1. Reliability J&J - São José dos Campos

2. Asset Reliability Definition:
“Reliability is the probability of an asset to achieve the user needs over a period of time, under determined conditions”
The desired reliability is only achieved from the synergy of people directly involved with the asset: Operation, Maintenance, Engineering and others indirectly involved with it.

3. Human Reliability Definition:
“The probability of performing a service or task satisfactorily by a person at any stage required in the operating system within a minimum time limit specified.”

4. Environment People Asset TPM TAG (5S, steps 1...) RCM, FMECA RCFA, LCC
CPM
TPM
(5S, steps 1...)
TAG

5. Reliability Criticality Technics Measurement Structure Training
- Cont. improvement
- Mnt methodology
- Periodic review
- RCM
- FMECA
- RCFA
- LCC
Early Mgm
ME² - Reliabilty
Asset Criticality
Criticality analisys
- MTBF
MTTR
Availability
- Reliability Policy
Supplier Interaction
Engineering Interaction
TAG / TPM Interaction
EHS Interaction
Project Management
- Cost
- Quality
- Time
- Scope
- HR
- Comunications
- Risks
- Aquisition
- Integration
Technical background
Human Reliability

6. System Reliability
Equipment
Human factor
Operator
Maintenance
staff

7. Reliability Process Management
Development of projects
Creation of PM
Implementation
of projects
Implementation of
FMECA or RCM
Strategy definition
Trainnings
Criticality analysis
Trainnings
Monitoring Results
Strategy effectiveness
analysis
Change Plans (PM)
Service orders analysis
MAP approval
Feedback meetings

8. Production process Criticality analysis A, B, C (Critical A)
RCM project
(Critical A)
Criticality review
Redesign
Improvement
Predictive
Searching
failure task
Maintenance
strategy
KPI´s
Preventive
CMMS PM
Corrective (OTF)
Plan review
Task combination
Planning and
execution
Procedures

9. Reliability Process - RCM /FMECA
Identify Equipments Y A
Implement RCM or
FMECA 1 e 2
Evaluation of criticality >2 years?
Criticality analysis B
Implement RCM or
FMECA 2 N C
Implement manufacturer recomendations / maintenance knowledge Y
Was there a change of criticality?
There have been significant changes?
Start the process of revising RCM or FMECA
Select maintenance strategy
Critical A and B: FMECA or RCM
Critical C: Manufacturer recommendations. Y N N
Evaluate significative changes implemented, taking into account:
- Maintenance plan job (PM)
Change Control Process
Improvements (EUREKA)
Failure analysis (5W/ RCFA)
KPI: Availability (IIMM / FI), MTBF, MTTR
Define:
Frequency
Resources
Spare parts
Programmingand execution PM
Creation of Plans and load CMMS
SAP / MAXIMO

10. Bottling 100 to 300 ml on a speed of 55 up to 100 bottles/min
RCM2 project
Filling Machine S-1
Function:
Bottling 100 to 300 ml on a speed of 55 up to 100 bottles/min

11. Failure modes analysed
S1 - RCM project
Failure modes analysed
Roda alimentadora (Feeding wheel) 37
Envasadora (Filler) 97
Tampadora (Capping) 50
Etiquetadora (Labeler)
109
Aplicadora de Lacre (Sealer) 42
Total
335

12. S1 - RCM project Maintenance strategy Summary
Redesign ( Improvements ) 17
4,8%
Preventive (disposal) 11
3,2%
Preventive (recovering) 8
2,4%
Predictive (task condition) 53
15%
Searching failure task 21
5,9%
Operate til Fail (OTF)
242
68,7%

13. Comparing old and new plans
Labor
Equipment
Failure modes analysed
Task
Old plan
Duration
Annual
(minutes)
Actions RCM
New plan annual
Reduction
(%)
Roda alimentadora
Feeding wheel 37 9
1536 5
1506 2
Envasadora
Filler 97 68
8274 43
3564 57
Tampadora
Capping 50
6981 20
1538 78
Etiquetadora
Labeler
109 38
5132 25
2782 46
Aplicadora de Lacre
Sealer 42 32
3857 11
540 86
Total
335
25780
9930 61

14. Comparing old and new plans
Material cost
Equipment
Quantity of tasks
Old plan
New plan
Material cost reduction
(%)
Roda alimentadora
Feeding wheel 12 8 2
Envasadora
Filler 59 33 53
Tampadora
Capping 57 20 86
Totais
128 61 74

15. Redesign (Improvements)
Function
Functional failure
Failure mode
Cap bottles filled at a speed of 40 to 120 per minute, with torque from 3.5 to 7.0 Nm
Do not cap bottles
Bottles misaligned in relation to cap
Failure effect
Action
If the jaws are misaligned, the cap does not fit properly. This can cause spillage of product or kneading the bottle. Repair time 10 minutes
Provide training about adjustment to the operational group

16. Redesign (Improvements)
Function
Functional failure
Failure mode
Cap bottles filled at a speed of 40 to 120 per minute, with torque from 3.5 to 7.0 Nm
Do not cap bottles
Improper adjustment in the pan
Failure effect
Action
Improper adjustments to set the vibration can damage the pan and stop the process
Time to repair the pan is about 2 hours
Create maintenance procedure to adjust appropriately the electronic parameters of the machine

17. KPI – IIMM (2009)

18. KPI - MTBF and MTTR (2009)

19. KPI – Maintenance Cost (2009)

20. Criticality Prioritization
Criterias:
Criticality factors based on EH&S, Quality, Planning, Utilization, Downtime, MTBF and Waste
Maintenance cost
Maintenance impact on OEE

21. Critical “A” definition
Score
Impact
Cost ( average month )
Points
1 - baixo
1 a 6%
até R$ 5.000,00
até 1000
2 - Médio
>6 a 10%
>R$ 5.000,00 a R$ ,00
>1000 a 1500
3 - Alto
acima 10%
acima R$ ,00
acima 1500

22. Confiabilidade

23. Thanks!