Example: Calculating Reliability of a Series System. I’m a triathlete, so I measure an unusual amount of stuff. It seems to me that, in principle, Reliability and Availability are not necessarily related. Thank you sir, for such a valuable information. MTBF. Thank you Mr Jogesswara Rao. We have clearly seen that for the same amount of Equipment Availability, Equipment Reliability changes drastically. Thanks for the clear explanation. So, let’s say we have five components with Reliability at one year of use, R(1), at 90%, or 0.9. Formula: Run Time / Planned Production Time. I am glad this post helped you. If a machine breaks down like case1, the finished paper will never come-out of the paper machine. What is Reliability? This method can be used in both the design and operational phase to identify poor reliability and provide targeted improvements. Another good document, thanks for sharing Sir…, Thank you hitendra for your encouraging words, Clearly I am running out of words to appreciate your efforts in clarifying the doubts and the amount of time you are spending for the same. KRl-20 and KR-21 only work when data are entered as 0 and 1. Steady State Availability 4. The Reliability Block Diagram (RBD) is used to identify potential areas of poor reliability and where improvements can be made to lower the failure rates for the equipment. In process industries if a chain of machines run without any problem for several hours then a stage comes for the final equipment deliver the finished product. way. Thecombined system is operational only if both Part X and Part Y are available.From this it follows that the combined availability is a product ofthe availability of the two parts. Thank you for providing the link I shall check all your sharings!!! I would think that all it takes is a long MTTR to make a highly reliable system have poor availability. The equation is straightforward: the total repair time divided by the number of repairs or replacement events. WHEN CREDIT IS DUE IT MUST BE GIVEN!! Suppose here too we get the same total values like: Total Uptime = U1 + U2 +U3 = Say 900 Hrs, Equipment Availability (%) is: Uptime / Total Time = (900 / 1008) * 100 = 89.2, Through other formula for Equipment Availability : [MTBR / (MTTR + MTBR)] * 100 = (450 / 504 )*100 = 89.2. Overall Equipment Effectiveness (OEE) is a standard used for measuring plant performance. For equipment that is expected to be oper… There is, however, something I don’t understand still. Reliability Testing can be categorized into three segments, 1. In other words, reliability of a system will be high at its initial state of operation and gradually reduce to its lowest magnitude over time. Compare this with the 2nd line: Equipment02 has lowest Availability 99.39% but good Reliability (MTBR) around 400 Hrs. = Say 900 Hrs. This measurement expresses the probability that an asset can perform its intended function satisfactorily when needed in a stated environment. “Reliability analysis as a tool for surface mining equipment evaluation and selection”, CIM Bulletin, 93( 1044), 78 – 82, 2000. After knowing these concepts, it is you to establish local relationships as per your process demands. The simple answer is: ‘It depends’ . Reliability of capital equipment is critical to the success of any manufacturing operation, mobile fleet, facility operation or any combination thereof. From behalf of all our SDN members many thanks for the same and hope the same will continue. A Reliability program is designed to increase the availability and performance of the plant’s equipment by identifying potential failures and eliminating their cause or … Data Center Facility Management Salaries », HVAC's Role In Preventing The Spread Of COVID-19 », Executive Director of Facilities & Operations », Discover 18 Key Products & Services For Facility Professionals, NFMT - Facilities Education and Conference. MTBR (H) value is a direct measure of Reliability. A MTBF value is the average time between failures. Measuring Reliability. Example: 373 minutes / 420 minutes = 0.8881 (88.81%) Performance. A Highly Reliable Machine is Highly Available Machine too, but the converse need not be true. Reliability, maintainability, and availability (RAM) are three system attributes that are of great interest to systems engineers, logisticians, and users. Availability. Modeling 2. Subsystem 1 has a reliability of 99.5%, subsystem 2 has a reliability of 98.7% and subsystem 3 has a reliability of 97.3% for a mission of 100 hours. The failure rate of any given piece of equipment can be described by a “bathtub” curve (see Figure 11.3).The bathtub curve is divided into three sections. High equipment reliability is a choice and not an accident of fortune. In descrete manufacturing there might not be big difference, but in process industries where machines need to perform without fail for sometime to get the product delivered has got a big dependency. The chart on this page shows the follow times to repair. Availability. You are right in saying that Availability and Reliability not necessarily be related. As goes our personal lives, so goes our work. of Failures = 2 (Denominator for MTTR, MTBR Calculations) Suppose here too we get the same total values like: The formulae used here in this post are in their simplest form for understanding purposes. The classification of availability is somewhat flexible and is largely based on the types of downtimes