Improved Design for Reliability Designing Maintenance Out of the System F IND Y OUR H IDDEN P LANT

D ESIGN FOR R ELIABILITY IN A CTION

DesignProcuringCommissioningOperatingMaintainingDecommissioningDisposing A SSET L IFE C YCLE

1.Equipment Specifications 2.Performance Clauses 3.Maximize Warranty Coverage DesignProcuringCommissioningOperatingMaintainingDecommissioningDisposing A SSET L IFE C YCLE

S YSTEM D ESIGN & M ANAGEMENT P HASES W HAT IS OUR UNDERSTANDING OF THESE P HASE C OSTS ? Conceptual Design System Planning System Feasibility Analysis Operational Requirements Maintenance Concept Functional Analysis System Specifications Preliminary System Design Identifications of system elements Allocation of Requirements Design synthesis, analysis, and optimization Test and evaluation of engineering and preproduction models Detailed Design and Development Detailed design of prime system elements Detailed design of maintenance and support System integration and test Construction Construction, test, and verification System assessment System modifications for corrective actions System Operation and Support System operation System assessment System upgrades and modifications System decommissioning System disposal

L IFE C YCLE C OSTING Life-cycle costing theory suggests that most of the costs are implicitly determined in the early phases of development despite the fact that the majority of costs of a finished good are generated in later phases such as manufacturing and distribution

L IFE C YCLE C OSTING – D EVELOPING AN U NDERSTANDING * Accumulated Costs Committed Costs Cost Reduction Opportunity Asset System Design & Management Stages Costs Conceptual Design Preliminary System Design Detailed System Design Construc- tion System Operation 10% 66% 85% 95% 100% *Proposed by Benjamin S. Blanchard, Professor Emeritus, Virginia Tech

H OLISTIC D ESIGN = T EAM A PPROACH Design engineers must recognize that the systematic approach to maximize process availability by increasing asset reliability woefully falls short of actual performance in most cases To improve the design process, engineers must include representatives of the operations and maintenance teams on the design team. This action results in Improved Operability Maintainability Costs

T HE A RT OF S YSTEM E NGINEERING D ESIGN & M ANAGEMENT

I MPROVED S YSTEM D ESIGN : M AINTENANCE R EVIEW Conceptual Design System Planning System Feasibility Analysis Operational Requirements Maintenance Concept Functional Analysis System Specifications Preliminary System Design Identifications of system elements Allocation of Requirements Design synthesis, analysis, and optimization Test and evaluation of engineering and preproduction models Detailed Design and Development Detailed design of prime system elements Detailed design of maintenance and support System integration and test Construction Construction, test, and verification System assessment System modifications for corrective actions System Operation and Support System operation System assessment System upgrades and modifications System decommissioning System disposal Maintenance Team Integration Maintainability Testing & Demonstration Maintenance Data Collection, Analysis, & Corrective action Maintainability Prediction Maintenance Task Analysis Maintainability Analysis (RCM) RCM Analysis RCM is too often done after the fact – it should be done up front Note: Maintenance Concept is usually the OEM maintenance requirements. These are often wrong and the reason is simply that most OEMs focus on the functional output requirements and maintenance strategies are an afterthought

R ELIABILITY C ENTERED D ESIGN Q UESTIONS 1.What are the functions and associated performance standards of the asset in its proposed operating context? 2.How could it fail to fulfill its functions? 3.What will cause each functional failure? 4.What will happen when each failure occurs? 5.Why does each failure matter? 6.Can & should the failure mode be designed out? 7.What should be done if a suitable proactive task cannot be found?

L IFE C YCLE C OSTING – H OLISTIC R ESULTS Age Costs Design 1 Design 2 Design 3 Conceptual Design Preliminary System Design Detailed System Design Construc- tion System Operation 10% 66% 85% 95% 100%

B ENEFITS TO P ROCUREMENT & T HE C OMPANY The output of the holistic design process are comprehensive Reliability Centered Engineering Specifications & User Requirement Specifications (URS) based on the actual users – not just the design engineers Procurement is now empowered with precise specifications that includes the information to implement reliability / performance guarantee clauses in the contract: The Specific Performance clause requires a defaulting party to perform the contractual obligations in accordance with the terms of the bargain. While a warranty is a standard clause in an equipment contract, a performance guarantee is not and should be negotiated either as a separate contract or as an integral part of the equipment quotation/contract.

D OCUMENTED LCC E FFORTS RCM was applied later in life to the USS YORKTOWN (CG-48) in 1996 (15 years after launch). Results in 46.7 percent reduction in ship’s force workload without adverse impact on safety, mission, or the environment. DoD Directive requires that a total systems approach be used in acquisition programs to optimize total system performance and minimized the cost of ownership. Ownership costs historically have accounted for 60 to 70 percent of life-cycle costs for weapons systems In 1994, US Navy attack submarines spent 22% of their lifecycle in depot, being repaired or overhauled. In 1998, that percentage was reduced to 17%. Today, attack submarines spend only 12% of their lifecycle constrained to depot which has allowed the US Navy to maintain the same levels of presence and readiness with fewer ships.

CAI: L EADERS IN R ELIABILITY & A SSET M ANAGEMENT S TANDARDS : ISO 55000Asset Management SAE JA1011Evaluation Criteria for RCM SAE JA1012Guide to the RCM Standard C ERTIFICATIONS : CMRP and CMRT (CMRP’s Certified M&R Professionals) Predictive Technologies RCM & RCA Facilitation PMP (Project Management Professional)

CAI – O UR S ERVICES

Global Support for Manufacturing Operations F IND Y OUR H IDDEN P LANT