Currently all organizations, be it product or service, work hard for the good performance of what they do, whether it be the product they manufacture or the service they can provide, the motto that the customer is right and above is not a mystery. that motto organizations are still working as a base.
Just think about the number of products that companies such as Apple, Samsung, LG manufacture or think about the number of services that others such as Uber, Aribnb, Amazon, Facebook, among others, have to provide. Let's think about that large number of smartphones that are sold in each of these brands, let's think about each of the rented houses, the transportation and shipping services.
However, what happens when there is an error in one of the equipment, when there is something deficiency in any of the services, organizations cannot afford to damage their image and allow errors in their products or at least no errors. serious or serious that can expose the organization and make it lose millions of dollars.
There have been cases in which this has happened and the losses are multimillion-dollar, because how can an organization be able to "monitor" millions and millions of products or services it provides? The answer to this is complicated, however, organizations make massive efforts to prevent this from happening.
One way to minimize this kind of errors is by implementing quality tools, philosophies and strategies that allow reducing all kinds of errors or failures that may affect the performance of a team or the performance of a service and for this, organizations focus on the reliability engineering.
Concepts
In order to understand a little more about the subject on which this article will be discussed, some terms will be broken down that facilitate the development of the subject.
According to (definition.de, 2009) Engineering means the following:
We can find another definition of engineering provided by (wikipedia.org) which tells us the following:
On the other hand looking for the definition of reliability and we find the following according to (Sueiro) means:
Another meaning for reliability according to (eumed.net) is:
Based on these definitions and in the same way looking, it is found that reliability engineering means the following according to (spm-ing.com, 2017):
Basic concepts.
- Failure: Termination of the ability of an item to perform a required function (ISO 14224). Failure Mode: Effect by which a failure is observed in a failed item. (ISO 14224). Cause of Failure: Circumstances during design, manufacture or use that have led to failure (ISO 14224). Time to Failure: It is the period of time that elapses from the moment the component, equipment or system starts its operation until it stops operating as a result of a failure (The time to failure is a random variable). (reliarisk.com, 2017)
Measures for reliability
Probability is the classic measure to assess reliability. However, there are many other widely used measures, so “reliability” is a generic term that describes all these measures without necessarily being related to probability. Most of these measures correspond to statistical averages or expected values that are called
"Reliability indices". (Zapata, 2011)
Some examples are presented below:
Examples of Repair Times
How to improve reliability
There are two ways in which it is possible to improve the reliability of a component or a system, these ways are the following:
- Through quality, referring to the quality of the materials with which the product is made, the tests and calibrations that are made before it is released to the market. Through redundancy, where a backup component is placed, it serves to perform the function of the one that fails.
There are also two types of redundancy.
- Active: Where the redundant component is always in parallel with the component to which it is going to support. Stand-by: It is when the redundant component is connected at the moment in which the component it supports fails or exits.
Cost of reliability
As the level of reliability increases, the level of investment required increases and vice versa. The cost of reliability must be weighed against the overall benefits for both the user and society. The acceptable level of reliability depends on what users and society as a whole are willing to pay for it. (Zapata, 2011)
This acceptable level of reliability may be different from the mathematical optimum. To justify investments in reliability improvement, the costs associated with service failures or interruptions (outputs) for users, distribution companies and society must be defined. The outage cost is defined as the value of the economic losses due to failure or exit. (Zapata, 2011)
Graph of the cost of reliability.
Cost of Reliability
Reliability assessment process
According to (Acuña, 2003) in his book he proposes a process for the evaluation of reliability which consists of 4 steps that will be described below:
- Definition of objectives and requirements. In this step, the objectives and reliability requirements of the product or process will be defined, it is carried out by a multidisciplinary group where the opinion of the client and the engineering area of the company are taken into account, in the same way the resources and limitations that are available, technological, machinery, materials, etc. Product breakdown. In this step, the process or product is disintegrated into its different components to evaluate the reliability of each element, it is advisable to use a block diagram and gozinite diagram to carry out an orderly and clear disarticulation. Prediction of product reliability.The relationship of the reliability of the parts of an element gives rise to a value of general reliability of the element, for this step probability theory is used to make an adequate estimate. Product analysis. At this point the strengths and weaknesses are located and the opportunities for improvement are determined, the faults that the product or process may present during its useful life are analyzed to correct them.