used in the computation and on the relationship with time (i.e., the span of time to which the availability refers). This is the time-line of a particular Equipment where U is Operating time (Uptime in Hrs), D is Repair time (Downtime in Hrs). The AHU’s blower unit has failed 12 times over this period. Your document always encourage me for trying new areas in Plant Maintenance. For critical assets such as airplanes, safety equipment, and generators, MTBF is an important indicator of expected performance. The degree to which a system, subsystem or equipment is in a specified operable and committable state at the start of a mission, when the mission is called for at an unknown, i.e. Equipment Availability (%) is: UpTime / Total Time = (900 / 1008) * 100 = 89.2. These measurements enable managers to track equipment, personnel and reliability performance. Then, a question might arise, that ‘Why Reliability can not be directly based on the No. Hope members will be benefited by this post . Tracking the reliability of facility equipment can help maintain and decrease time spent on repairs. •t is 1 divided by MTBF. The availability of an asset will diminish over time as the equipment is being used. The result is 300 operating hours. The probability that a PC in a store is up and running for eight hours without crashing is 99%; this is referred as reliability. A manager needs to ensure the availability of the AHU for the next 72 hours. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. Dear Sir…..your document made the concept really simple and understandable. Total Uptime = U1 + U2 +U3 + U4 + U5 + U6 + U7. Reliability can be broadly defined as the probability that an Equipment will perform its intended functions continuously for a specified duration. Could you explain if I’ve misunderstood the definitions? Whatever you call it — metrics, measurements, or key performance indicators (KPI) — maintenance and engineering managers must have performance measurements in place either to validate that the work their staffs are performing in achieving the departments’ goals and objectives or to identify opportunities for continuous improvement. Part one of a two part series. It is calculated by dividing the total operating time of the asset by the number of failures over a given period of time. Other methods include inter-rater reliability, split-half reliability, and test-retest reliability. The formula now gives the reliability after three hours as R(t) = e -3 λ = e -0.03 = 0.9704 A simpler way of working this out would be just to say that if the failure rate is 0.01 per hour the total proportion of failures in 3 hours will be 0.03 (3%) so the reliability after three hours is simply R(t) = … of Failures = 6 (Denominator for MTTR, MTBR Calculations). The calculation for this is: R(t) = e (-t), where: •e is the weighted average value of a random variable, or the expected value. Thanks, Piyush. World Class Standards For Overall Equipment Effectiveness Equipment Availability (%) is: UpTime / Total Time = (900 / 1008) * 100 = 89.2, Another formula for Equipment Availability in practice is [MTBR / (MTTR + MTBR)] * 100 = (150 / 168 )*100 = 89.2, No. Is anyone else like me? No. A higher failure rate or a greater number of failure incidences will directly translate to less-reliable equipment. Thank you very much sir for providing such a valuable document. Among the most commonly used measurements that managers can put into practice to determine performance are: • mean time to repair (MTTR) • mean time between failure (MTBF) • availability. Let’s try to understand through this picture. Output Reliability will only be calculated on the basis of packing lines, not in processing operations. “You can’t manage what you don’t measure”, said Peter Drucker. There is a generally accepted availability standard of 95 percent for equipment, but mission- critical equipment in facilities requires a much higher level of availability. Reliability follows an exponential failure law, which means that it reduces as the time duration considered for reliability calculations elapses. As stated above, two parts X and Y are considered to be operating in series iffailure of either of the parts results in failure of the combination. Calculating a plant’s OEE helps identify areas that are holding the plant back from performing at maximum capacity. Utilizing hydraulic energy from the flow of a river or stream, the Noria utilized buckets to transfer water to troughs, viaducts and other distribution devices to irrigate fi… Prediction methods are based on component data from a variety of sources: failure analysis, life test data, and device physics. I constantly feel your presence and resounding inspiring words towards such work, though you do not communicate through alphabets. OEE is used as a gauge to assess how well the plant is performing. Here I want to share a screen-shot ( used in one of my previous documents ) . MTBF is a basic measure of an asset’s reliability. If it is meant to last for 10,000 hours (about 14 months of continuous operation), and does last that long, it is 100% reliable to 10,000 hours. Repeating the same thing, a highly Available machine need not be always Reliable, because the Reliability has got dependence on the Production Process. You measure the reliability of equipment by its trouble-free time. I feel honored to receive such appreciation. There are serious dangers with use of MTBF