Johnson & Wales University Trouble Brews at Starbucks Case Study Analysis Put the previous 5 assignments together into a presentation depicting the lifecy

Johnson & Wales University Trouble Brews at Starbucks Case Study Analysis Put the previous 5 assignments
together into a presentation
depicting the lifecycle of this
project and highlighting the tools
used and potential links between
the tool input(s) and output(s)
Class 9
Maintenance and Support
Reading
•
Read Section C.1 and provided Reliability Centered Maintenance
•
Review Sections 2.5, 2.7, B.1 and provided Fault Tree Analysis
Maintenance and support
•
Maintainability is an inherent characteristic of system design that pertains to the ease,
accuracy, safety, and economy in the performance of maintenance actions.
•
Initially one must deal with the flow of activities and where the system is utilized.
•
In addition, there is a flow of activities and materials involving the system maintenance
support capability
•
Sections 2.5 and 3.4 list a number of activities/documentation and calculations
associated with maintenance.
•
A variety of tools and techniques are useful in this area – functional analysis using
functional flow block diagrams (FFBDs), trade studies to identify resource
requirements, Technical Performance Measures (TPMs), Reliability Block Diagrams,
FMECA, Fault-tree Analysis (FTA), Reliability-centered Maintenance (RCM), etc
Reliability
Centered
Maintenance
(RCM)
Emphasis is on the establishment of a cost-effective preventive
maintenance program based on information from the FMECA
Other methods, such as Pareto analysis of equipment based on
downtime, unreliability or other relevant metrics, may also be
applied. Whichever method (or combination of methods) is selected,
the goal is to focus RCM analysis resources on the equipment that
will provide the maximum benefit to the organization in terms of
safety, legal, operational, economic and related priorities.
Section 3.4.2, Blackboard Reference – Reliability Centered Maintenance
The purpose of RCM is to ensure maintenance and inspection tasks
are centered around improving the reliability and safety of
equipment.
FMECA, covered in Lesson 7, is a tool that has many
different applications
• It’s used in cause-and-effect relationships
• It’s used in maintainability in development of diagnostic routines
• It’s used in supportability analyses
• It’s a major input to RCM
• It supplements FTA and hazard analyses
FTA is narrower in focus than FMECA and does not require
as much data
• It is a deductive analysis of different ways a particular failure can occur
and the probability of is occurrence
• A separate FT may be developed for each critical fault
FMECA – Failure Modes, Effects and Criticality Analysis
FTA – Fault Tree Analysis
Section 3.4.2
FMECA and
FTA
FTA (Fault Tree Analysis)
and RBD (Reliability Block
Diagram)
start
•
Although the symbols and structures of the two diagram types
differ, most of the logical constructions in a fault tree diagram can
also be modeled with an RBD. In general, a fault tree can be easily
converted to an RBD. It is generally more difficult to convert an
RBD into a fault tree, especially if one allows for highly complex
configurations
•
A Reliability Block Diagram (RBD) is a graphical representation of
the components of the system and how they are reliability-wise
related. The diagram represents the functioning state (i.e., success
or failure) of the system in terms of the functioning states of its
components.
•
Consider a system with two components, A and B. The system fails
if both A and B fail. The fault tree and reliability block diagram for
the system are shown.
end
parallel
https://www.reliasoft.com/products/reliability-analysis/blocksim/rbd-analysis
http://reliawiki.com/index.php/Fault_Tree_Diagrams_and_System_Analysis
Another FTA & RBD example
Consider a system with three components, A, B and C. The system fails if A, B or C fails.
The next two figures show both the FTD and RBD representations.
series
•
Designer to review requirements for
specific quantitative values, relative
degrees of importance, criticality and
priorities.
•
Inherent within the top-level system
specification should be the
identification and prioritization of
Technical Performance Measures
(TPMs).
