Term
|
Definition
| A method to illustrate an improvement project/ RCA process on one single sheet of A3 paper. |
|
|
Term
|
Definition
| Performance quality of asset to be met by OEM and tested upon receiving to ensure it has no defects that will cause it to fail early (infant mortality). Vibration testing, functional test, etc. This is a task to reduce life cycle costs. |
|
|
Term
|
Definition
| Asset criticality ranking is a method to combine consequence, likelihood and detectability of an asset in order to rank all known assets. This enables prioritization of reliability improvement, and development of an RCM. |
|
|
Term
|
Definition
| Artificial intelligence, machine learning. To handle large amounts of data to create evidence to support decisions. |
|
|
Term
|
Definition
| Method to analyze data to assist with decision making processes. |
|
|
Term
|
Definition
| Asset opportunity ranking. Similar to ACR, ranks assets by their value to produce high quality products/ create reliability improvements. This helps with work prioritization. |
|
|
Term
| Availability, both terms. |
|
Definition
1) (production time - downtime)/ production time
2) for OEE calculations, actual production time / possible production time |
|
|
Term
|
Definition
| Describes failure rate over lifetime of asset. Starts high and decreases overtime (infant mortality failures), reaches time with constant failure rates (random failures, mid-life), and then increases again with time (wear-out, age related failures). |
|
|
Term
|
Definition
| Best efficiency point. This is where we want operators to maintain assets at operationally. |
|
|
Term
|
Definition
| Bill of materials. Uses master asset list and attaches useful information for business use. This includes; serial #, part type, history, CM details, location, operating specs etc. This is critical to conduct any sort of reliability review of assets. |
|
|
Term
|
Definition
| Business process review. Review of processes in business to ensure we are meeting our business objectives, highlight areas of opportunity and improvement. All areas of maintenance and operations and work management are reviewing during BPR. |
|
|
Term
|
Definition
| Where an entire process is drawn out, including steps and decision making, documentation, interfaces points. This enables a review of where the pain points/ areas of opportunity are in this process. |
|
|
Term
|
Definition
| Maintenace related to breakdown of an asset. |
|
|
Term
|
Definition
| Condition based maintenance. When the failure of an asset time wise is not known, and the failure can be prevented, condition-based monitoring should be employed to track performance/ state of an asset to see if maintenance works are required. |
|
|
Term
|
Definition
| Cumulative density function. This is a curve which describes the cumulative probability of an asset failing as a function of time. |
|
|
Term
|
Definition
| Many facets of reliability are living systems. Continuous improvement means to never stagnate on reliability efforts. The job is never done. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| Computerized maintenance management system - MAXIMO. |
|
|
Term
| Conditional and Unconditional Failure Intensity |
|
Definition
| Failure intensity = rate of failure. Conditional assumes asset is good as new at t0. Unconditional does not assume the asset is good as new at t0. |
|
|
Term
|
Definition
| Where two assets failure rates share a probability relationship/ are realted. |
|
|
Term
|
Definition
| Likelihood * Consequence * Detectability = Criticality of an asset (ACR) or failure mode (FMECA). |
|
|
Term
|
Definition
MTBF (cumulative) = failure rate * (time operating) ^ growth rate
growth rate is the reliability improvement.
Duane model considers the log-log linear relationship between cumulative failure rates and cumulative testing time, and is able to estimate the MTBF for a certain point in time, or forecast it into the future. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| Extension of Dunane model. Reliability growth plots are used to predict the future failures of assets with multiple failure modes. This plot can show graphically if relibaility is increasing or decreasing overtime. |
|
|
Term
|
Definition
| To encourage everyone in a business to operate to meet business goals. The goal is to make people aware of how they play a role in and benefit from the change. |
|
|
Term
|
Definition
| Utilizing data to confirm something that is not evident. I.e., correlation analysis is data analytics. |
|
|
Term
|
Definition
| Elimination of defects in a system by proactively eliminating root causes of failures. It proactively acts to eliminate the onset of failure at all stages of an assets life. |
|
|
Term
|
Definition
| SME consultation when problem solving decisions. |
|
|
Term
|
Definition
| Consider reliability in life cycle costs. Consider how an asset should be designed to ensure it's critically is not intolerable to the business. Prevent design issues early in the process through procedure and review. |
|
|
Term
|
Definition
How likely is it that a failure mode will be detected for an asset, number between 0-1.