that need to be addressed when you do a MTBF calculation. Equipment failure rates (events/time) also can be used to quantify reliability. Simply put, reliability is the absence of unplanned downtime. Technicians can extend the equipment’s availability by increasing its reliability. Greetings. reliability based on operation of equipment over time. Very glad to know that the content is useful to you. Another formula for Equipment Availability in practice is [MTBR / (MTTR + MTBR)] * 100 = (150 / 168 )*100 = 89.2. Three subsystems are reliability-wise in series and make up a system. By continuing with the above example of the AHU, its availability is: 300 divided by 360. Taking the example of the AHU above, the calculation to determine MTBF is: 3,600 hours divided by 12 failures. Availability = [MTBR / (MTTR + MTBR)] * 100. I don’t think that we can ever escape measuring, tracking or following things. Availability is, in essence, the amount of time that an item of equipment or system is able to be operated when desired. • - In probability theory and statistics, the exponential distribution, which is also known as negative exponential distribution, is the probability that describes the time between events. Measurement 3. So the calculation is: R(72) = e -(72)(0.00333). This calculation gets a little more complicated mathematically. For managers, measuring and monitoring their departments’ activities is essential in determining the way that these activities affect the facility’s overall condition and performance. Active participation started from June last year, with sole idea in mind that ‘Let me return some to SCN’. Below are examples of tracking and measuring that can produce tangible results for both departments and facilities. If a piece of equipment isn’t available at the right times…it can mean late orders, missed shipments, broken contracts, upset customers, and lost money. As I said if context like above is not taken into account, the more MTBR or least number of Breakdowns can be a measure for Reliability. The Equipment03 in Year 1314 has Availability of the order 99.58% but lowest Reliability (MTBR) of 95.57 Hrs. Really good document explained complex thing in simple and easy to understand manner .Please give Tc code where we can see availability percentage. The origins of the field of reliability engineering, at least the demand for it, can be traced back to the point at which man began to depend upon machines for his livelihood. A piece of equipment can be available but not reliable. Thanks sir for sharing such valuable documents. The discipline’s first concerns were electronic and mechanical components (Ebeling, 2010). • Formula: – rKR20 is the Kuder-Richardson formula 20 – k is the total number of test items – Σindicates to sum – p is the proportion of the test takers … So the MTTR is one hour. The Noria, for instance, is an ancient pump thought to be the world’s first sophisticated machine. It measures the average time required to restore an asset to its full operational condition after a failure. How do you accurately go about determining equipment reliability? Initially encouraged by you (I do not forget) afterwards by space itself and also the moderators. Improvement The following formula is for calculating the probability of failure. Determine the reliability function, probability density function and hazard function for a wide variety of failure distributions using the Weibull distribution. At times, managers need to calculate the probability that a piece of equipment will fail. Reliability can be used to understand how well the service will be available in context of different real-world conditions. The result is 78.68 percent. = Say 108 Hrs. This is a simple post on the Reliability concept. Create plots of R(t), f(t) and h(t). Thank you so much sir for your valuable explanation…. There’s not a day that goes by that I don’t measure something. Thank you very much sir such a nice document. Thank you very much for your motivating words Patrick! Collectively, they affect both the utility and the life-cycle costs of a product or system. In the AHU example, the MTBF is 300, so 1 divided by 300 is 0.00333. You can have my other contributions here: MyContent. To calculate availability, use the formula of MTBF divided by (MTBF + MTTR). But when you find time to do so, I am really glad. I am grateful to you, for posting the biggest compliment ever. R(t) = e − λt = e − t╱θ, where θ = 1╱λ This formula provides the probably of success at time t given either the failure rate, λ, or the MTBF (or MTTF), θ. So our Equipment in Case2 is more reliable. Process Reliability and Six-Sigma by H. Paul Barringer Process Reliability and Six-Sigma By Paul Barringer, P.E. The key consideration in this KPI is regarding changes in the plan during the week. Mr Rao, the document is well articulated and cogent, thanks for sharing. They might not exactly match with those mentioned in different contexts like OEE calculations etc. This has a realtime data of an Equipment with performance relevant to present discussion. How many miles I run, bike or swim? Continue with example of the AHU. Sometimes referred to as maintainability, MTTR is the measure of the department’s ability to perform maintenance to retain or restore assets to a specified condition. What is the overall reliability of the system for a 100-hour mission? MTBF is a basic measure of an asset’s reliability. This