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This video makes three maintenance decisions in ReliaEn from reliability data: which failure modes preventive maintenance should cover, when to replace a part before it fails, and how many spare parts to hold.

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First, the preventive-maintenance scope.

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A production line has 12 failure modes, each with its total downtime, its number of failures and the cost of one preventive visit, from one year of records.

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Open File and choose Import Data (Excel / CSV / JSON)…, then choose the line's file.

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Press Open and accept the wizard's columns.

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Open System and choose PM-Scope Optimization…

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Set the four columns: the mode, the downtime, the failures and the cost per visit.

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The line runs 8760 hours a year and loses 10000 for every hour it stands still, the form's defaults.

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Press OK — Calculate.

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ReliaEn ranks the modes by their mean downtime per failure and builds 5 control levels, from the narrowest scope to the widest.

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The Optimal control level is Class II: put modes C, E, F, G and H under PM, and accept the breakdowns of the other 7.

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That costs 7,418,537 a year in all, 1,848,170 less than the next-best scope.

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The control-level table shows why: controlling every mode would cost 28,536,619 a year, because prevention then costs more than the breakdowns it removes.

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Second, the replacement age.

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Fourteen mechanical seals were tested: 10 failed, and 4 were still running.

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Open File and choose Import Data (Excel / CSV / JSON)…, then choose the seals' file.

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Press Open and accept the wizard's columns.

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Open the Weibull (2P) form, with the failures in column A and the survivors in column B.

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In the age-replacement group, type the planned cost, 6000, the breakdown cost, 60000, 10 machines and 6000 hours a year.

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Press OK — Calculate.

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The shape β is 1.8157, and its whole interval lies above 1: the seals wear out, so replacing them on age can pay.

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The age-replacement card gives the best age, T star, 75.5 hours.

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The cost rate falls from 302.30 an hour when seals run to failure to 181.30 an hour, a saving of 40.0%.

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Only 13.0% of seals still fail before their planned change, and across the 10 pumps the saving is 7,259,949 a year.

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Third, the spare parts.

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Four pumps each run one mechanical seal with a constant failure rate of 0.001 per hour, through a 600-hour campaign with no resupply.

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Open System and choose Spare Parts Optimization…

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Choose Manual, the exponential family and λ 0.001, 4 machines, a horizon of 600, and a target service level of 90%.

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The expected demand is 2.4 failures over the campaign.

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The Recommended stock s* is 4 spares, with a service level of 90.41%: 4 spares cover all failures in the campaign 90.41% of the time.

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So the line's PM covers 5 modes, the seals are changed at about 75 hours, and the campaign carries 4 spare seals.

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The next video turns to the CMMS: assets, work orders and PM schedules.