Reliability Tips

1. Want to calculate production losses associated with a machine running poorly?
2. Want to compare production losses from machine downtime to losses incurred while the machine is running poorly?

3. Want to estimate the production value of eliminating an hour of equipment downtime?

Want to calculate production losses associated with a machine running poorly? 

You just need to know

1. Maximum Production Rate.

2. Time period (How long did the machine run poorly?)

3.  On-spec production during the time period.

NOTE: Everything should be in consistent units.  For example, if Maximum Production Rate is reported as pounds of pure silver per hour, then the time period should be in hours and on-spec production should be in pounds of pure silver

 The equation to calculate Production Loss is

Production_Loss = Maximum_Production_Rate x Time_Period – On_Spec_Production

If you want to know more about Maintenance and Reliability Metrics, check out our Reliability Training Videos.

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Want to compare production losses from machine downtime to losses incurred while the machine is running poorly?

Use Equivalent Downtime.  Equivalent downtime is the machine downtime that would equal the production loss from running poorly.

 To calculate Equivalent downtime you need to know

1.  Maximum Production Rate.

2. Production Loss (See Tip 1)

NOTE: Production Loss and Maximum Production Rate should be in consistent units.  For example, if Maximum Production Rate is reported as pounds of pure silver per hour, then your Production Loss should be in pounds of pure silver.  In this case, the units for Equivalent Downtime are hours. 

The equation to calculate equivalent downtime is

Equivalent_downtime = Production_Loss / Maximum_Production_Rate

Calculating Equivalent Downtime allows you to start seeing the total production impact of Maintenance and Reliability Practices.  If you want to know more about Maintenance and Reliability Metrics, check out our Reliability Training Videos.

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Want to estimate the production value of eliminating an hour of equipment downtime?

Did you know that if you eliminate an hour of critical equipment downtime, the incremental production is less than one hour of production at maximum rates?  Even if you wanted to run flat out.  You can estimate the production value using the following equation. 

Incremental_Production = Actual_Annual_Production  / 8760

This only works if you don't have in-process buffers (storage tanks or Work In Progress).  With buffers, incremental production can be substantially less and you will need a Reliability Model to calculate incremental production.  If you want to know more about why you can't get an hour of production, check out our Reliability Training Videos.

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Copyright © 2004  [RonaMax, LLC]. All rights reserved.
Revised: 03/12/04.