Why choose quality Engineering
During the last fifteen years the industrial world has undergone enormous and dramatic changes.
- The globalization process has increased competition, forcing industries to adjust more and more rapidly to new and complex realities. Today companies are forced to invest based on incomplete, uncertain or diffuse information, and at the same time they must produce with the lower cost, higher quality, and greater reliability Legal and environmental requirements require more reliable processes Reliability Engineering is a fundamental aspect of risk analysis Reliability engineering serves as a platform for estimates that allow weigh the influence of uncertainty associated with the variables and technical problems of the production process with financial parameters such as NPV and / or IRR. The world's leading companies are working hard on Reliability Engineering.Decision-making processes must be supported by sustainable estimates from a technical point of view with verifiable qualitative and quantitative results.(reliarisk.com, 2017)
Competencies of a reliability engineer
- Know the strategic objectives of your organization. Possess the necessary skills that allow you to understand the contribution of your roles and functions to the achievement of the organization's objectives. Understand how the maintenance and reliability goals are aligned with the strategic objectives of the organization.
Starting from these premises, we are going to proceed to describe some of the functions that a Reliability Engineer must carry out. (reporteroindustrial.com, 2015)
- Define the hierarchical structure and taxonomy of plant assets Lead the development of criticality analysis of plant assets Manage the database of the organization's assets, taxonomy, hierarchy, and criticality Guarantee maintenance plans assets according to their failure modes Implementation and management of the Predictive Maintenance program Develop statistical analysis and modeling of asset failures to optimize maintenance plans Lead Root Cause Analysis programs Lead Maintenance implementation plans Focused on
Reliability. (reporteroindustrial.com, 2015)
Company that offers Reliability Engineering (maintenance engineering)
The Reliability Centered Engineering proposed by SPM begins with a solid theoretical-technical base raised from the field by specialist engineers in the area who submit the data to rigorous studies that directly support the Maintenance Cycle and the elimination of faults.
Among the studies carried out by SPM are:
- FMEAFMECAFTARBIRCADLPWeibullJack-Knife
SPM Seeks to offer support that positively impacts the Maintenance Cycle and the organization's objectives. Their experience in various maintenance engineering projects allows them to approach this type of study with a focus on practical and real results, through indicators linked to the maximization of equipment availability.
In addition, they have a staff of highly qualified professionals in specific projects in Reliability Engineering, with extensive experience in data analysis. All its developments are focused on and aligned to reliability standards and international recommendations such as: SAE JA1011, ISO 14224, IEC 60812, among others. (spm-ing.com, 2017).
Phases of reliability engineering.
Planning: Planning focusing on maintenance refers to the process by which all the elements required to carry out a task are determined and prepared before starting work. The planning process includes all the functions related to the preparation of techniques to detect faults present during the process and the best way to avoid or eliminate them.
Programming: Within the same context, programming allows us to organize and determine what tools, methods or techniques will be implemented to organize the work that was raised in the planning phase.
Execution: within this phase, the application of methods, techniques or tools will be carried out to carry out the planned work and thereby allow the correction, reduction or elimination of failures within the processes of an organization.
Reliability as an analysis methodology must be supported by a series of tools that allow the behavior to be evaluated in a systematic way in order to determine the level of operability, the amount of risk and the other mitigation actions that are required, to ensure its integrity. and operational continuity. (Gutiérrez, 2016)
Reliability methods.
Benchmarking: It is the process to improve the performance of products and processes, identifying, understanding, and adapting the best practices, processes and characteristics, and performance of world-class products and processes, on an ongoing basis. Benchmarking compares products, processes, or services and can be internal or external.
Design for Manufacturing and Assembly (DFMA): It is a methodology
interdisciplinary that provides a method for analyzing a proposed design from an assembly and manufacturing point of view.
Design of Experiments (DOE): Used to provide a structured statistical method for planning and executing tests. It is based on the systematic variation of parameters to determine the effect of those parameters on the result.