|
|
|
Term
|
Definition
| Define, measure, analyze, improve, control. Data driven improvement process. |
|
|
Term
|
Definition
| Enterprise asset management system. Like CMMS but encompasses more than just reliability and maintenance management. |
|
|
Term
|
Definition
| Function. Unreliability function. R(t) + F(t) = 1 |
|
|
Term
|
Definition
| The effect an failure will have on the system. Used in FMEA analysis. Not the same as consequence. |
|
|
Term
|
Definition
| The ways in which an asset can fail. |
|
|
Term
|
Definition
| Fast fourier transform. Takes time-based data and makes it frequency-based. Used in Spectral analysis of vibration and ultrasound measurements. |
|
|
Term
|
Definition
| 1/MTBF. Rate of failure. R(t) = e^-(time*failure rate) |
|
|
Term
|
Definition
| Failure Mode and Effect Analysis |
|
|
Term
|
Definition
| Failure mode effect and criticality analysis. Risk priority number given to failure modes and ranked. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| Fourier transform Infared analysis. A technique used in oil analysis to detect organic compounds. |
|
|
Term
|
Definition
| The function of an asset, operating specifications for what it is required to do until it reaches functional failure. Must contain an verb, object and action. |
|
|
Term
|
Definition
| When an asset is unable to meet its function it is considered functionally failed. |
|
|
Term
|
Definition
| Graph which illustrates the variability of failure likelihood from MTBF. This can only be used when the failure rate is constant (i.e., mid life). |
|
|
Term
|
Definition
Should be G1.
The grades of residual imbalance, expressed as g-mm/kg for a particular speed. This is the force of imbalance, not the vibration displacement/ velocity of imbalance. |
|
|
Term
|
Definition
| The failure rate when it is not constant and can be different at time, for non-repairable assets. |
|
|
Term
|
Definition
Harmonics are when current and voltage are imbalanced in an electrical system and the waveforms deviate from their sinusoidal shape. This can cause heating in motors and transformers as they become less efficient and lose energy to heat.
Resonant spectra related to bearing failure vibration results. These are additional wavelengths produced when a bearing failure "rings like a bell". |
|
|
Term
| Hidden Failure Finding Task |
|
Definition
| Task with specific interval undertaken to assess if a failure has occurred on a non-detectable failure mode, before the consequences can be experienced. |
|
|
Term
|
Definition
| Bar chart showing frequency of failures over ranges of times. This can be used to illustrate a pattern if there is any, i.e., increasing rate of failure over time, or highlight a certain time where many failures tend to occur for further analysis. |
|
|
Term
|
Definition
| Unit of frequency, Hertz. |
|
|
Term
|
Definition
| Occur when people are not trained, do not have the right tools, are in a poorly managed environment or just random. Human errors are inevitable but can be minimized. |
|
|
Term
|
Definition
| High but decreasing failure rate at the start of an asset life. One reason we perform condition monitoring as we don't know when a failure will occur. |
|
|
Term
| Interval Based Maintenance |
|
Definition
| Maintenance takes place at pre-defined interval. Been proven task will not be valuable or effective with condition-based monitoring. |
|
|
Term
|
Definition
| Infared, the emission of radiation from a heat source. |
|
|
Term
| Integrity Operating Window (IOW) |
|
Definition
| Kit should have upper and lower operating ranges so operators know where to keep kit operating to meet functional needs. |
|
|
Term
|
Definition
| Taxonomy for classifying and identifying equipment hierarchy, for the master asset list. |
|
|
Term
|
Definition
| Specifies the personal certification schemes to validate and ensure the integrity and independence of the training. |
|
|
Term
|
Definition
| Standard(s) for those who will be conducting condition monitoring and diagnostic tasks. |
|
|
Term
|
Definition
