When a essential asset like an costly piece of equipment or infrastructure breaks unexpectedly, it impacts prospects and may value corporations hundreds of thousands. To achieve success, companies must have clear, real-time visibility into the situation of their belongings and a plan to maintain them operating easily and make repairs rapidly when issues break. Enterprises are always in search of new methods to optimize efficiency, enhance reliability and prolong asset lifespans—all with out including pointless prices.
That is why asset reliability is such a essential part of enterprise technique. Earlier than we dive into it, let’s check out some related phrases.
What’s an asset?
The time period “asset” can seek advice from each bodily and non-physical gadgets that corporations personal and use to create worth. Examples of bodily belongings embody equipment, factories, workplace provides, manufacturing crops, meeting traces, car fleets, buildings and civil infrastructures. Examples of non-physical belongings embody software program, mental property, logos and patents.
What’s asset reliability?
Asset reliability is the flexibility of an asset to carry out underneath sure situations over a specified interval with out breaking down. To be thought-about “dependable,” an asset asset should carry out at a sure stage and adjust to all regulatory necessities surrounding its operation.
The distinction between asset reliability and asset availability
The phrases asset reliability and asset availability are straightforward to confuse, however there are a number of key variations value noting. First, availability measures the operational capability of an asset over time. In different phrases, how lengthy can a bit of kit carry out the duties related to its operation efficiently. Reliability, then again, refers to an asset’s capacity to operate with out downtime or disruption underneath sure situations. An asset is just deemed “dependable” when it operates with out surprising shutdowns with a purpose to carry out needed repairs.
Whereas reliability and availability are each measured in percentages, it’s potential—even doubtless—that these percentages will differ even when referring to the identical piece of kit. For instance, a bit of kit working at 100% reliability would possibly solely be 90% out there if 10% of the time was used to carry out essential, deliberate upkeep essential to hold it operating.
How does asset reliability work?
As a way to take a proactive strategy to asset reliability, upkeep managers depend on two extensively used metrics: mean time between failure, (MTBF) and mean time to repair (MTTR). Each KPIs assist predict how belongings will carry out and help managers in planning preventive and predictive maintenance. First, let’s take a look at MTBF and MTTR.
Imply time between failure (MTBF) and imply time to restore (MTTR)
Each MTBF and MTBR could be calculated utilizing easy mathematical formulation. Right here’s the formulation technicians use to calculate MTBF:
MTBF = Whole working time / Variety of failures in a particular time interval
For instance, if a bit of kit is used for 20,000 hours and fails 5 occasions throughout that interval, its MTBF could be 20,000 hours / 5 failures = 4,000 hours. In different phrases, this tools could be anticipated to fail each 4,000 hours. Armed with this data, operators can plan upkeep actions to make sure tools doesn’t break down unexpectedly, leading to expensive downtime.
Whereas understanding an asset’s MTBF is essential to preserving it acting at peak ranges, it doesn’t assist operators decide how a lot time they might want to restore it. That is the place MTTR is available in. To calculate MTTR, operators first must understand how a lot time it takes to carry out the next duties on an asset:
- Notify asset upkeep groups
- Let the damaged tools cool earlier than it may be labored on
- Carry out repairs and reassemble any needed gadgets
- Take a look at the tools completely earlier than restarting manufacturing
Right here’s the mathematical formulation operators use to calculate MTTR:
MTTR = Whole downtime / Whole variety of failures over a particular time
For instance, if over the course of a yr, a system failed 10 occasions, leading to 20 whole hours of downtime, its MTTR could be: 20 hours / 10 repairs = 2 hours. In different phrases, it takes, on common, 2 hours to restore this piece of kit every time it breaks.
Like MTBF, MTTR is used to find out asset reliability and, extra particularly, to permit operators to measure the effectivity of their upkeep packages and to make changes the place needed.
Preventive and predictive upkeep
Each preventive and predictive maintenance are upkeep methods utilized by enterprise leaders to extend asset reliability.
