DEVELOPMENT AND DESIGN

R&M PLANNING

Activities associated with the R&M planning stage include:

1. Conduct process concept review.

2. Identify design effects for other related equipment (automation, integration, processing, etc.).

3. Standardize fault diagnostics (controls, software, interfaces, level of diagnosis, etc.).

4. Develop R&M/PM plan (process/machinery FMEA, mechanical/electrical derating, materials compatibility, thermal analyses, finite element analysis to support machine condition signature analysis, R&M predictions , R&M simulations, design for maintainability, etc.).

5. Establish R&M/PM testing requirements (burn-in testing, voltage cycling, probability ratio sequential testing, design of experiments for process optimization, environmental stress screening, life testing, test-analyze-fix, etc.).

At this point it is important to ask and answer these questions: Does the R&M plan address each project target? Is the R&M plan sufficient to meet project targets?

PROCESS DESIGN FOR R&M

Activities associated with the process design for R&M stage include:

1. Conduct process design review.

2. Develop process flow chart.

3. Develop process simulation model.

4. Conduct process design simulation for multiple scenarios by analyzing operational effects of various R&M design trade-offs.

5. Develop life cycle costing analysis on process-related equipment.

6. Review process FMEA.

7. Complete final process review and simultaneous engineering team input.

At this point it is important to ask and answer this question: Is the process FMEA complete, and have causes of potentially common failure modes been addressed and redesigned?

MACHINERY FMEA DEVELOPMENT

Activities associated with the machinery FMEA development stage include:

1. Develop plant floor computer data collection system (activity tracking, downtime, reliability growth curves).

2. Establish machinery data feedback plan (crisis maintenance, MTBF, MTTR, tool lives, OEE, production report, etc.).

3. Verify completion of machinery FMEA on all critical machinery. Confirm design actions, maintenance burdens, things gone wrong, root cause analyses, etc.

4. Develop fault diagnostic strategy (built in test equipment, rapid problem diagnosis, control measures).

5. Review equipment and material handling layouts (panels, hydro, coolant systems).

At this point it is important to ask and answer these questions: Is the machinery FMEA complete, and have causes of potentially common failure modes been addressed and redesigned? Is the data collection plan complete?

DESIGN REVIEW

Activities associated with the design review stage include:

1. Conduct machinery design review (field history, machinery FMEA, test or build problems, R&M simulation and reliability predictions, maintainability, thermal/mechanical/electrical analyses, etc.).

2. Provide R&M requirements to tier two suppliers (levels, root cause analyses, standardized component applications, testing, etc.).

At this point it is important to ask and answer this question: Have the R&M plan requirements been incorporated in the machinery design?