A visit to Quincy Market in Boston clears up a big misconception about RCM. It isn’t feasible to do RCM on all your equipment. Here’s why… [Read more…]
Do you have to apply RCM on all equipment? A visit to my hometown gives us the answer…
Articles
Find all articles across all article series listed in reverse chronological order.
The Impact of Industrial Automation on Machine Reliability
Setting up industrial operations is part of the capital expenditure a business has to undertake. Businesses now analyze the lifetime cost of any capital expenditure before making a decision. This includes the inventory cost, labor expenses, maintenance costs, cost incurred due to expected downtime, and expenses for upgrades. This tilts the decision in favor of options that provide long-term machine reliability and reduced maintenance.
The “3 P’s” – Avoiding the Most Common Pitfalls of Establishing a Reliability Program
I often talk to engineers who have just been told that they are now a ‘reliability guy or girl’ for their organization. The CEO or perhaps a director decides that reliability is now important, so a group of poor unfortunates are hastily and collectively anointed as ‘the’ reliability program. Is this familiar?
Sometimes this works. Sometimes these rebranded ‘reliability guys and girls’ create amazing programs that [Read more…]
Top Reason RCA Won’t Work…Where I Work!
Does this paradigm apply at your workplace?:
“We NEVER seem to have the time and budget to do things right, but we ALWAYS seem to have the time and budget to do them again!”
While this article was written for manufacturing many years ago, is it any less applicable today, in any industry?
Understanding ISO 14224: You Guide to Sustainable Defect Elimination
Capture The Right Failure Data to Power Your Defect Elimination Activities
In the petroleum, natural gas and petrochemical industries, great attention is being paid to safety, reliability, and maintainability of equipment. This is true in any industry and as such the learnings and information found within ISO 14224 can be applied to any industry. [Read more…]
Lean or Industrial Anorexia
In 2014, at an IMEC conference organized by the University of Toronto, Art Rice of Maintenance Technology Magazine said that in many cases “Lean is a form of Anorexia”. He was right then, and he is still right today.
When I heard him, I realized that in many cases where I’ve seen attempts at “lean manufacturing” the lean really means “understaffed”. In those cases some of the lean manufacturing tools have been implemented, often with the help of outside expert help but lean results haven’t occurred. The introduction of “lean” in those companies was yet another attempt to cut costs without any deep thought as to what caused the high costs before introducing “lean”. [Read more…]
The New Normal: What Was the Old One?
Guest Post by Malcolm Peart (first posted on CERM ® RISK INSIGHTS – reposted here with permission)
Working From Home (WFH)…just one of the things that the “New Normal” will bring according to a few voices from the populations of various workforces who have contributed to economies during lockdowns. People seem to have enjoyed the utopia of ‘flexible’ working hours with a freedom to work when they want, attending virtual meetings and collaborating in on-line virtual offices. [Read more…]
Converting A Capability Index to PPM Defective
One of the most common questions I get from students in my Process Capability Class is, how can I use the capability index from my process to approximate a defect level for my process? [Read more…]
Data is Beautiful
I recently held a lunch and learn about infographics. The recorded session is below. In our work as engineers, we often spend a great deal of time extracting amazing information from complex data sets only to find no clear way to get our message to those who need it which can include leadership, peers, or even the customer.
Changing how we present information can be the difference between driving change and simply being a slide in a weekly status meeting that solicits the response “next.”
What-if Analysis
What if you knew all the possible outcomes for your product’s reliability performance due to component variations, for example? What if you knew the future with enough certainty to make a difference?
Building on brainstorming, what-if analysis involved using models or prototypes that allow you to change something and see how it alters the output or performance. What if we change this support bracket from iron to aluminum? What if we swap out this 100 ohm resistor for a 200 ohm one?
As a curious engineer you could spend many, many hours conducting what-if based experiments, so there is a bit more to this idea then just a random walk of changes. [Read more…]
The Difference Between RCM and Preventive Maintenance Optimization (PMO) Explained by a Daffodil
There is a big difference between Preventive Maintenance Optimization (PMO) and Reliability Centered Maintenance (RCM). Daffodils are a perfect way to explain the difference. [Read more…]
10 Reasons you Need to do Reliability Engineering
Reliability engineering has an image problem. It is seen as an imbugerance that destroys budget, schedule and fun. People sometimes think reliability engineering is simply statistics, data analysis and other mind-numbing stuff. Reliability purgatory. Which brings us to the first reason you need to do reliability engineering.
#1 – Reliability engineering is not reliability purgatory. Reliability purgatory is all effort and no outcomes. Reliability happens at the point of decision. Design decisions. Manufacturing decisions. Maintenance decisions. True reliability engineering helps you make better decisions – which often comes down to organized judgment and not statistics.
Human Factors in Design Error?
As I headed to work this morning in my Chevy Silverado Truck, this message appeared on my dash console.
As if there aren’t enough distractions these days built into our vehicles (i.e. – GPS, telephones, use of our various electronic devices, iTunes, Email, Text, etc.), do we really need a warning message to read while driving, that is telling us to focus on the road? [Read more…]
The Plug and Perf Process
Multi-stage horizontal wells have been drilled and completed in shale formations in North America for two decades, and now account for nearly 90% of new wells drilled in the U.S. The Plug and Perf process (PnP) is used for completing most of these wells. [Read more…]
Is Making Assumptions Similar to Making Mistakes
Over the past week, I received a couple of interesting questions. One concerned assuming a Weibull beta value for an accelerated life test plan. The second involved assuming expected life models for elements within a reliability block diagram.
In both cases, we faced incomplete data and uncertainties, yet felt the need to assume some values in order for the math to work out. We do make assumptions in order to solve problems. We also can make mistakes that lead to unwanted consequences. [Read more…]