| Standard for balance quality for various classes of machines (rigid state motors) |
|
|
Term
|
Definition
| Cleanliness codes for oil analysis -> 4um, 6um and 16um |
|
|
Term
|
Definition
| Guide for asset management system |
|
|
Term
|
Definition
| Key performance indicator. Can be used to communicate the value of reliability if done well. Leading -> future (oil results etc), or lagging (MTBF etc) |
|
|
Term
|
Definition
| Bearing life, described as 10% have failed but 90% are okay. |
|
|
Term
|
Definition
| Calculation used to determine if reliability is increasing or decreasing. Can only be used in constant failure rate state |
|
|
Term
|
Definition
| Life Cycle Costing - to estimate the total cost of ownership, so business does not make decisions on upfront capital alone. |
|
|
Term
|
Definition
| Lean business model = maximizing value by minimizing waste |
|
|
Term
|
Definition
| The probability of occurrence of a failure |
|
|
Term
|
Definition
| Machine Learning, can be used in data analysis, condition monitoring etc. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| A structured process for communicating, recording, approving changes to PMs, master asset list, assets themselves etc. |
|
|
Term
|
Definition
Motor current analysis: analyses current flowing through one or more phase to pick up on noise which could indicate electrical or mechnical faults with the motor. Cracking rotor bars, end rings or motor eccentricity.
Motor circuit analysis: testing motor while it is offline to check connections and cable quality. |
|
|
Term
|
Definition
| Motor signature analysis: where current readings are analyzed in the FFT domain. It collects only motor current data. Cracked rotor bars, eccentricity, loose wedges, and high resistance joints |
|
|
Term
|
Definition
|
|
Term
|
Definition
| Computational method to determine the probability of many outcomes for an uncertain event. |
|
|
Term
|
Definition
| Maintenance, Repair and Operations, Maintenance Repair and Overhaul: 40-60% of maintenance costs are the cost of parts to repair and overhaul. |
|
|
Term
|
Definition
| mean time between failures -> can be described as time/failures but assumes constant rate, can also be estimated using gaussian with mean, var |
|
|
Term
|
Definition
| mean time between functional failure |
|
|
Term
|
Definition
|
|
Term
|
Definition
| Non-destructive testing. The aim is to leave the asset in good working condition if no faults are found. |
|
|
Term
|
Definition
| Operations and maintenance |
|
|
Term
|
Definition
overall equipment effectiveness
OEE = Availability * Performance% * Quality% |
|
|
Term
|
Definition
| Kit is repaired or replaced due to evidence for need given condition monitoring |
|
|
Term
|
Definition
Analysis of oil to determine:
Contaminants (water, external)
Wear (copper, other metals, silicon, internal)
Chemistry (additive quantities, viscosity)
This data can show if the asset has issues or is failing
|
|
|
Term
|
Definition
| Partial discharge: When electric field exceeds dielectric threshold of the insulating material and has a baby arc. |
|
|
Term
|
Definition
| Probability density function: function which can show the probability of failure at any one time. |
|
|
Term
|
Definition
|
|
Term
|
Definition
| Potential failure curve, functional failure curve |
|
|
Term
|
Definition
| Interval between potential failure beginning and functional failure. This interval is not always known. |
|
|
Term
|
Definition
| 80% planned, 20% unplanned. Maintenace which is known within at least one weeks' notice. |
|
|
Term
|
Definition
| Planned maintenance optimization |
|
|
Term
|
Definition
| Work is done to meet standards and specifications adhered to by the business. When alignment has no offset or angularity, when bolts are fastened to correct tension, when imbalance is not exceeding imbalance standard (ideally G1), when all tasks have been performed in a way to ensure longest possible asset life. |
|
|
Term
|
Definition
| Step up from predictive maintenance, where not only condition is forecasted but work is scheduled in response to this forecast and the necessary action is taken. |
