile

Tim. C. Claypole.

Maintenance Strategy
For each element strategy depends on:
Life
Failure Consequences

Hidden failures

Not detected but organisation exposed

Safety and Environmental

Economic consequences

Loss of productivity
Loss of quality
Loss of service

Tim. C. Claypole.

Operational Consequences

Economic decision
Loss of productivity
Loss of quality
Loss of service

Non operational Consequences

e.g. Pump failure

Stand by takes over
How long to repair?
How long is the organisation exposed to risk?

Tim. C. Claypole.

Benefits of Maintenance
Programme
Less unplanned stops

More aware of equipment performance

and capability
More frequently use non OEM consumables
Know which spares to have in stock

Maintenance adapted to suite diverse

operational demands

Tim. C. Claypole.

Companies with
Maintenance System
Run faster
Press Speed
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

<25
25 - 40
40 - 60
60 - 70
70 - 80
80 - 90
90 - 100
Maintenance System

Tim. C. Claypole.

All

Which came first?

Speed or
Maintenance

Long Break down (>shift)

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

Never
1 per year
1 per quarter
1 per month
1 per week

Maintenance System

Tim. C. Claypole.

All

Short stoppages (10 min to 3 hours)

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

1 per year
1 per quarter
1 per month
1 per week
Everyday

Maintenance System

Tim. C. Claypole.

All

Monitor Machine Sensors

Something goes wrong

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

External service
Once a week by
maintenance
Once a shift by
maintenance
Once a shift by operator
Maintenance
System

Tim. C. Claypole.

All

Continuously

Follow Manufacturers Maintenance Procedures

70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
None

Some

Maintenance System

Tim. C. Claypole.

Procedures
precisely
All

Sheet fed

Do more

Replace Parts
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%

When breaks
Output declines
Inspection
Supplier recommended

Maintenance
System

Tim. C. Claypole.

All

Tim. C. Claypole.

In order of most
importance
Stock key parts

Monitor KPI

Match tasks to skill

Very High

Involve departments

40%

External suppliers

High

Staff training & tools

50%

Top down prority

Low

Standard procedure

60%

Publish checklists

Very low

Part of production

Matching tasks
to skill level important
100%
90%

80%

70%

30%

20%

10%

0%

Top priorities for maintenance

Maintenance as an integrated activity

Management System

Plan as part of production

Top down priority
Publish check lists
Standard procedures

Operator Involved Maintenance (OIM)

Staff training and tools

Matching tasks to skill levels

Tim. C. Claypole.

Successful Maintenance Programme

Maintenance as an integrated activity

Management System

Driven by need to improve whole process

Ensure we all use the best method

Operator Involved Maintenance (OIM)

Commitment and involvement from top to

bottom

Tim. C. Claypole.