{"id":7272,"date":"2022-03-10T23:13:42","date_gmt":"2022-03-11T06:13:42","guid":{"rendered":"https:\/\/limblecmms.com\/?p=7272"},"modified":"2025-05-30T13:05:35","modified_gmt":"2025-05-30T19:05:35","slug":"reliability","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/reliability\/","title":{"rendered":"7 Ways to Improve Equipment Reliability"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<span style=\"font-weight: 400;\">Ever since the first industrial revolution, in one form or the other, improving equipment reliability has been the core subject of interest for <\/span><a href=\"https:\/\/limblecmms.com\/blog\/reliability-engineer\/\"><span style=\"font-weight: 400;\">reliability engineers<\/span><\/a><span style=\"font-weight: 400;\"> and maintenance professionals alike.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Designing highly reliable equipment requires subject matter knowledge of the <\/span><a href=\"https:\/\/limblecmms.com\/blog\/reliability-engineering\/\"><span style=\"font-weight: 400;\">concepts of\u00a0 reliability<\/span><\/a><span style=\"font-weight: 400;\">, working principles of the equipment under consideration, levels of desired performance, and the context of the operation where the equipment is intended to operate in.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Below are seven ways equipment reliability can be improved at the design and operational phases.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">1) Improve data quality<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">The presence of high-quality data represents the single most important thing to have at any <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/asset-lifecycle-management\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">stage of the asset lifecycle<\/span><\/a><span style=\"font-weight: 400;\">.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Oftentimes, the equipment failure and maintenance data is either not available or it is contaminated with errors and biases. This lack of quality data leads to reliability engineers judging equipment performance based solely on their experience &#8211; resulting in decision-making that is not able to squeeze the maximum value out of the available assets.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The best way to ensure data quality is to simplify, standardize, and automate equipment data collection and reporting.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">All of that can be done by implementing a <a href=\"https:\/\/limblecmms.com\/cmms\/cmms-mobile-app\/\">mobile-enabled CMMS app<\/a> like Limble. It serves as your centralized data repository with instant access to maintenance information like:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Who has performed what, when, and for how long<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">An overview of all <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-work-request\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">work requests<\/span><\/a><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">List of tools and parts used during the repair process<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Detailed <\/span><a href=\"https:\/\/limblecmms.com\/blog\/equipment-maintenance-log\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">equipment maintenance log<\/span><\/a><span style=\"font-weight: 400;\"> with technicians\u2019 notes for each asset (which can be used to identify common problems and failure modes)\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Costs associated with each part, asset, vendor, and contractor<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Various <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-kpi\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">maintenance metrics and KPIs<\/span><\/a><span style=\"font-weight: 400;\"> you set up and decide to track (for example, Limble automatically calculates metrics such as MTBF, MTTR downtime, etc.)<\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-5950 aligncenter\" style=\"border: black; border-width: 2px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS.png\" alt=\"Tracking maintenance metrics with Limble CMMS\" width=\"1097\" height=\"1105\" data-darkreader-inline-border-top=\"\" data-darkreader-inline-border-right=\"\" data-darkreader-inline-border-bottom=\"\" data-darkreader-inline-border-left=\"\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS.png 1097w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-298x300.png 298w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-1017x1024.png 1017w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-150x150.png 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-768x774.png 768w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-236x238.png 236w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-290x292.png 290w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-60x60.png 60w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-402x405.png 402w, https:\/\/limblecmms.com\/wp-content\/uploads\/Tracking-maintenance-metrics-with-Limble-CMMS-100x100.png 100w\" sizes=\"auto, (max-width: 1097px) 100vw, 1097px\" \/><\/p>\n<p><span style=\"font-weight: 400;\">Reliability and <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-engineer\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">maintenance engineers<\/span><\/a><span style=\"font-weight: 400;\"> can use this granular information to improve future equipment\/component designs and <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-strategy\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">develop maintenance strategies<\/span><\/a><span style=\"font-weight: 400;\"> and schedules that address the most problematic failure modes.\u00a0\u00a0\u00a0\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">2) Rank assets based on criticality<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">An industrial facility can feature hundreds or even thousands of equipment pieces. Performing reliability analysis for each one is neither feasible nor cost-effective.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The equipment has to be prioritized based on some criticality score. The most common approach is to <\/span><a href=\"https:\/\/limblecmms.com\/blog\/fmea-and-fmeca\/#how-to-perform-FMECA-analysis\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">perform Failure Mode Effect and Criticality Analysis<\/span><\/a><span style=\"font-weight: 400;\">, which can be used to rank assets based on the severity of the impact of their failures on the overall operation.