Design for Reliability Enabled by Industrial IoT Technologies

Design for Reliability (DfR) blends engineering principles and subject matter expertise (SME) to eliminate defects and verify robust design.  ARC Sr. Analyst, Paula Hollywood, discussed the DfR concept with Sandra DiMatteo, Digital Twin Solution Marketing Director at Bentley Systems, and Marie Getsug, Jacobs Asset Management Consultant and Program Manager.  You can listen to the entire podcast here.

What is Design for Reliability?

When asked to define the DfR concept, Ms. DiMatteo worked backwards from the goal, reliability, to explain it.  “Complex assets that are made up of systems and sub-systems depend on the reliability of their components.  Reliability is the probability that the asset will continue to perform over a specified interval of time, under specified operating conditions.  Predictability and consistency all start in the design stage.”  As a champion of DfR throughout her career, Ms. Getsug, offered, “Through application of DfR practices, the demand for highly-reliable systems can be met while ensuring that the latest methods for the assessment of robust design and risk-management are properly addressed.  The design and concept stage gates become the most significant triggers for DfR and the mechanism for the timely application of each DfR element.”  “DFR is systematic, streamlined, engineering that drives reliability into the asset lifecycle,” added Ms. DiMatteo.    

The value proposition is significant, elaborated Ms. Getsug, “TCO can be reduced by up to 40%.  A more rapid and less variable project vertical startup can be achieved by reducing startup time and the number of problems encountered from the CapEx to OpEx switch.  Performance and reliability are improved through proactive and timely identification and elimination of defects related to lost performance and reliability.  The Defect Discovery and Prevention Process (DD&PP) is applied to address defects as the assets and project matures.”  Ms. Di Matteo agreed, adding “DfR places the emphasis on reliability across the entire asset lifecycle.”

Industrial IoT Technologies Form DfR Feedback Loop

The DfR concept is not new, but the technology to close the loop from the O&M stage of the lifecycle back to the design stage is at hand.  Industrial IoT technologies are changing the dynamic.  Ms. DiMatteo elaborated, “As digitalization and IoT adoption increases in an enterprise, data will grow exponentially.  With every sensor added and every design modification to improve performance, the underlying engineering information, system of record, needs to be updated.  That doesn’t happen in timely manner.  Accessing the right data at the right time can be time-consuming and troublesome if you are not sure of its accuracy.  That’s why I like to talk about digital line of sight.  Digital line of sight, digital proof if you will, means that management has proof of accurate information to make decisions and that workers have the proof of the reasons behind their daily activities.” 

From the practitioner perspective, Ms. Getsug offered, “I see Industrial IoT Technologies as a driver, tool, and efficiency and effectiveness approach to support asset management, including DfR and many other interests and functions.  Ultimately, I see the Industrial IoT Technologies as a means to take asset management and DfR from proactive decision making with SME and stakeholder engagement to prescriptive modeling and simulation supported by data and SME.  The challenge is finding ways to reflect experience in the data supporting the Industrial IOT models.”

The DfR - Asset Management Connection

Both women agree that the connection between DfR and asset management is risk.  Ms. Getsug offered, “The process begins by establishing a clear set of risk-based and science-based standards, specifications, and protocols that optimize delivery of the critical success factors, such as reliability, performance, and risk in physical assets prior to procurement, fabrication, and installation.”  Ms. DiMatteo concluded, “Assets need to deliver value to their stakeholders, we need alignment of reliability and asset management strategies and plans to manage risk, proactive leadership to drive the plans and ensure sustainability, and then constant and consistent assurance of data and governance as a defensible process.”