Efficient Plant July 2018 - 8

column | implementations

Buy for
Maintainability
Dr. Klaus M. Blache
Univ. of Tennessee Reliability
& Maintainability Center
(RMC)

Life-Cycle Cost Commitment
Life-cycle cost
funds committed

95+%

85%

0

Operate and maintain

Construction

Final design

50

Concept/
preliminary design

65%

Planning

Percentage life-cycle
cost committed

100

Life-cycle phases

Life-cycle
cost reduction
opportunity

More than 95% of the life-cycle cost of
machinery and equipment is established
at the time it's constructed. Adapted
from B.S. Blanchard in NASA RCM Guide

Based in Knoxville, Klaus M. Blache
is director of the Reliability &
Maintainability Center at the Univ. of
Tennessee, and a research professor in
the College of Engineering. Contact him
at kblache@utk.edu.

8

| EFFICIENTPLANTMAG.COM

I

T'S OFTEN STATED in reliability and maintainability training that
more than 95% of the life-cycle cost of
machinery and equipment is established
at the time it's constructed (see accompanying graph). What does that mean and
what should you do about it?
While you won't pay for that cost at the
time of purchase, you've decided about
how much it will cost over the lifetime of
the equipment. Purchasing departments
typically get rewarded for saving on initial
costs. However, acquisition cost represents
only 15% to 30% of the total life-cycle
cost. So, doesn't it make sense to consider
the other 70% to 85%, when deciding on
new assets? This is done by "designing-in"
maintainability concepts.
Some examples of principles of maintainability design from NIOSH
(National Insitute for Occupational
Safety and Health, Washington,
cdc.gov/niosh) are:
 Maintainability should be a
designed-in capability.
 Great maintenance procedures
cannot overcome poor design.
 A complex design solution is
often easier than a simple solution
until you have to maintain it.
 Every maintenance point should
be directly visible and fully accessible to the maintainer.
 All parts or components are
replaced eventually; design for these
eventualities.
 Do not design for the "average" or
50th-percentile person. To do so could exclude as many as 60% of the users. Design
for the user population, which includes the
10th- to 90th-percentile person.
 Design maintenance and troubleshooting procedures to put the odds in the
maintainer's favor.

 To help a maintenance person remember instructions, write them down and
post on the machine where he/she will
make the repair decision.
 Design every interface so you can
install only the correct replacement part or
component correctly.
 Since the unexpected can occur at any
time, ensure that you sufficiently de-rate
all mechanical, electrical, hydraulic, and
pneumatic systems to withstand unexpected overloads without failures, degradation
in performance, or safety consequences.
 Design line-of-sight visibility for all
maintenance tasks that require visual
inspection, servicing, adjustment, alignment, in-place repair, or removal and
replacement of components.
 Design all systems and subsystems to
fail to a safe mode or state so that a component or subsystem failure will not result
in additional asset damage or employee
injury.
 Because it is sometimes difficult to
see what is right in front of you, design all
systems so that failures are obvious.
 Special tools are rarely available when
maintainers need them, so design all
maintenance tasks to eliminate the need
for special tools.
 Design and locate all components and
interfaces so that they are directly and
easily accessible for maintenance.
 Because operators sometimes cause
equipment failure and damage, design
machines with operator-controlled
systems that include emergency relief
valves, overload safety devices, and other
precautionary features.
Use maintainability concepts (specific
to your operation) in equipment purchasing specifications and buy-off procedures
to assure you realize the full benefits of
life-cycle asset management. EP

JULY 2018


http://www.cdc.gov/niosh http://www.EFFICIENTPLANTMAG.COM

Table of Contents for the Digital Edition of Efficient Plant July 2018

Editorial
Implementations
Find Gold In Sustainable Manufacturing
Troubleshoot Control Systems Effectively
Automation Accelerates Beer Production
Lubed Chains Live Long Lives
SAP: Use These Tools For PM Compliance
Protect Your Site From Cyber Attacks
Build The Value Of Your CM Program
Choose The Correct Acclerometer
On The Floor
Intelligent Design Process Delivers For Substation
Solution Focus
Old Compressor Gets New Lease On Life
Products
Index
Showcase
Seeking Reliability
Efficient Plant July 2018 - Cover1
Efficient Plant July 2018 - Cover2
Efficient Plant July 2018 - 1
Efficient Plant July 2018 - 2
Efficient Plant July 2018 - 3
Efficient Plant July 2018 - 4
Efficient Plant July 2018 - 5
Efficient Plant July 2018 - Editorial
Efficient Plant July 2018 - 7
Efficient Plant July 2018 - Implementations
Efficient Plant July 2018 - 9
Efficient Plant July 2018 - Find Gold In Sustainable Manufacturing
Efficient Plant July 2018 - 11
Efficient Plant July 2018 - 12
Efficient Plant July 2018 - 13
Efficient Plant July 2018 - 14
Efficient Plant July 2018 - 15
Efficient Plant July 2018 - 16
Efficient Plant July 2018 - 17
Efficient Plant July 2018 - Troubleshoot Control Systems Effectively
Efficient Plant July 2018 - 19
Efficient Plant July 2018 - 20
Efficient Plant July 2018 - 21
Efficient Plant July 2018 - Automation Accelerates Beer Production
Efficient Plant July 2018 - 23
Efficient Plant July 2018 - 24
Efficient Plant July 2018 - 25
Efficient Plant July 2018 - 26
Efficient Plant July 2018 - Lubed Chains Live Long Lives
Efficient Plant July 2018 - 28
Efficient Plant July 2018 - 29
Efficient Plant July 2018 - SAP: Use These Tools For PM Compliance
Efficient Plant July 2018 - Protect Your Site From Cyber Attacks
Efficient Plant July 2018 - Build The Value Of Your CM Program
Efficient Plant July 2018 - Choose The Correct Acclerometer
Efficient Plant July 2018 - On The Floor
Efficient Plant July 2018 - 35
Efficient Plant July 2018 - Solution Focus
Efficient Plant July 2018 - 37
Efficient Plant July 2018 - 38
Efficient Plant July 2018 - 39
Efficient Plant July 2018 - Old Compressor Gets New Lease On Life
Efficient Plant July 2018 - 41
Efficient Plant July 2018 - Products
Efficient Plant July 2018 - 43
Efficient Plant July 2018 - 44
Efficient Plant July 2018 - 45
Efficient Plant July 2018 - Index
Efficient Plant July 2018 - Showcase
Efficient Plant July 2018 - Seeking Reliability
Efficient Plant July 2018 - Cover3
Efficient Plant July 2018 - Cover4
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