Preventive upkeep depends on situation monitoring to assist managers strategically plan for asset repairs and downtime in a approach that minimizes the affect to the general enterprise. Predictive upkeep takes the upkeep capability of preventive upkeep one step additional. Sensors acquire information in real-time that’s then fed into an enterprise asset administration (EAM) or computerized upkeep administration system (CMMS), the place AI-enhanced information evaluation instruments and processes like machine learning (ML) spot points and assist resolve them. This data is then used to construct predictive fashions of an asset’s efficiency over time and assist spot potential issues earlier than they come up.
One of many methods upkeep managers refine and enhance predictive analytics to extend asset reliability is thru the creation of a digital twin.
Digital twin expertise
Digital twin expertise permits for the creation of a digital illustration of an asset that spans your complete asset lifecycle and is topic to the identical situations as the true asset. Digital twins use real-time information, simulations and machine studying to help decision-makers within the administration of their most important belongings.
Digital twins could be created for belongings as unique as manned-spacecraft or as frequent as a wind turbine. As in predictive analytics, sensors linked to the bodily object acquire information from the true world that’s then mapped onto a digital mannequin. By monitoring the asset’s digital twin, managers can spot essential insights into how the asset is reacting to its setting and develop methods to enhance its reliability.
Asset efficiency administration
Enterprise leaders understand how essential it’s to have a deep understanding of when their belongings are more likely to fail to allow them to take speedy motion to cut back threat to general enterprise operations. Asset efficiency administration, or APM, helps decision-makers improve asset administration insights with automation, analytics and artificial intelligence (AI) capabilities.
Via AI-powered distant monitoring, root-cause analysis, Failure Mode Evaluation (FMEA), pc imaginative and prescient and predictive upkeep, APM permits the fashionable enterprise to cut back unplanned restore work, handle threat, prolong asset lifecycles and enhance profitability.
Enterprise asset administration (EAM) and CMMS
Enterprise asset management (EAM) is an asset administration system that mixes software program and companies to assist organizations keep, management and optimize the standard of operational belongings all through their lifecycles. With the quantity of knowledge being generated by way of IoT, upkeep managers are relying an increasing number of on administration software program and AI-enhanced information evaluation to assist them make extra knowledgeable selections. The aim of EAM is all the time to enhance tools reliability, enhance productive uptime and cut back operational prices.
Many EAM initiatives work in tandem with a computerized maintenance management system (CMMS) to assist upkeep departments centralize very important asset data. A CMMS tells upkeep managers the place an asset is, what sort of companies or repairs it requires and who ought to carry out them. A robust CMMS can improve upkeep planning by making the details about an asset instantly accessible and auditable.
Why is asset reliability essential?
Asset reliability affords fashionable enterprises peace of thoughts in relation to their most precious assets. By deploying essentially the most cutting-edge applied sciences out there, coupled with rigorous upkeep administration methods and adherence to key metrics like MTBF and MTTR, enterprises can cut back prices, enhance asset dependability and maximize their return on funding (ROI) of their most precious belongings.
The advantages of sturdy asset reliability embody the next:
- Elevated uptime: Having good asset reliability means top-performing belongings run at peak ranges for longer with out rising their threat of failure. By performing preventive and predictive upkeep as a part of an general upkeep technique, companies can cut back the quantity and frequency of breakdowns.
- Decreased prices: When asset reliability improves, upkeep labor, stock, and dealing capital prices go down—it’s that easy. Reliability packages assist managers plan strategically for downtime and carry out repairs solely when the affect on enterprise continuity could be minimized.
- Improved employee security: One other advantage of asset reliability is the development of office situations for upkeep employees. By decreasing the probability of kit failures, workplaces keep away from accidents and accidents related to surprising tools failures.
- Smarter asset administration: The continual monitoring of belongings by way of an EAM or APM strategy to enhancing asset reliability generates insights into present and future (anticipated) asset states that enhance the decision-making capabilities of upkeep managers.
Discover asset reliability options
Asset reliability relies on a powerful, coordinated strategy to asset administration that comes with the newest technological options out there. The IBM Maximo Application Suite is a completely built-in platform that helps corporations enhance asset reliability by way of higher upkeep operations.
IBM Maximo permits the evolution of timed scheduling upkeep to condition-based, predictive upkeep knowledgeable by real-time insights. It has a confirmed observe report of serving to enterprises enhance asset efficiency, prolong asset lifespan and cut back prices and downtime.