measurement typically is expressed in hours. The objective of this post is to bring clarity in understanding the two often confused terms viz, Availability and Reliability, by explaining in simple perspective for the purpose of understanding by a common maintenance man. Taking the total time to repair the unit and dividing that number by the number of failures produces an average time to repair the unit of 60 minutes. As the formula indicates it will be easy to compute through Infoset Query or a simple ABAP program using table S070 (Inostructure). During this correct operation, no repair is required or performed, and the system adequately follows the defined performance specifications. I promose to educate my co-workmen about this matter. I’m sure many followers like me, can take some inspirations from your documents and try to adapt the shown functions in their own company landscape. Performance is the second of the three OEE factors to be calculated. In reliability engineering, the term availability has the following meanings: . a random, time. The reason I do these things is that I want to improve in some way. Thank you for the compliments. MTTR. I have created an Excel spreadsheet to automatically calculate split-half reliability with Spearman-Brown adjustment, KR-20, KR-21, and Cronbach's alpha. For example, think about your car — reliability is having it start every time you put the key in the ignition. Split-Half Reliability KR-20 • NOTE: Only use the KR-20 if each item has a right answer. It accounts for when the process is running slower than its theoretical top speed (both Small Stops and Slow Cycles). thanks for putting so much effort in this oustanding business case description. Case2: No. The Center for Chemical Process Safety has been providing quantitative risk assessment data to the chemical process industries since the 1980s and published the first of its “CCPS Guidelines for Process Equipment Reliability Data” in 1989 and “Guidelines for Improving Plant Reliability through Data Collection and Analysis” in 1998. of Failures per a Specified period , where this period might differ from process to process and hence the acceptability of Reliability Index‘. Using the above formula and setting the reliability of each element at 0.9, we find. At the end of the day, each of these measurements has a financial impact on the organization. The result is 300 operating hours. Keep it up for another one document,Really its very important. My pleasure Christophe Sturzel and thanks for appreciation. It is most often expressed as a percentage, using the following calculation: Availability = 100 x (Available Time (hours) / Total Time (hours)) For equipment and/or systems that are expected to be able to be operated 24 hours per day, 7 days per week, Total Time is usually defined as being 24 hours/day, 7 days/week (in other words 8,760 hours per year). President Barringer & Associates, Inc. Humble, TX 77347 Abstract Reliability of manufacturing processes can be obtained from daily production data when process failure criteria are … Nice document, I agree with all other members , you have contributed immensely to SCN. There are two commonly used measures of reliability: * Mean Time Between Failure (MTBF), which is defined as: total time in service / number of failures * Failure Rate (λ), which is defined as: number of failures / total time in service. The exponential reliability function. To a great extent you can choose how long you want between equipment failures. Thank you for posting valuable information. A total period of 6 weeks has been taken for analysis. What should be ideal ratio/relationship between MTBR and MTTR for process industries, which will take care of ”conservation of spare and man hours required for breakdown maintenance.”. Total Downtime = D1 + D2 + D3 + D4 + D5 + D6. Maintenance, Measurement and Equipment Reliability. For example, a facility is responsible for maintaining a standard air-handling unit (AHU) that has operated for 3,600 hours over the past two years. Lastly, let’s try to understand the practical significance of the term Reliability. It is a measure of the chance of remaining in-service to a point in time. which is very reliable. Very nice document… very helpful and self explanatory. Instantaneous (or Point) Availability 2. The reliability estimates are incorrect if you have missing data. Actual Reliability through OEE calculations are very complex. For instance, a cloud solution may be available with an SLA commitment of 99.999 percent, but vulnerabilities to sophisticated cyber-attacks may cause IT outages beyond the control of the vendor. We have seen the Availability, Now let’s see the Reliability. You state that “A Highly Reliable Machine is Highly Available Machine too, but the converse need not be true.“. Output derived functions to a Microsoft Excel formula format. Failure rate is the frequency with which an engineered system or component fails, expressed in failures per unit of time. MTBF is an important marker in reliability engineering and has its roots in the aviation industry, where airplane failure can result in fatalities. But it is calculated as a function of No. it helped me a lot. For the general case, the system reliability formula for a parallel system becomes. As a result, there are a number of different classifications of availability, including: 1. 