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">For example, you will not spend the same amount of resources on tracking the condition of the traction converter for the locomotive versus the small manual transfer switch installed on the same locomotive.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">As pointed above, the presence of quality data plays a crucial role in performing criticality analysis.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Some of the components which may look non-critical at first sight can have a significant impact on the overall plant reliability. A detailed level of impact and criticality can only be understood if the component level breakdown information is available.\u00a0\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">3) Improve the effectiveness of maintenance work<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">The quality of performed maintenance work on an asset will have a direct impact on its reliability.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">There are many ways to improve the quality of executed maintenance work:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Ensure that maintenance techs and mechanics <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-training\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">are properly trained<\/span><\/a><span style=\"font-weight: 400;\"> and have access to the right <\/span><a href=\"https:\/\/limblecmms.com\/blog\/industrial-maintenance-tools\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">maintenance tools<\/span><\/a><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Implement condition monitoring sensors, <\/span><span style=\"font-weight: 400;\">non-destructive testing<\/span><span style=\"font-weight: 400;\">, and <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/predictive-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">predictive maintenance<\/span><\/a><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Use <\/span><a href=\"https:\/\/limblecmms.com\/blog\/standard-operating-procedure-sop\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">SOPs<\/span><\/a><span style=\"font-weight: 400;\"> and <\/span><a href=\"https:\/\/limblecmms.com\/blog\/preventive-maintenance-checklist\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">maintenance checklists<\/span><\/a><span style=\"font-weight: 400;\"> to standardize maintenance work according to best practices<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"\/cmms\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">Use a CMMS system<\/span><\/a><span style=\"font-weight: 400;\"> to set up maintenance schedules (and stick to them!)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Use CMMS and other analytics to gather and analyze data and improve upon every point mentioned above\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Getting all of this right will reduce the occurrence of unexpected downtime, as well as unnecessary planned downtimes and thus improve the overall levels of reliability and equipment availability on your plant floor.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">4) Develop metrics that track reliability<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">It is hard to improve something you do not measure. Use metrics like MTBF, MTTF, MTTR, and availability to estimate and improve the reliability of critical equipment.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In some cases, critical equipment comes with sensors that provide a real-time overview of equipment performance and health. With these sensors, the equipment time of operation can be automatically logged &#8211; along with the time and frequency of failures.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The real-time display of reliability measures provides situational awareness to the equipment operator and enables <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/corrective-maintenance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">proactive corrective actions<\/span><\/a><span style=\"font-weight: 400;\">. This reduces the probability of failure and initiates intervention before the equipment reaches complete failure, thus prolonging the <\/span><a href=\"https:\/\/limblecmms.com\/blog\/pf-curve-and-pf-interval\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">P-F interval<\/span><\/a><span style=\"font-weight: 400;\"> and equipment reliability.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">5) Increase equipment redundancy<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">One of the methods to improve the reliability of any system is to introduce redundancies that eliminate single points of failure.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Take an oil refining facility as an example. If the facility has only one specific mainline crude oil pump, it has to continuously operate to ensure the sustained operation of that facility. If it fails, the entire plant has to be shut down.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">With the use of redundancy, a plant operator can eliminate this scenario. They can install a similar-sized pump as a standby that can automatically take the load if the other one fails.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">It is a proven way to improve reliability, albeit a fairly expensive one. The investment is justified in capital-intensive industries where the impact of equipment failure on overall plant reliability is enormous.<\/span><\/p>\n<blockquote><p><span style=\"font-weight: 400;\">The same principle can be applied while designing parts and equipment. Engineers can use redundancies to address specific failure modes and create more <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/fault-tolerance\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">fault-tolerant systems<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/p><\/blockquote>\n<h3><span style=\"font-weight: 400;\">6) Improve training and skills of equipment operators<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Improving the knowledge and skill of equipment operators and other people that come in contact with the equipment is among the most cost-effective and easy ways to improve equipment reliability.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Most of the machines operated in industrial settings have to interact with humans in one way or another. No matter how sophisticated the controls for tracking machine health are, if the operators are not properly trained, the equipment is bound to experience frequent failures.