Reliability Design Checklist

A. General strategy for Reliability participation in FAT 1) Ensure that Reliability Engineer is included in the development of the FAT document for each piece of equipment manufactured. 2) Ensure that the reliability requirements are submitted to vendor prior to the design completion – possibly with this checklist 3) Ensure that the FAT template contains specific and actionable reliability requirements and references applicable reliability standards

B. Include in FAT template for Reliability / Maintainability

General Requirements  Provide documentation that the equipment meets the GMI Vibration Standards. o Location of vibration pads and sensors are noted. o Equipment is isolated to minimize shock and vibration.  Grinders, hammer mills and similar equipment have on board vibration and temperature monitoring devices.  Provide documentation that the equipment meets the GMI Alignment Standards.  Equipment component selections meet GMI Component Standards or have been previously approved. Refer to Schedule P and Schedule Z .  Equipment in excess of 100 pounds is equipped with proper rigging eyes and supports.  Equipment is designed for preventative maintenance tasks while in operation.  System/equipment has the proper protective devices, including fuses, breakers, current limiting devices, temperature-limiting devices, mechanical stops, pressure limiting devices, interlocks, local disconnects and other devices that may apply.  All sources of power or stored energy have a lockable disconnect to ensure the machine is locked in the OFF position.  System/equipment is designed for secure but easy access to maintenance areas. (1/4 turn fasteners w/ tool, etc.)

Power Transmission  Power transmission drive trains (i.e. chains, belts, couplings) are accessible with use of a tool for inspection and maintenance.  Equipment should be designed with poly belt instead of steel chain  Worm gear drives are not allowed – helical drives are preferred  Integral gearbox/motor combinations are not allowed – want separate motor and reducer  Drive Train mounts have at least two jack bolts to aid in alignment and tension.  Equipment with an oil reservoir greater than 1 gallon has oil analysis sample valves.  Oil filled equipment has easy access to oil fill and drain ports.  Oil filled equipment has a level sight glass of polycarbonate or similar material.  Lubrication grease fittings can be accessed while the equipment is in operation.  Motors comply with the CIS 301 Electric Motor Design Guidelines with a strong preference for fan cooled variety.

Reliablity_Design_Checklist Page 1 of 2 Last Updated: April 15, 2010 Documentation  All critical fasteners have documented type, torque, size and grade specifications.  System/equipment has maintenance manual(s) which include lubrication (frequency and type), preventive maintenance, repair maintenance (with exploded view drawings), electrical drawings, pneumatic schematics, program printouts, I/O tables, and troubleshooting guide.  System/equipment has spare parts lists, which include original parts manufacturer’s part number and recommended stocking quantities.

Visual Marking  Rotating equipment is clearly marked with the direction of rotation.  Piping is marked with flow direction and fluid type.  All changeover or adjustment points have a scale or setting mark.

Fluid Flow  System/equipment has appropriate gauges, pressure, vacuum, temperature, etc. with polycarbonate lenses.  Piping and valves are sized appropriately for the flow conditions  Pneumatic valves are either free standing or located in their own control panel.  Air to cloth ratio for filters and collectors validated and acceptable

Electrical  Equipment must comply with CIS 314 OEM Electrical and Controls Standard.

Reliablity_Design_Checklist Page 2 of 2 Last Updated: April 15, 2010