Reliability Solutions    To prevent unscheduled downtimes and for a systematic elimination of recurring faults

Sporadically recurring faults represent a serious challenge to reliability in complex production plants. A detailed root cause analysis (RCA) in connection with an optimization concept improves reliability. In order to prevent unscheduled downtimes, our customized condition monitoring offers reliability and excellent exploitation of the lifetime of critical plant components by means of an individual combination of appropriate monitoring processes.

The challenge Modern production plants usually consist of complex systems connected up in a network. Due to this complexity, errors are often concealed. The results are sporadically recurring faults whose causes often remain a mystery, therefore posing an ever-present risk of outages. Whether caused by such problems or not, unscheduled downtimes must always be avoided. Individual measures or global solutions are often not effective. Customized condition monitoring is the truly appropriate instrument here.

Our solution

Enhancing reliability Our specialists have developed a system for improving reliability that brings recurring disruptions under control. First of all, an as-is assessment of the critical sub-systems and their process parameters is performed in the context of a reliability inspection. Interviews are also conducted with production and maintenance managers. The results then serve as a basis for a problem-oriented analysis concept. With the help of selected analysis procedures, a detailed root cause analysis (RCA) is performed. Any errors which are found are immediately remedied and a concrete optimization concept devised to eliminate the causes. The final step is the technical implementation of the optimization measures. Customized condition monitoring Condition monitoring is a suitable instrument for avoiding unscheduled downtimes – but not in the form of individual measures or global solutions. It is the combination of a variety of condition monitoring processes that allows effective and efficient predictive maintenance. The as-is assessment of the components and sub-systems to be monitored lays the foundation for this approach. The result is a specific analysis mix: a concept aligned to the plant concerned which considers questions of criticality and combines a variety of analysis processes. The required measurements are performed at specified intervals or in the form of continuous online monitoring. This allows early prognosis of imminent damage. In order to obtain precise assessments and to give information about the condition and remaining useful lifetime, the assessment algorithms are adapted to the respective ambient conditions. A diagnosis report describes the current condition of the plant, contains trend analyses and provides a plan of action for eliminating any defects. As a result, the potential remaining useful lifetime of critical plant components is virtually exploited to the full and the schedule for any necessary servicing activities can be optimally coordinated with the production plan.

Good reasons for Reliability Solutions

Unscheduled downtimes avoided;

Causes of recurring faults eliminated;

Early forecasting of imminent faults;

Exploitation of technically possible lifetime of components and plant;

Sustained increase in plant reliability.