Willkommen in der „HOHEN SCHULE" für RAM / LCC-Experten
Leseprobe RAM / LCC
Andreas Kroenert Mobil (D): +49 1520 1683 928
im Auftrag von International Competence Centre Rail GmbH
Mitteldorfstrasse 17
CH – 6315 Oberaegeri
Switzerland
www.cc-rail.com
Schutzklausel
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© 2018 INTERNATIONAL COMPETENCE CENTRE RAIL GmbH oder ihre Tochtergesellschaften. Alle Rechte vorbehalten.
Confidential proprietary information © INTERNATIONAL COMPETENCE CENTRE RAIL GmbH – for personal use only
A brief overview …
▪ Day 1 : Module 1 – Introduction to RAM
▪ Requirements within standards and regulations
▪ Normative requirements: IRIS, IEC 62278, EN 50126-1, TR 50126-3
▪ RAM life cycle phases and RAM tasks at tender, design and demonstration phases
▪ Day 2 : Module 2 – Reliability, Availability, RAM Demonstration and FRACAS
▪ Basic calculation methods, Reliability function, Availability up and down states
▪ Failure Mode and Effects Analysis (FMEA)
▪ Failure Reporting and Corrective Action System (FRACAS)
▪ Day 3 : Module 3 – Maintainability, Maintenance and Life Cycle Cost
▪ Maintainability as a design objective
▪ Preventive and Corrective Maintenance Analysis, LCC calculation
▪ Day 4 – Summary, tips and tricks, RAM and Integrated Logistic Support, final test
▪ Tips and tricks for RAM analyses and quotations
▪ Written examination and end of the training
Contents of the Course
3
Introduction
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RAMS/LCC – Definitions and Measures
4
A brief introduction to the topic ...
Reliability Availability Maintainability Safety LCC Life Cycle Cost
Definition:Ability to perform as required for a given time interval under given conditions
Definition:Ability to be in a state to perform as and when required,under given conditions, assuming that the necessary external resources are provided
Definition:Ability to be retained in, or restored to a state in which it can perform as required, under given conditions of use and maintenance
Definition:Safety is the state of being protected against failure, damage, error, accidents, which could be considered non-desirable
Definition:Cost of ownership
Measure:E.g. Mean Distance Between Failures (MDBF) according to a specified failure category (e.g. delay)
Measure:E.g. number of up time hours compared to total hours or number of trains of a fleet available in the morning
Measure:E.g. Mean Time To Repair (MTTR), man-hours, tools
Measure:E.g. Safety Integrity Level (SIL), Tolerable Hazard Rate (THR)
Measure:E.g. maintenance cost, energyconsumption calculated and validated according to an agreed model
Module 1 – Introduction to RAM
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IRIS Requirements
5
Requirements with a view to RAM Management
▪ Maintainability of the product shall be an integrated part of the design and development Process
▪ Standardized routines for the Maintenance of software shall be established and recorded according to IEC 62278 (EN 50126), IEC 62279 (EN 50128), IEC 62425 (EN 50129) or other agreed equivalent models in accordance with the design and development Process
▪ The organization shall have a documented Procedure in place to cover all the aspects of RAMS activities, including:
▪ Calculation and documentation
▪ Data collection, analysis and improvement action plan set up
▪ Implementation of defined tasks of the action plan
▪ Implementation of defined tasks of the action plan
Module 1 – IRIS standard
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System RAM Life Cycle
6
RAM programme and life cycle phases EN 50126 and TR 50126-3
1 Concept
2System definition and application conditions Risk analysis
3 Risk analysis
4 System requirements
5 Apportionment of system requirements
6 Design and implementation
7 Manufacture
8 Installation
9 System validation
10 System acceptance
11 Operation and maintenance
12 Performance monitoring
13 Modification and retrofit
14 Decommissioning and disposal
TenderPhase
DesignPhase
OperationPhase
DemonstrationPhase (9,10,11)
PreliminaryAnalysis (1,2,4,5)
Module 1 – Implementation of RAM / Life cycle phases
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Survival function with the example of human beings
The probability of survival for a 60-years old man is 80%80% of men will reach an age of 60 years or more, this is a probability of failure of 20%
Reliability
7
0%
20%
40%
60%
80%
100%
0 20 40 60 80 100
Rel
iab
ility
(Pro
bab
ility
of
surv
ival
)
Age of death (‘failure‘)
R(t
)
Module 2 – Reliability / Survival function
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Failures
8
Bathtub curve – schematic diagram
Module 2 – Reliability / Failures
Failu
re r
ate
Time
IDecreasing failure rate
IIConstant
failure rate
IIIIncreasingfailure rate
Wear out failures
Early failures(‘infant mortality’)
Random failures
Observedfailure rate
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Reliability Performance Indicators
9
Reliability parameters – examples for repairable items
Symbol Parameter Dimension
MTBF Mean Time Between Failure Time
MDBF Mean Distance Between Failure Distance
MCBF Mean Cycles Distance Between Failure Cycle
MTBSF Mean Time Between Service (Affecting) Failure
Time
MDBSF Mean Distance Between Service (Affecting) Failure
Distance
Module 2 – Reliability / Reliability performance indicators
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Versions of the FMEA
▪ Identification of weak points in the manufacturing process (also operation and maintenance)
▪ Process failures (human errors, machines, methods, etc.) are analyse with regard to their impact of the system and/or components
Failure Modes and Effects Analysis