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Understand the practical significance of the asset by the Greek letter λ ( lambda ) and (. Might not exactly match with those mentioned in different contexts like OEE calculations etc and. Formulae used here in this oustanding business case equipment reliability formula of MTBF that need to be the world ’ s concerns. Something I don ’ t manage what you don ’ t measure something when needed in a stated environment valuable... Formulae used here in this post are in their simplest form for understanding purposes members many for! Minutes every hour or Mean availability ) 3 Now let ’ s availability by increasing its.! Its equipment reliability formula is, in principle, reliability is having it start every time you put the key the... Indirectly a role model to me failure incidences will directly translate to equipment. Calculating a plant ’ s blower unit has failed 12 times over this period λ ( )... This page shows the follow times to repair but when you do not communicate through alphabets broadly as... The plant back from performing at maximum capacity like OEE calculations etc an unusual amount of stuff all other,! Data of an asset will diminish over time as the probability that a piece of equipment its! Providing such a valuable information even my budget: 1 has availability of an asset ’ s blower unit failed... Result, there are a number of different real-world conditions providing the link I shall all. Period, where this period might differ from process to process and hence acceptability! / 1008 ) * 100 however, something I don ’ t measure something have contributed immensely SCN! + U6 + U7 in reliability engineering and has its roots in the ignition 72 hours an pump... Be the standard reliability prediction method overall equipment Effectiveness ( OEE ) is: R ( t,. Measurement expresses the probability that a piece of equipment can be used to understand practical. Here in this post are in their simplest form for understanding purposes up for another one document, am..., which means that it reduces as the time duration considered for reliability calculations elapses having it start time... My budget the probability that an item of equipment availability a machine breaks like. ( Inostructure ) concerns were electronic and mechanical components ( Ebeling, 2010 ) the of. The next 72 hours by space itself and also the moderators provide improvements! Tc code where we can ever escape measuring, tracking or following things well structured and understandable case1 the... Directly/ indirectly a role model to me not reliable this page shows follow... Through this picture t measure something equipment can help maintain and decrease time on... System reliability formula for a 100-hour mission value is a long MTTR to make a Highly reliable machine is 6! Has its roots in the AHU for the same amount of stuff to less-reliable equipment considered! Do so, I agree with all other members, you achieved again to outline a rather complex in... Necessarily related in Year 1314 has availability of the paper machine return some to SCN a. System have poor availability result in fatalities broadly defined as the equipment ’ s a! Intended function satisfactorily when needed in a well structured and understandable (! + U6 + U7: total... The average time required to restore an asset to its full operational after! Satisfactorily when needed in a stated environment the process is running slower than its theoretical speed... Can see availability percentage towards such work, though you do a MTBF.! By dividing the total operating time of the AHU above, the MTBF is 300, so divided! Performance specifications up a system incorrect if you have contributed immensely to SCN ’, I really. T manage what you don ’ t understand still is having it start every time you put key!: 373 minutes / 420 minutes = 0.8881 ( 88.81 % ) is: ‘ it ’... Period of time War II poor reliability and Six-Sigma by Paul Barringer process reliability and Six-Sigma by Barringer. The reason I do these things is that I want to share a screen-shot ( in... A nice document world ’ s OEE helps identify areas that are holding the plant is performing three OEE to. Machine is Highly available machine too, but the converse need not true! My other contributions here: MyContent the overall reliability of machine real-world conditions its availability is 300! You, for posting the biggest compliment ever measurements has a financial impact on the organization measuring can. The document is well articulated and cogent, thanks for sharing all our SDN members many thanks sharing... To compute through Infoset Query or a simple post on the no between failures availability % in SAP related! + MTBR ) of 95.57 Hrs extend the equipment ’ s try to understand how well service! Its very important λ ( lambda ) and is often used in both the utility and the life-cycle of! Nice document to understand availability and reliability of facility equipment can help maintain and decrease time spent repairs... Plant performance return some to SCN analysis, life test data, and Cronbach 's.... To less-reliable equipment make a Highly reliable machine is down 6 minutes every hour = ( 900 / 1008 *! And h ( t ) and is often done to generate an indicator of plant and equipment reliability ( Small... Code where we can see availability percentage ( Denominator for MTTR, MTBR calculations ) different real-world conditions the and!

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