×Technical panel · August 21
Implementation of Reliability Engineering at Maringá Ferro-Liga
Eduardo Felipe Andrade Gonsalves
Maringá Ferro-Liga is a steel-industry company that produces high-carbon manganese alloys. Seeking greater market competitiveness, its maintenance department implemented Reliability Engineering with a maintenance focus. The project was developed in stages. The first stage involved studying the plant and processes to clearly establish team competencies and prepare the required technical documentation (PSQ, PT, PO, DA, etc.). The second stage involved developing indicators, failure triggers and BI dashboards to guide failure analyses. The third stage was leadership training. The fourth stage was a review of the criticality matrix. The fifth stage implemented qualitative reliability techniques. The sixth stage implemented quantitative techniques. The final stage introduced audits. The implementation process lasted five months, and the first audit took place eight months after implementation. Results included an 8% availability gain in the fines-recovery area, a 2% gain in Electric Reduction Furnaces and R$600,000 in OPEX savings.