10
FMEA
Functional FMEA(System FMEA)
Design FMEA Process FMEA
▪ Identification of weak points in the system layout and configuration
▪ Analysis of the effect of functional failures
▪ Derivation of improvement measures within the system architecture
▪ Aim: Improve reliability
▪ Identification of weak pointsin the system (component) design
▪ Analysis of the potentialfailure modes of system components
▪ Strengthening of component design (e.g. environmental resistance)
▪ Aim: Improve reliability (quality)
Component FMEA
Module 2 – Reliability /FMEA
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Availability
11
Availability calculation using up and down states of a system
▪ Ratio of (Up’s) the operational time of an item and the total (possible) time
▪ Availability A = Up’s = Up’s = 26 h = 0,87 = 87%T Up’s + Down’s 30 h
▪ Availability A [%] = Total time – Down timeTotal time
▪ Or: Availability A = MTBFMTBF + MDT
Total time T = 30 hrs
‘Down’ = 1 hrs ‘Down’ = 1 hrs ‘Down’ = 2 hrs
X 100
X 100 with MDT = Mean Down Time
Module 2 – Availability / Up and down states
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FRACAS
12
FRACAS – Failure Reporting, Analysis and Corrective Action System
▪ Systematic approach to gather and analyse field data with the aim of identifying weak areas and introducing corrective measures for improvement
▪ Key features: FRACAS closed loop and Failure Review Board (FRB)
Reporting- Failure reporting and monitoring- Key performance indicator, KPI:
MTBF, MDBF, MTTR, …
Analyse- target actual-comparison, Pareto-Diagram- root cause analysis
Corrective actionResolution andimplementation
Control improvement- Verify corrective action- Close-out Report
Control group
Module 2 – FRACAS / Definition
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0
20
40
60
80
100
120
Weak Point Analysis
13
Identification of weaknesses and derivation of corrective actions
0
20
40
60
80
100
120
FPM
K (
km)
Time (month)
Target
FPM
K (
km)
Time (month)
Failure mode 1Corrective action 1
Failure mode 2Corrective action 2
Failure mode 3Corrective action 3
Target
Module 2 – Reliability Growth / Weak point analysis
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Maintainability Targets
14
Catalogue of basic requirements see VDI 2246 Part 2
▪ Ability to identify
▪ Accessibility
▪ Interchangeability
▪ Serviceability
▪ Inspection
▪ Testing
▪ Transportation
▪ Storage
▪ Standardisation
http://www.pixabay.com
Module 3 – Maintainability / Maintainability targets
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Maintenance Types
15
Maintenance types according to EN 13306‘Maintenance – Maintenance terminology’
Maintenance
PreventiveMaintenance
CorrectiveMaintenance
Predetermined Maintenance
Scheduled,on request, or
continuousScheduled Deferred Immediate
Module 3 – Maintenance / Maintenance types
Conditioned Based
Maintenance
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Maintenance Types
16
Potential-to-functional failure interval for Conditioned Based Maintenance
Co
nd
itio
n
Time (cycles, Mileage)
Worsening: Point where the failure starts to occur
Potential failure symptom:Point where it can find out that an item is failing
Failure
P
F
P-F intervalLead time between the ability to detect a failure process and the actual loss of function
Prerequisite:P-F interval needs to belong enough !
Module 3 – Maintenance / Maintenance types
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Aspects for determining the maintenance strategy
▪ Safety and Availability
▪ Operation
▪ Environment
▪ Design (difficulty, complexity)
▪ Resources
▪ Maintenance staff
▪ Qualification
▪ Workshop facilities
▪ equipment
▪ Economic criteria and costs
▪ Laws, regulations, ordinances
▪ …
• preventive
• corrective
• condition based
Maintenance type
• line maintenance
• shop maintenance
Maintenance level • user
• manufacturer
• third party
Maintenance provider
Maintenance Strategy
17
Module 3 – Maintenance / Maintenance strategy
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LCC cost elements – example for railway applications (rolling stock)
Life Cycle Cost
18
Life cycle cost
Acquisition cost Disposal costOperation cost Maintenance cost
▪ Vehicles
▪ Initial spare part stock
▪ Strategic (main) spare parts
▪ Workshop and equipment
▪ Special tools
▪ (Initial) Training
▪ …
▪ Driver and/or train attended
▪ Warehousing
▪ Logistic, transport
▪ Periodic training
▪ Energy consumption
▪ Cleaning(external/internal)
▪ Management and administration
▪ …
▪ Preventive maintenance▪ Inspection▪ Service▪ Overhaul
▪ Corrective maintenance▪ Failures▪ Vandalism▪ Accidents
▪ Maintenance of spares
▪ …
▪ Disposal▪ Replaced spare parts▪ Operating materials
▪ Recycling
▪ …
Module 3 – Life Cycle Cost / Cost elements
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Summary – RAM activities along the V-cycle
Wrap-up
19
FMEALRU/LLRU_ID
FAIL_ID
PM/CM-AnalysisLRU/LLRU_ID
FAIL_ID
Failure effect andmaintenance task
identification
Maintenance task analysis (planning and support)
FTA / RBDFAIL_ID
(Technical)Breakdown of parts
LRU/LLRU_ID
System / Subsystem description
Overall Systemreliability analysis
Operationprofile
Field dataFRACAS
RAM Demonstration
RCM / Field Experience /subcontractor recommendations
standard and authorities regulations
Module 4 – Wrap-up
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Contact
20
Your contact at CC-Rail
Module 4 – Contact
Andreas Heinzmann International Competence Centre Rail GmbH
CH – 6315 OberaegeriSwitzerlandwww.cc-rail.com
Mobil (D): +49 172 622 32 73Phone (D):+49 333 977 33 37
I would be very happy to hear from you again.
If you leave me a message, I will aim to return within 24 hours.