|
|
Term
|
Definition
| Plant replacement value = cost to replace existing structure with new one given function, materials, standards and codes. |
|
|
Term
|
Definition
| a system that requires r units to function out of n system |
|
|
Term
|
Definition
reliability
=e^(-t*failure rate) |
|
|
Term
|
Definition
| reliability, availability and maintainability |
|
|
Term
|
Definition
| responsible, accountable, support, consult and inform. RACI is a responsibility matrix set out by the business |
|
|
Term
|
Definition
Root cause analysis (5 whys, fishbone, step, FTA), RCFA
FRACAS = failure reporting and corrective asset system (A3, 8D, 16J) |
|
|
Term
|
Definition
| Reliability is the duration of a failure free performance of an asset under stated conditions and specific time period and can be calculated to have a number between 0 and 1 |
|
|
Term
| Reliability block diagrams |
|
Definition
Ability to calculate joint reliability
series = a*b
Parallel = 1-(1-a*b))
|
|
|
Term
|
Definition
| External force vibrating at the same frequency as the natural frequency of an item causing violent vibration. |
|
|
Term
|
Definition
| Rate of occurrence of failures, in the bathtub curve the vertical axis is ROCOF |
|
|
Term
|
Definition
Risk priority number = severity * occurrence * detection
RPN = SOD
RPN is used to compare issues for prioritization |
|
|
Term
|
Definition
Evalutation criteria for RCM processes.
function, failure effects, failure modes, failure consequences, proactive tasks, default actions
|
|
|
Term
|
Definition
| process and tools for process improvement. Six sigma is one in which where 99.99966% of all features are expected to be free of defects. |
|
|
Term
|
Definition
| Where one or multiple feet of an asset is shorter or longer than the others and is very common for rotating machinery. Should be less than 0.05mm |
|
|
Term
| Spectrometric Oil Analyses |
|
Definition
| Where an oil sample is burned to observe the light emotion of the various chemistries in an oil sample. This is used to count particle totals with small particles dominating the count (<7um). |
|
|
Term
|
Definition
| Censored data from MTBF calculations due to failure not occurring yet. |
|
|
Term
|
Definition
| structured risk identification workshop method |
|
|
Term
|
Definition
| Total effective equipment performance. TEEP = OEE * Utilization = A * Q% * P% * U%. Takes into account both equipment losses and schedule losses. |
|
|
Term
|
Definition
| Total cost of ownership -> total costs of life, including purchasing, maintaining, operating and disposing. |
|
|
Term
|
Definition
| Total productive maintenance. Optimization approach to minimizing breakdowns, downtime and Maintenace. |
|
|
Term
|
Definition
| Total Quality Management: encourage employees to deliver high quality product/ service to customers |
|
|
Term
|
Definition
| Used to detect high frequency vibration/ sound which can indicate bearing failures and electrical issues such as corona, PD and arc flash. 20-50kHz range detection. |
|
|
Term
|
Definition
Rotor unbalance is where the center of gravity is not located at the geometric center of the asset, resulting in detectable vibration and associated damage.
U = m * r
m = unbaalnce mass
r = radius from center to ubalance mass
U, imbalance measured in g/mm
Unbalance can be fixed in-situ using vibration analysis and welding/ removing weights as required, or via shop which would measure force of imbalance to fix the issue.
Residual unbalance should be graded to G1 as per standard ISO21940 (which measures force of imbalance not vibration). |
|
|
Term
|
Definition
| Ferrography is a method of viewing an oil sample very closely to determine the quantity and types of wear particles. |
|
|
Term
|
Definition
| Method of determining the rate of failure when the rate of failure is not linear. B > 1 means increasing rate of failure end of life, B < 1 is decreasing rate of failure which is infant mortality, and B = 1 constant failure rate. |
|
|
Term
|
Definition
|
|
