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How do you use reliability engineering for facility risk?

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Reliability engineering is a discipline that aims to improve the performance and safety of systems and processes by reducing the probability and consequences of failures. In facilities engineering, reliability engineering can help you manage the risks associated with operating and maintaining complex and critical facilities, such as power plants, hospitals, airports, or industrial plants. In this article, you will learn how to use reliability engineering for facility risk in six steps.

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1 Define the scope

The first step is to define the scope of your reliability engineering project. This means identifying the facility or system that you want to analyze, the objectives and criteria that you want to achieve, the stakeholders and customers that you want to satisfy, and the resources and constraints that you have to work with. Defining the scope will help you focus your efforts and communicate your expectations to others.

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Kleber Siqueira

Owner and Principal Consultant
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Defining a reliability engineering project's scope is foundational. It involves specifying the facility or system, objectives, stakeholders, resources, and constraints. This step is crucial in new asset design, guiding investors after risk analysis. Assets in operation evolve over time, requiring a strategic asset management plan (ISO 55000). Establishing a high-level asset management organization is vital, especially for safety and environmental priorities.

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2 Identify the failure modes

The second step is to identify the failure modes of your facility or system. A failure mode is a way that something can go wrong or fail to perform as expected. You can use various methods to identify the failure modes, such as brainstorming, checklists, historical data, expert opinions, or fault tree analysis. Identifying the failure modes will help you understand the potential problems and hazards that you have to prevent or mitigate.

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Kleber Siqueira

Owner and Principal Consultant
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To enhance asset performance in operation, prioritize those with potential performance gaps. Apply the RCM approach, following standards like SAE JA-1011 and SAE JA-1012. Initially, assemble a team of experienced operators and maintainers, guided by an RCM Facilitator. They'll create a structured analysis, similar to FMEA, listing asset functions, functional failures, failure modes, and their effects. This foundational data forms the basis for selecting reliability strategies tailored to the asset under review. It's crucial to establish appropriate analysis boundaries, neither too broad nor overly detailed.

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3 Assess the failure effects

The third step is to assess the failure effects of your facility or system. A failure effect is the impact or consequence of a failure mode on the performance, safety, or availability of your facility or system. You can use various methods to assess the failure effects, such as risk matrix, failure mode and effects analysis (FMEA), reliability block diagram (RBD), or event tree analysis. Assessing the failure effects will help you prioritize the most critical and severe failure modes that you have to address.

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Kleber Siqueira

Owner and Principal Consultant
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Accurate description of failure mode effects is vital for assessing risks and consequences. This information is instrumental in crafting a reliability strategy to preempt, mitigate, or eliminate potential risks. It's essential to factor in total downtime, not just repair time, when evaluating the impact of failures.

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Thilaga Raj

Engineer-Reliability Rotating at Shell
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A comprehensive failure effect should encompass the following aspects: 1. When the failure mode (FM) is most likely to occur. 2. The frequency of occurrence if no preventive measures are taken. 3. Evidence indicating the occurrence of the failure. 4. The potential threats posed to safety or the environment. 5. Impact on production processes. 6. Physical damages resulting from the failure. 7. Any secondary damages caused by the failure. 8. The revenue loss incurred due to the failure. 9. Steps required to repair the failure.

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4 Determine the failure causes

The fourth step is to determine the failure causes of your facility or system. A failure cause is the root or underlying reason that leads to a failure mode. You can use various methods to determine the failure causes, such as fishbone diagram, 5 whys, Pareto analysis, or root cause analysis. Determining the failure causes will help you identify the factors and variables that you have to control or influence to prevent or reduce failures.

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5 Implement the failure solutions

The fifth step is to implement the failure solutions for your facility or system. A failure solution is a corrective or preventive action that aims to eliminate, reduce, or compensate for a failure mode or cause. You can use various methods to implement the failure solutions, such as design for reliability (DFR), reliability-centered maintenance (RCM), failure reporting and corrective action system (FRACAS), or reliability growth testing (RGT). Implementing the failure solutions will help you improve the reliability and reduce the risk of your facility or system.

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6 Monitor and improve the reliability

The sixth step is to monitor and improve the reliability of your facility or system. This means measuring and evaluating the performance and reliability indicators of your facility or system, such as failure rate, availability, downtime, or cost of failures. You can use various methods to monitor and improve the reliability, such as reliability testing, reliability modeling, reliability data analysis, or reliability optimization. Monitoring and improving the reliability will help you verify the effectiveness of your failure solutions and identify new opportunities for improvement.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Jason Strahan

Superintendent of Improvement at Nyrstar
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Look at what has the most impact on your organization. Utilize a risk matrix and find out your regulatory and statutory requirements. Once you know the impact, reduce risk by prioritizing value added efforts

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How do you use reliability engineering for facility risk?

1

2

3

4

5

6

7

1 Define the scope

2 Identify the failure modes

3 Assess the failure effects

4 Determine the failure causes

5 Implement the failure solutions

6 Monitor and improve the reliability

7 Here’s what else to consider

Facilities Engineering

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How do you use reliability engineering for facility risk?

1

2

3

4

5

6

7

1 Define the scope

2 Identify the failure modes

3 Assess the failure effects

4 Determine the failure causes

5 Implement the failure solutions

6 Monitor and improve the reliability

7 Here’s what else to consider

Facilities Engineering

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