Engineering for Reliability

80% of your maintenance costs are determined during design

Four hours of downtime equals $4,200 in damage. The real cost? $18,000 over three years - because during design a cheaper motor was chosen that saved $3,000. Every $1,000 saved in design causes on average $47,000 in extra maintenance costs over the asset's lifetime.

The problem: 80% of reliability problems originate during design and construction. This book shows you how to build reliability in from the very first design decision. Every phase treated systematically with concrete methodologies and calculation models.

Complete methodology in 6 phases

• Phase 1: Understanding the problem - the 80/20 rule of reliability engineering, the 5-Why technique for root causes, the iceberg principle: real costs are 3-5 times higher than visible repair costs
• Phase 2: Specifications - stakeholder analysis, Early Equipment Management, and RAMS methodology (Reliability, Availability, Maintainability, Safety) to define quantitative objectives
• Phase 3: Criticality analysis - set priorities across five risk dimensions: safety, environment, delivery reliability, quality, and sustainability. Determine which assets deserve $50,000-$500,000 in engineering versus a $500 basic analysis. Result: $1.3 million in savings, 18% higher availability
• Phase 4: Design - FMEA: seven core questions identify all failure modes, RPN prioritizes improvements. Maintainability: five design principles (accessibility, visibility, standardization, modularity, diagnostics). RCM prevents both over- and under-maintenance
• Phase 5: Economic justification - Life Cycle Costing: pump B ($12,000) saves $85,000 versus pump A ($8,000) through lower energy and maintenance costs. NPV calculations and business cases that convince management
• Phase 6: Realization - commissioning, systematic supplier selection, and portfolio management creating $1.4 million in additional value

• 35% lower lifecycle costs through thorough analysis
• Up to 47:1 return on reliability investment
• $1.3 million savings through criticality analysis
• $50,000-$100,000 gain per asset through LCC
• 60-80% fewer commissioning problems