The investigation of the corrective maintenance procedures, preventive maintenance strategies, and equipment design revealed equipment that was not operating at the optimum maintenance interval. This means that there is a Pareto effect. Reliability analysis includes reliability calculations performed at the stages of preliminary design and detailed design, failure data analysis based on the results of special and operational tests as well as data received from a customer/user. The benefit of this systematic breakdown is a focused review of a limited number of components. The Pareto Principle: Also referred to as the 80-20 rule. Continuous Improvement Toolkit . To minimize operation and maintenance costs, plant equipment needs to operate at a maximum maintenance interval. Wilfried Pareto discovered that 80% of the wealth (Land) of … In fact, once the 3 percent of spare parts lists was completed by maintenance experts, it would then be reasonable to use a process, such as the "automatic" spare parts list function available in many maintenance computer systems, to gradually develop the lists for the other 97 percent. When ordered by the count of work requests for each component, the analysis identifies the “vital few” components that contribute the most to plant maintenance and distinguishes them from the “trivial many” that have a small contribution. Work requests from 2001-2003 were reviewed at Harris and sorted by equipment type. Would you like to get the full Thesis from Shodh ganga along with citation details? When there is a lack of data, a substitute for a Pareto analysis is to interview experienced operators, tradespeople and their supervisors to find out, for example, which equipment is repaired most frequently. A study of corrective maintenance work orders revealed that bearings had failed. Pareto analysis is a . Again this systematic breakdown permits a focused review of a manageable number of fan applications. Pareto analysis was developed by an Italian economist (amongst other fields) who analysed the wealth of Italy. In a large pulp mill, a study of three years of equipment-level downtime records showed that, of the more than 12,000 items in the plant, 87 (less than 1 percent) caused 80 percent of all unscheduled maintenance downtime. Break down by manufacturer, modelThe work requests for a specific equipment type are reviewed then by manufacturer and model. statistical technique that is used in decision making for the selection of the limited number of tasks that produce the most significant overall effect. 4. 2. The counts for equipment that comprised 40 percent of all maintenance performed at the plant over the 3-year period are shown in Fig. The most important spare parts lists are for those equipment items on which corrective maintenance or routine parts replacement is carried out most frequently. 3. Personnel perform thousands of maintenance activities annually. 1. Daryl R. Gruver is supervisor, component engineering, at the Harris plant of Progress Energy, 5413 Shearon Harris Rd., New Hill, NC 27562; (919)-362-2820. The cam-lock style roller element bearings were failing on an average of every 2-3 years compared to their L10 design life of 12-15 years. In one plant where a project to establish new spare parts lists had begun, an analysis of work-order records showed that 60 percent of all corrective maintenance was carried out on less than 3 percent of all equipment. There are several hundred equipment types in use at the plant. A thorough review was conducted of the maintenance practices for belt and bearing replacements, the preventive maintenance strategy employed on the fan, and the design of the fan. 1. Steve Bonacorsi explains how. 3). The application of the Pareto principle in problem solving and analysis can provide a great starting point with simple data analysis of process, plant failure or production data to provide an early insight into problem causes and effects without intense or complex analysis. This method uses the Pareto Principle – also known as the 80/20 rule – which states that in most situations, 80% of effects are generated by 20% of the causes. www.citoolkit.com The Pareto Principle: Also referred to as the 80-20 rule. This statement is merely a rule of thumb and is not an immutable law of nature. The solution was to install a low cost varistor for voltage suppression that will eliminate the electrical arcing. Pareto analysis identifies the most important quality-related problems to resolve in a process. The systematic application of a Pareto analysis resulted in improved equipment reliability and reduced equipment maintenance. » Pareto Analysis Example. If the resulted Pareto chart clearly illustrates a Pareto pattern, this suggests that only few causes account for about 80% of the problem. It is a form of a vertical bar chart that puts items in order (from the highest to the lowest) relative to some measurable effect of interest: frequency, cost or time. It organizes and displays information to show the relative importance of various problems or causes of problems. 5. Pareto analysis is a creative way of looking at causes of problems because it helps stimulate thinking and organize thoughts. A Pareto chart is a bar graph. Several properties of this distribution are reported and their usefulness in reliability theory indicated. Once the problem is recognized, a solution can be formulated. Here are a few examples. Since initial plant operation in 1987, Harris has experienced repeated position indication (i.e., dual indication or loss of indication) with a particular manufacturer’s solenoid valves. The Asset Criticality Ranking and Pareto analysis are two powerful and easy to generate metrics that enable you to prioritize everything you do with your reliability improvement program. The Pareto analysis was effective at uncovering the equipment reliability problems. Fig. Pareto Analysis . Starting with this 3 percent obviously would provide a much faster return on the cost of developing this critical information than working through the entire plant. Pareto analysis is a formal technique useful where many possible courses of action are competing for attention. Specifically, the Pareto principle states that 20% of the causes generate 80% of the effects, and vice-versa. This approach helps uncover reliability problems obscured by the volume of plant work requests. What Is Pareto Analysis? Three models were responsible for 75 percent of the problems. Of the 14 work requests on the model SZ-3024 fans (a centrifugal belt driven fan), 36 percent were triggered by vibration and 64 percent by loose belts (Fig. What is the Pareto Principle? The best place to start can be identified by performing a "Pareto analysis.". Pareto analysis states that 80% of a project's benefit or results are achieved from 20% of the work, or conversely, 80% of problems are traced to 20% of the causes. This is an excellent example of the value of good maintenance/operating information. The Pareto Principle is named after Italian economist Vilfredo Pareto, who in 1906 observed that 80% of land in Italy was owned by 20% of the population. Good information records will identify the 20 percent that will provide the greatest benefits. 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