How can you enhance system reliability through engineering practices?

While redundancy is an excellent tool for enhancing system reliability, it is important to consider the economic cost. Implementing redundancy can be expensive, so it must be done strategically. For instance, if your system can tolerate a downtime of 30 seconds, then redundancy might not be necessary and could result in an unjustified extra expense. However, if your application is mission-critical and needs to be online 100% of the time, redundancy becomes an invaluable tool.

Whilst the initial setup of maintenance strategies should be based on the OEM recommendations it is crucial to monitor component life once an item has been removed prior to failure. If your observations are that there is still potential life left then a comparison of LCC life versus Demonstrated life needs to be defined. Using this method it is possible to extend the life and therefore reduce operating cost over the life of the equipment. One such example is the measurement of wear versus an hourly replacement strategy.

Agree 100%, you need to put in place a preventative maintenance system for your assets from when you acquire them to ensure they perform to the levels required and achieve or exceed their useful life cycle. You ideally need a CMMS to maintain the discipline.

Regular maintenance plays a pivotal role in bolstering system reliability within engineering practices. In recent project I oversaw, implementing a robust maintenance schedule significantly contributed to enhancing system reliability. By conducting scheduled checks and preemptively replacing worn components, we averted potential breakdowns and ensured uninterrupted operation of critical systems. This proactive approach not only prolonged the lifespan of our equipment but also minimized the risk of unexpected failures, thereby enhancing overall system reliability. By adhering to a well-planned maintenance regimen tailored to the specific needs of our systems, we were able to instill confidence in the reliability of our engineering solutions.

Implementing stringent quality control measures serves as a cornerstone for enhancing system reliability in engineering practices. In a recent project I managed, we emphasized quality control to ensure system reliability. Through meticulous testing and inspection, we scrutinized components for defects early in manufacturing. This proactive approach enabled prompt issue rectification, minimizing operational disruptions. Upholding uncompromising quality standards instilled confidence in our engineering solutions.

A closed loop Failure reporting and corrective action system aka FRACAS is the right approach. This ensure you issue is track from identifying them, providing appropriate containment till issue is getting resolved, solving the issue by conducting RCA, validating its effectiveness and implementing across your site. Continuing the process all through the product life leads you develop more reliable solution/ products. You get clear feedback for developing new system/solution as 1-mission profile 2- operator behaviours 3- User experience 4- ease out and improve your maintenance

During the the FEED stage, conduct A. Reliability, Availability & Maintainability (RAM) Study by a third party specialist consultant. B. Corrosion Management Plan study & C. Detailed Material Selection study by qualified metallurgists