RAMS Knowledge

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What is RAMS..?

RAMS Stands For…

Reliability
Availability
Maintainability
Safety

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What is RAMS..?

RAMS is an innovative approach to solving production related

risks.

• Reliability is a product's or system's ability to perform a

specific function and may be given as design reliability or
operational reliability.

• Availability is the ability of a system to be kept in a

functioning state.

• Maintainability is determined by the ease with which the

product or system can be repaired or maintained.

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What is RAMS..?
• Safety is the requirement not to harm people, the
environment, or any other assets during a system's life
cycle.

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Objectives of RAMS
 Verification and validation of system.

 Planning of preventive and predictive maintenance.

 Planning for corrective maintenance and safety activities.

 Analysis of modifications and parts replacement.

 Forecast and planning of sourcing various key parts of the

system.

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Basic Elements of RAMS
 Mean Time to Repair (MTTR) :

 Average time between the occurrence of a fault and

service recovery.

 Mean Time Between Failures (MTBF) :

 Average time between recovery from one incident and

the occurrence of next.

 Mean Down Time (MDT) :

 Average time between the occurrence of faults to till

rectify the faults.
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Mean Time Between Failures and Mean Time To Repair
What is MTBF and MTTR
MTBF, or Mean Time Between Failures, is a metric that
concerns the average time elapsed between a failure and the
next time it occurs. These lapses of time can be calculated by
using a formula.

Whereas the MTTR, or Mean Time To Repair, is the time it

takes to run a repair after the occurrence of the failure. That is,
it is the time spent during the intervention in a given process.

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MTBF

MTBF
Total time of correct operation in a period/number of failures.
For example: a system should operate correctly for 9 hours
During this period, 4 failures occurred. Adding to all failures, we
have 60 minutes (1 hour). Calculating the MTBF, we would have:
MTBF = 9/4 = 2.25 hours.
This index reveals that a failure in the system occurs every 2
hours, leaving it unavailable and generating losses to the
company. The opportunity to spot this index allows you to plan
strategies to reduce this time.

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MTTR

MTTR
Total hours of downtime caused by system failures/number of
failures
Using the same example, we come to the MTTR, by using the
following formula:
MTTR = 60 min/4 failures = 15 minutes.
Above, we have the average time of each downtime.
Therefore, the company knows that every 2 hours, the system
will be unavailable for 15 minutes. Being aware of our
limitations is the first step to eliminate them.

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Uptime calculation

 How long the system should work: e.g. : 24 Hr

 How much elements considered for the RAMS: 12 Nos.

 No of working days as per KPI Monthly / Weekly.

 Formula : No of Operating hours X No of Equipments X No

of Days (Monthly or Weekly).

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Availability
The probability that an item will operate satisfactorily at a given
point in time when used in an actual or realistic operating and
support environment.
It includes logistics time, ready time, and waiting or
administrative downtime, and both preventive and corrective
maintenance downtime.
Formula :
MTBF
MTBF+MTTR

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Failure Analysis Methods
Every product or process has modes of failure.

 An analysis of potential failures helps designers focus on

and understand the impact of potential process or product
risks and failures.

 Several systematic methodologies have been develop to

quantify the effects and impacts of failures.

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Why perform failure analysis?
Product Development:

 Prevent product malfunctions.

 Insure product life.

 Prevent safety hazards while using the product.

Process Development:

 Insure product quality.

 Achieve process reliability.

 Prevent customer dissatisfaction.

 Prevent safety or environmental hazards.

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Common Failure Analysis Techniques

Cause-Consequence Analysis

Checklist

Event Tree Analysis

Failure Modes & Effects Analysis (FMEA)

Failure Modes, Effects and Criticality Analysis (FMECA)

Fault Tree Analysis (FTA)

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Common Failure Analysis Techniques

Hazard & Operability Analysis (HAZOP)

Human Reliability

Preliminary Hazard Analysis (PHA)

Relative Ranking

Safety Review

What-If / Checklist Analysis

What-If Analysis

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Two common but Fundamentally different Techniques

1. Failure Modes Effects Analysis (FMEA)

2. Fault Tree Analysis

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Failure Modes & Effect Analysis (FMEA)
 Tabulation of equipment/components and their associated single point
failure modes, consequences and safeguards.

 Identification/assessment of risk is derived from looking at each

component (or machine in the case of multi-unit manufacturing).

This is commonly referred to as a bottom-up approach.

Example :
Failure
Item Identification Description Effects Safeguards Actions
Modes
-Supports Weight
-Traction -Stranded Spare Tire Acceptable
1 Car Tire Flat
-Cornering -Loose Control In Trunk as is
-Smooth Ride
-Empty -Fuel Gage
-Stall Acceptable
2 Gas Tank Holds fuel -Blows -Locate away
up -Car Destroyed from Engine as is

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Implementation of FMEA

An FMEA can be implemented using a hardware or functional

approach, and often due to system complexity, be performed
as a combination of the two methods.

Hardware = loss of a component

Functional = loss of a function or feature

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Failures
Need to understand failures which can be any of the
following:
– Failure is any loss that interrupts the continuity of production.

– Failure is a loss of asset availability.

– Failure is the unavailability of equipment.

– Failure is a deviation from the status quo.

– Failure is not meeting target expectations.

– Failure is any secondary defect

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FMEA Procedure
 Review and understand product or process design;
breakdown into components (product) or steps (process).
Brainstorm modes of failure.
Rate the severity of each effect of failure.
Rate the likelihood of occurrence for each failure.
Rate the likelihood of detection for each cause of failure
(i.e. the likelihood of detecting the problem before it
reaches the customer or operator).
Compute the Risk Priority Number, RPN = Severity x
Occurrence x Detection

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FMEA Procedure
Implement corrective actions to minimize the occurrence of
the more significant failure modes (i.e. the highest RPN’s).
Re-assess the product or process by another cycle of FMEA
after the actions have been completed.
Perform regular (re)assessments of failures as needed.

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FMEA Table
Example: Hydraulic Hose Failure

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Analysis of FMEA Table

 Severity, Occurrence and Detection ratings are based on a 1

= low to 10 = high scale.

 The FMEA results clearly show the greatest risk is

associated with overpressure failure, and the lowest risk is
due to weathering-related failure.

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Fault Tree Analysis

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Fault Tree Analysis
Fault Tree Analysis (FTA) is another technique for reliability
and safety analysis. Bell Telephone Laboratories developed
the concept in 1962 for the US Air Force for use with the
Minuteman system.
It was later adopted and extensively applied by the Boeing
Company.
Fault tree analysis is one of many symbolic "analytical logic
techniques" found in operations research and in system
reliability.

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Fault Tree Analysis

 Graphical model that displays the various combinations of

equipment failures and human errors that can result in the
main system failure of interest.

 Identification/assessment of risk is derived by first identifying

faults/hazards.

It is a top down approach.

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Fault & Failure
FAULT :

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Fault Tree Example

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