What are the best ways to identify reliability issues in the design process?

System modeling through reliability block diagrams and Starting with RCM during the design stage should ensure a bottom line to guarantee reliability issues free design. Also integrating the history of failures of similar systems in the new design can also enhance the reliability in design and RCM process further

Julgo importante realizar estudos do tipo RCM/FMEA para identificar todos os modos de falha e suas causas, estabelecendo a??es preventivas baseadas neste estudo.

The ultimate goal for anyone managing assets is to ensure that the assets run as designed. This could mean no failures and or less downtime planned or unplanned. Reliability in design is the cheapest way to achieve a good result. The use of a relatively block diagram to understand the expectation of the system is a great baseline. Using approved equipment list for design that standardizes new assets based on achieved reliability results, asset strategies and inventory is a great way to start. Proper operational procedures for startups, shutdowns and operations is also part of the design. Performing a Bretby analysis will help design the equipment that makes asset’s easier and faster to maintain reducing the downtime.

Nessa caso o RCM é indicado. A fun??o de Manuten??o Centrada na Confiabilidade (RCM) é identificar as fun??es dos equipamentos, avaliar os modos de falha e determinar estratégias de manuten??o para otimizar a confiabilidade operacional, a seguran?a e a eficiência. A importancia está em priorizar a??es de manuten??o com base no impacto dos falhas, buscando a eficiência dos recursos e maximizando o tempo de opera??o dos sistemas.

Gathered failure information from operation log, anomalies report, CMSS and Incident Report Conduct reliability statistical analysis to understand failure pattern, contributing factors, reliability classifications. Perform deep dive analysis and determine top 5 contributors. Assign relevant failure modes for categorization. Based on the observation and team's discussion, pinpoint reliability layers that have been breached. Determine the correction and corrective action for each flaw found in reliability layers. Steward the follow ups and recalculate statistical reliability analysis.

This is also the stage where you identify single points of failure within the system and suggest or choose the optimal sparing for the process equipment for example 1oo2, 1oo3, 2x50% etc

Aqui s?o implementados métodos qualitativos de solu??o de problema. As ferramentas da qualidade s?o indicadas também nesta etapa, sendo elas, pareto, histograma, folha de verifica??o.

Neste passo os métodos quantitativos podem ser empregados, como análise de dados de vida, RCA, análise de regress?o dentre algumas modelagens.

Para monitorar desempenho uma ferramenta importante é o controle estatístico de processo, onde se consegue identificar causas especiais e tratar antes que falhas severas ocorram.

In my experience, Consider applying reliability centered maintenance RCM study during the design phase for an efficient evaluation of system and equipment reliability. 1. Use a holistic approach by combining data collection, expert input, and maintenance records for a comprehensive reliability assessment. 2. Gather data on failures from operational records and corrective maintenance from SAP to assess reliability issues. 3. Seek expert opinions on the system to understand various perspectives on reliability. 4. RCM Failure modes analysis.

O RCM e FMEA s?o mapeados contramedidas para evitar que as falhas ocorram. Monitorar e utilizar as cartas de controle, bem como check de indicadores e padroniza??o com documentos e treinamentos s?o essenciais.

Mechanical packaging for electronics is critical. Also, the manufacturing process requires ESS screening to weed out solder joint issues.

Perform a Reliability and Availability Management (RAM) Analysis on the design to determine if it aligns with the business’s reliability and availability targets. Following the assessment, pinpoint the causual factors that impacting the target and carry out sensitivity analyses with various design options. This will help us pinpoint a design that is both cost-efficient and suitable for the process.

It is really depends. What is the business goal of the project. Short term which is on schedule on budget or long term which we need to have reliable operations? Leader need to decide this since beginning, so the knowledge of existing operations and maintainance can be blend into a solid project goal, which in my view for long term reliable operation. There is a lot intens to optimize the cost, any cost including good cost which some reliability improvement will come from ; where sometimes reliability analysis we calculate is not enough to justify or can be ignored.