•
The TPM provides designers guidance
for accomplishing their task
Section 2.6
Technical performance
measures (TPM)
Corrective Maintenance
Types of
Maintenance
Preventive Maintenance
• Scheduled actions to retain system
performance
• When the cost to replace a component
before it fails is less than the cost to replace
the component after it fails, it makes sense
to maintain the component preventively. The
optimum preventive maintenance time can
be found using equations.
http://www.weibull.com/hotwire/issue96/relbasics96.htm
• Unscheduled actions to restore a system to
its required performance
Availability &
Maintainability
Calculations
•
Mean Time to Failure (MTTF)
 Time that a system is not failed, or is available, referred to as
“uptime”
•
Mean Time to Repair (MTTR)
 Basic measure of the maintainability of repairable items,
average time required to repair a failed component or device
(downtime/number of system failures)
•
Mean Time Between Failures (MTBF)
 Amount of time that elapses between one failure and the next
(uptime/system failures) (MTBF= MTTF + MTTR)
•
Inherent Availability for single component A I=MTTF/(MTTF+MTTR)
[only corrective maintenance]
•
Inherent Availability for system AI =MTBF/(MTBF+MTTR) [only
corrective maintenance]
•
Mean Time Between Maintenance Actions (MTBM) (uptime/(number
of failures+number of system downings)
•
Operational Availability (Ao) (uptime/total time system was
functioning during operating cycle)
•
This is a design characteristic
•
Materials can produce toxic effects
•
Injuries to operators and maintainers
•
Fluids can be explosive
•
Electrical hazards
•
Personal injury
•
FTA is used to determine events that can
become hazards (Fault-tree logic diagrams)
•
Hazard analysis – evaluates the design and
finds events that may result in hazards at
the system level (closely related to FMECA)
Section 3.4.5
Safety engineering
Quality engineering
•
Quality engineering is the management, development, operation and maintenance of
systems and enterprise architectures with a high quality standard.
•
Six sigma
•
Total Quality Management (TQM) – the iterative process of continuous improvement
 Design for quality
•
Concurrent Engineering – a systematic approach to the integrated, concurrent design
of products and their related processes
 Should improve quality and effectiveness of system
 This should result in cost reduction
•
Robust design should be insensitive to normally encountered variations
Supply Chain
Management
•
Chapter 1 – Supply Chain Management (SCM) pertains to the management of
the supply chain, or group of supply chains, with the objective of providing the
required customer services, both effectively and efficiently.
•
Supply chain management is the management of the flow of goods and services
and includes all processes that transform raw materials into final products
 It requires a highly integrated approach, employing the appropriate resources
(e.g., transportation, warehousing, inventory control and information)
•
Connection between Logistics and SCM
 Logistics is a specialized field of its own comprised of shipping, warehousing,
courier services, road/rail transportation, and air freight.
•
Supply chains present a weak link for cybersecurity
 Organizations can’t always control the security measures taken by supply
chain partners
 Creates opportunities for cybercriminals to attack by first infiltrating a supply
chain partner
 In today’s world of Internet of Things (IoT), digital buyer-seller relationships,
and robotic process automation, vulnerabilities to cyber damage are
increasing
Supply Chain
Management best
practices
•
Make sure the supply chain itself has appropriate staffing
•
Technology is your friend
•
Establish synergistic relationships with key suppliers
•
Engage in collaborative strategic sourcing
•
Don’t just consider price when making supply chain decisions. Consider the “total
cost of ownership.”
•
Inventory optimization is essential.
•
Establish appropriate controls throughout the supply chain system to minimize risk
•

Keep the supply chain sustainable with social responsibility and green initiatives
•
Many companies have used robotics or artificial intelligence to digitize and automate
labor-intensive, repetitive tasks and processes such as purchasing, invoicing, accounts
payable, and parts of customer service. Predictive analytics are helping companies
improve demand forecasting, so they can reduce or better manage volatility, increase
asset utilization, and provide customer convenience at optimized cost.
•
The trend is clear: Technology is replacing people in supply chain management — and
doing a better job. It’s not hard to imagine a future in which automated processes,
data governance, advanced analytics, sensors, robotics, artificial intelligence, and a
continual learning loop will minimize the need for humans.
Discussion Board Posts
•
Post a response in the Week 9 Discussion Board and consider replying to someone
else’s post. This should be done by midnight July 19 or it will not be graded.
•
Choose either the Fault Tree Analysis, Technical performance Measures or Supply Chain
Management, do additional research as needed and discuss how do you think it could
be used effectively on a project, such as your Ancient Roman Engineering Project.