Error-proofing (POKA YOKE): It is the practice of designing products or processes in a way that minimizes or prevents the probability of human or mechanical errors.
Applies to:
- Prevent products from being improperly manufactured or assembled Design the manufacturing process to avoid over-assembled parts Design software that does not allow entry in incorrect fields.
Functional Block Diagrams (FBD): They are graphical means to reduce complex systems into smaller parts of understandable elements for the purpose of performing analysis (FMEA / FMECA / Reliability, etc.), also referred to as “BOundary Diagrams”.
Process map / flow diagram: It is a graphical representation to reduce complex processes to understandable smaller elements, which facilitate the analysis of (PFMEA), simulation and continuous improvement. It provides a map of the activities carried out and their interdependencies (internal / external) for a given product that will be produced in a process. (Gutiérrez, 2016)
conclusion
Currently, organizations invest a lot of money in reliability engineering, if they really want this to work to be projected in all their products it is necessary to do it, it is worth investing millions of dollars to ensure much larger profits than to save those millions and see stratospheric losses, many Companies have suffered from this type of bad decisions, Samsung Galaxy Note 7 case in which the battery had a detail that made it explode, all to speed up the manufacturing process and not stop to see the details before the sale.
Another case mentioned and remembered is the case of Volkswagen when it was discovered that its carbon dioxide emissions were above legal levels, really a company of this size has all the economic potential to be able to make their cars pass without any problem this type of verifications, however, the incorrect decisions of the leaders can lead to millions of dollars in losses.
Reliability engineering may seem like an expense and does not seem to reflect any benefit because it is when things go well it is not noticeable that it is part of everything so that things turn out like this, however today companies such as Toyota, Apple, Samsung, among others spend without thinking about the investment cost because in the end a simple failure can affect their actions. They imagine vehicles without having undergone tests, without being sure that they do not fail, they imagine rockets launched into space without passing checks, I think the answer is a definite no and is that today the consumer pays the cost included of all that but looking for the same benefit, that your purchased product or service is reliable and of quality.
Thesis proposal
Development of a plan for the application of reliability engineering in the Ruíz Carpentry located in Córdoba Veracruz.
Overall objective
Apply reliability engineering in its production process for the maximum use of resources and the minimization of defects that furniture may have, thus increasing the benefit for the organization.
Thanks
I thank my mother who is the strength to continue every day and who has made me get to where I am, my teachers who have given me their time and knowledge to continue my studies, Doctor Fernando Aguirre y Hernández since He has given us all his experience and knowledge in this matter of Fundamentals of Administrative Engineering, as well as CONACYT since it gives us its support to motivate us to move forward in our adventure for mastery.
Bibliography
Acuña, J. (2003). Reliability engineering. Costa Rica: Technological of Costa Rica.
definition of. (2009). https://definicion.de. Retrieved on April 20, 2018, from https://definicion.de:
eumed.net. (sf). http://www.eumed.net. Retrieved April 20, 2018, from http://www.eumed.net:
Gutiérrez, KY (May 12, 2016). https://www.gestiopolis.com. Retrieved on April 20, 2018, from https://www.gestiopolis.com:
reliarisk.com. (January 5, 2017). http://reliarisk.com. Retrieved April 20, 2018, from http://reliarisk.com: http://reliarisk.com/es/node/230 reporteroindustrial.com. (April 29, 2015). http://www.reporteroindustrial.com. Retrieved on April 20, 2018, from http://www.reporteroindustrial.com:
spm-ing.com. (2017). http://www.spm-ing.com. Retrieved on April 20, 2018, from http://www.spm-ing.com:
Sueiro, G. (sf). https://avdiaz.files.wordpress.com. Recovered on April 20, 2018, from https://avdiaz.files.wordpress.com: https://avdiaz.files.wordpress.com/2012/06/calidad-y-confiabialidad.pdf wikipedia.org. (sf). https://es.wikipedia.org. Retrieved on April 20, 2018, from https://es.wikipedia.org:
Zapata, CJ (2011). engineering reliability. Pereira, Colombia: Publiprint Ltda.