<\/span><\/p>\n<p style=\"text-align: center;\"><iframe loading=\"lazy\" class=\"giphy-embed\" src=\"https:\/\/giphy.com\/embed\/hTWp5BTK4czW8\" width=\"480\" height=\"417\" frameborder=\"0\" allowfullscreen=\"allowfullscreen\"><\/iframe><\/p>\n<p style=\"text-align: center;\"><a href=\"https:\/\/giphy.com\/gifs\/truck-correct-forklift-hTWp5BTK4czW8\" target=\"_blank\" rel=\"noopener\">via GIPHY<\/a><\/p>\n<p><span style=\"font-weight: 400;\">There are several ways to minimize the chances of human errors and minimize their impact on equipment reliability both at the design as well as operational stages.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">At the design stage, reliability engineers can work with ergonomic consultants to simplify the design from a human perspective. In other words, to balance equipment efficiency with its ease of use and maintainability.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Once the human factors are incorporated in the designs, the next phase is often to make sure that operators get proper training and education.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The error-free operation of the equipment and its <\/span><a href=\"https:\/\/limblecmms.com\/blog\/what-is-troubleshooting\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">effective and quick troubleshooting<\/span><\/a><span style=\"font-weight: 400;\"> produce a direct impact on reliability by reducing unscheduled downtimes and other unpleasant surprises. As such, they should be one of the building blocks of a solid asset management program.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">7) Improve the reliability culture<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Most maintenance and plant managers should already know the importance of equipment reliability. This is because they have a broader understanding of the cash flows and profits that equipment is generating for them.\u00a0<\/span><\/p>\n<p><span id=\"developing-an-equipment-reliability-program\"><\/span><span style=\"font-weight: 400;\">The bottom-line workers, on the other hand, often fail to realize why it is such a big deal for management when equipment that was failing once every six months has all of the sudden started to fail once every four months. The workers may see this change as insignificant.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">You need to educate people at all levels of the organization about the importance of asset reliability. It is the only way to foster a culture of reliability and continuous improvement. Ideally, every person of the organization should have a clear understanding of how a machine they operate is contributing to achieving the overarching business objectives.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row content_placement=&#8221;middle&#8221; kd_background_image_position=&#8221;vc_row-bg-position-bottom&#8221; kd_top_separator_style=&#8221;skew-left&#8221; kd_top_separator_height=&#8221;separator-height-small&#8221; kd_bottom_separator_style=&#8221;skew-left&#8221; kd_bottom_separator_height=&#8221;separator-height-small&#8221; kd_top_separator=&#8221;true&#8221; kd_bottom_separator=&#8221;true&#8221; css=&#8221;.vc_custom_1682969636891{margin-bottom: 40px !important;padding-top: 120px !important;padding-right: 40px !important;padding-bottom: 50px !important;padding-left: 40px !important;background: #dde4e8 url(https:\/\/limblecmms.com\/wp-content\/uploads\/cta-laired-hex-4.webp?id=9077) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;border-radius: 0px !important;}&#8221; css_tablet_landscape=&#8221;.vc_custom_1682969636891{padding-bottom: 80px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1682969636891{padding-bottom: 80px !important;}&#8221; css_mobile=&#8221;.vc_custom_1682969636892{padding-bottom: 80px !important;}&#8221;][vc_column][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner]<header class=\"kd-section-title col-lg-12 text-center  subtitle-below-title kd-animated fadeIn   vc_custom_1682969651819\" data-animation-delay=200><h2 class=\"separator_off\" style=\"font-size: 42px;font-weight: 500;margin-bottom:30px;\">The Essential Guide to CMMS<\/h2><h6 class=\"subtitle\" style=\"color: #152232;\">The Essential Guide to CMMS<\/h6><\/header>[\/vc_column_inner][\/vc_row_inner][vc_row_inner content_placement=&#8221;top&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner width=&#8221;1\/2&#8243; css=&#8221;.vc_custom_1631866454223{padding-right: 50px !important;padding-left: 0px !important;}&#8221; offset=&#8221;vc_col-lg-6 vc_col-md-12 vc_col-xs-12&#8243; css_tablet_landscape=&#8221;.vc_custom_1631866454223{padding-right: 0px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1631866454223{padding-right: 0px !important;}&#8221; css_mobile=&#8221;.vc_custom_1631866454224{padding-right: 15px !important;}&#8221;][vc_raw_html]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[\/vc_raw_html][\/vc_column_inner][vc_column_inner width=&#8221;1\/2&#8243;][vc_single_image source=&#8221;external_link&#8221; alignment=&#8221;center&#8221; css_animation=&#8221;fadeIn&#8221; custom_src=&#8221;https:\/\/3975608.fs1.hubspotusercontent-na1.net\/hubfs\/3975608\/Content%20Downloads\/CMMS%20Guide%20mockup.png&#8221;][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<\/p>\n<h2><span style=\"font-weight: 400;\">Equipment reliability is a team effort\u00a0<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Asset reliability can\u2019t be the responsibility of reliability engineers alone. Every stakeholder, be it a designer, reliability engineer, maintenance mechanic, or equipment operator, has an impact on the reliability of the equipment they are responsible for.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Effective organizations that excel in reliability recognize this and make sure that each stakeholder has the right tools and knowledge to do their job to the best of their abilities.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Start your reliability journey today by implementing <\/span><span style=\"font-weight: 400;\">Limble CMMS<\/span><span style=\"font-weight: 400;\">. It will offer you unprecedented access to the data you need to establish strong maintenance and reliability programs.<\/span>[\/vc_column_text][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]Ever since the first industrial revolution, in one form [&hellip;]<\/p>\n","protected":false},"author":24,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[737],"tags":[],"class_list":["post-7272","post","type-post","status-publish","format-standard","hentry","category-equipment-facility-maintenance"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>7 Ways to Improve Equipment Reliability | Limble CMMS<\/title>\n<meta name=\"description\" content=\"Everything you ever needed to know about improving equipment reliability and how it can help improve your maintenance operation today. 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