•
Prior to Lesson 10 Read Chapter 8 and Provided paper – Software Process and Process
Models
Reliability Centered Maintenance (RCM)
Reliability Centered Maintenance (RCM) analysis provides a structured framework for
analyzing the functions and potential failures for a physical asset (such as an airplane, a
manufacturing production line, etc.) with a focus on preserving system functions, rather
than preserving equipment. RCM is used to develop scheduled maintenance plans that will
provide an acceptable level of operability, with an acceptable level of risk, in an efficient and
cost-effective manner.
According to the SAE JA1011 standard, which describes the minimum criteria that a process
must comply with to be called “RCM,” a Reliability Centered Maintenance Process answers
the following seven questions:
1. What are the functions and associated desired standards of performance of the asset in
its present operating context (functions)?
2. In what ways can it fail to fulfill its functions (functional failures)?
3. What causes each functional failure (failure modes)?
4. What happens when each failure occurs (failure effects)?
5. In what way does each failure matter (failure consequences)?
6. What should be done to predict or prevent each failure (proactive tasks and task
intervals)?
7. What should be done if a suitable proactive task cannot be found (default actions)?
Although there is a great deal of variation in the application of RCM, most procedures
include some or all of the following steps.
Prepare for the Analysis
As with almost any project, some preliminary work will be required to prepare for the RCM
analysis. Some important up-front activities include assembling an appropriate crossfunctional team, making sure that all members of the analysis team understand and accept
the ground rules and conditions of the analysis (e.g., scope of the analysis, definition of
“failure,” etc.), gathering and reviewing relevant documentation, etc.
Select the Equipment to Be Analyzed
Because RCM analysis requires an investment of time and resources, the organization may
wish to focus analysis resources on selected pieces of equipment, based on safety, legal,
economic and other considerations. Selection Questions and Criticality Factors are two
methods of equipment selection that are commonly employed.
•
The Selection Questions method consists of a set of Yes/No questions that are
designed to identify whether RCM analysis is indicated for a particular piece of
equipment. For example, there are four questions in the MSG-3 guideline used to
develop initial scheduled maintenance plans for the aircraft industry. If the analyst
answers Yes to at least one of the questions, then detailed analysis is indicated for the
equipment.
•
The Criticality Factors method consists of a set of factors designed to evaluate the
criticality of the equipment in terms of safety, maintenance, operations, environmental
impact, quality control, etc. Each factor is rated according to a pre-defined scale (e.g.,
1 to 5 or 1 to 10) where higher ratings indicate higher criticality. The equipment’s
criticality value can then be used as a ranking and/or as a threshold.
Other methods, such as Pareto analysis of equipment based on downtime, unreliability or
other relevant metrics, may also be applied. Whichever method (or combination of
methods) is selected, the goal is to focus RCM analysis resources on the equipment that will
provide the maximum benefit to the organization in terms of safety, legal, operational,
economic and related priorities.
Identify Functions and Potential Functional Failures
One of the primary tenets of the Reliability Centered Maintenance approach is that
maintenance activities should be focused toward preserving equipment functionality.
Therefore, it follows that the first step in analyzing a particular piece of equipment is to
identify the function(s) it is intended to perform. Many RCM references recommend
including specific performance requirements in function descriptions, which will help to
specifically identify functional failures. For example, “To provide hydraulic pressure of 3000
psi +/- 200 psi.”
Functional failures describe ways that the equipment may fail to perform its intended
functions. This may include failure to perform a function, poor performance of a function,
over-performance of a function, performing an unintended function, etc. As mentioned
above, the performance limits that have been identified for the function may provide a
guide to the functional failure description. For example, “Provides hydraulic pressure of
more than 3200 psi,” “Provides hydraulic pressure of less than 2800 psi,” etc.
Identify and Evaluate (Categorize) the Effects of Failure
Identifying and evaluating the effects of failure will help the team to prioritize and choose
the appropriate maintenance strategy to address a potential failure. Many RCM references
contain logic diagrams that can be used to evaluate and categorize the effects of failure.
These logic structures often differentiate evident vs. hidden effects and whether the issue
has safety, environmental, operational and/or economic consequences.
Identify Causes of Failure
The cause of failure (sometimes also called failure mode) represents the specific cause of
the functional failure at the actionable level (i.e., the level at which it will be possible to
apply a maintenance strategy to address the potential failure). This determination is based
on engineering judgment and relies on the team’s experience and skill with the RCM
analysis process. The SAE JA1012 guideline presents a useful demonstration of the many
levels of detail that can be used to describe failure modes. For example:
•
Pump set fails
o
Pump fails
▪
Impeller fails
▪
Impeller comes adrift
▪
Mounting nut undone
▪
Nut not tightened correctly
▪
Assembly error
The recommendation states that “failure modes should be described in enough detail for it
to be possible to select an appropriate failure management policy, but not in so much detail
that excessive amounts of time are wasted on the analysis process itself.”
Select Maintenance Tasks
Once you have identified the
functions that equipment is intended to perform, the ways that it might fail to perform those
intended functions and evaluated the consequences of these failures, the next step is to
define the appropriate maintenance strategy for the equipment. The RCM analysis team’s
decision of which strategy (or strategies) to employ for each potential failure may be based
on judgment/experience, a pre-defined logic diagram (connected to the failure effect
categorization), cost comparisons or some combination of factors.
Many RCM guidelines include task selection logic diagrams based on the Failure Effect
Categorization. When safety is not an issue, another is to compare normalized cost values
for the available maintenance strategies and select the maintenance task that provides the
desired level of availability for the minimum cost. For example, if the cost per uptime of
performing corrective maintenance only (run to failure) is less than the cost per uptime of
performing a scheduled repair/replacement, and the run to failure approach provides an
acceptable level of equipment availability (uptime), then the team may recommend no
scheduled maintenance tasks for the equipment.
Maintenance Packaging
Once the appropriate schedule maintenance tasks have been identified, the final step is to
package them into a workable maintenance plan. This may involve choosing time intervals
at which groups of tasks can be carried out most effectively and efficiently.
Published Guidelines and Standards
There are a number of published guidelines and other references to describe the principles
and requirements of Reliability Centered Maintenance. Some useful references include:
•
Reliability-Centered Maintenance by F. Stanley Nowlan and Howard F. Heap of United
Airlines, issued in December 1978.
•
ATA MSG-3 “Operator/Manufacturer Scheduled Maintenance Development,” updated in
March 2003.
•
NAVAIR 00-25-403 “Guidelines for the Naval Aviation Reliability-Centered Maintenance
Process,” issued in February 2001 and updated in July 2005.
•
SAE JA1011 “Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes,”
issued in August 1999.
•
SAE JA1012 “A Guide to the Reliability-Centered Maintenance (RCM) Standard,” issued in
January 2002.
•
Reliability-Centered Maintenance (2nd Edition) by John Moubray, published in 1997.
•
Reliability Centered Maintenance: Gateway to World Class Maintenance by Anthony M.
Smith, published in 1993.
•
“Practical Application of Reliability-Centered Maintenance” by the Reliability Analysis Center,
issued in 2003.
•
MIL-STD-2173(AS) “Reliability-Centered Maintenance Requirements for Naval Aircraft,
Weapons Systems and Support Equipment,” issued in January 1986.
•
“NASA Reliability Centered Maintenance Guide for Facilities and Collateral Equipment,”
issued in February 2000.
http://www.weibull.com/basics/rcm.htm
Fault Tree Analysis
This quick subject guide provides an overview of the basic concepts in fault tree analysis
(FTA, system analysis) as it applies to system reliability, and offers a directory of some
other resources on the subject.
History of Fault Tree Analysis (FTA)
Fault Tree Analysis (FTA) is another technique for reliability and safety analysis. Bell
Telephone Laboratories developed the concept in 1962 for the US Air Force for use with the
Minuteman system. It was later adopted and extensively applied by the Boeing Company.
Fault tree analysis is one of many symbolic “analytical logic techniques” found in operations
research and in system reliability. Other techniques include reliability block diagrams
(RBDs).
What is a Fault Tree Diagram (FTD)?
Fault tree diagrams (or negative analytical trees) are logic block diagrams that display the
state of a system (top event) in terms of the states of its components (basic events). Like
reliability block diagrams (RBDs), fault tree diagrams are a graphical design technique, and
as such provide an alternative methodology to RBDs.
An FTD is built top-down and in term of events rather than blocks. It uses a graphic “…
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