Your Reliability Engineering Professional Development Site
This episode of the weekly podcast is about Work Managements Cycle. WMC is the most basic framework any organization has in place to evaluate its performance and make improvements if needed. This cycle consists of 7-steps that when completed successfully make it possible to execute the Maintenance Plan and Scheduling Process. These steps are as follows:
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This show of the podcast is based on Job Plans.
These job plans are documents that contain a step by step action routine for daily maintenance issues that arise in an organization. It is a procedural process that defines the performance standards for execution of day to day work.
These plans are improved over time as the technicians face issues in the field and give feedback on their experiences to the planner.
This leads to a job plan which has some safest and efficient ways to implement jobs in the field creating a good Knowledge Management System which works as a library for job plans.
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This episode of the weekly podcast covers all the aspects of maintenance planning and scheduling.
Planning is one of the most time-consuming yet important activity if an organization needs anything done efficiently and effectively.
Any strategy or procedure needs planning and scheduling if it were to be implemented successfully.
A well-planned maintenance strategy not only ensures a good outcome but saves a lot of money and time.
Every industry uses this approach when delivering ahead of the deadlines can result in catastrophic results.
Now, this is one of the initial stages and any organization needs human and physical resources to accomplish these planned goals.
Planning definitely takes time but in the long run, you can manage to do more work in the given time which is the manifestation of the Parkinson’s Law.
It also helps in solving problems and avoid failures, because you can find out that what went wrong and how are you going to fix it as it is a step by step process.
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This episode of the weekly podcast covers the 4 Pitfalls of OEM Recommendations.
The original equipment manufacturers provide a manual in which all the general instructions are provided in the form of an operating manual.
These can be helpful when someone is using the equipment for the first time but when the same apparatus has to be used in reputed organizations with a set-up of their own, this manual is not enough.
It is developed keeping in mind the general behavior of instruments and common environmental condition of workshops and laboratories.
Most of the times, manufacturers put together these recommendations considering the worst that can go wrong to cover their warranty policies.
That is why the organizations cannot rely only on this operating manual.
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Review RCM is a streamlined approach to improving plant performance.
It allows organizations to quickly address ineffective PM programs. How does it achieve this?
By using the operating environment, failure patterns, and P-F interval, we can answer three basic questions:
These three elements will help us to determine the type of PM strategy that is value-added.
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A few years into your reliability journey, you start to struggle to make the improvements you were able to when you first started.
Why is this? You were able to systematically eliminate all of the low hanging fruit using the existing data in your CMMS. But now you have to dig deeper to realize the improvements and that requires better data. [Read more…]
You arrive in the office early Monday morning, and you receive an email from your boss. It is one that you have been dreaded for days.
You have been told that you are participating in a Failure Mode Effect Analysis for the next week.
Failure Mode Effect Analysis is often feared and avoided by many. Mainly because they are not well understood or people have been forced to sit through FMEAs that were not facilitated properly.
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Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process.
“Failure modes” means the ways, or modes, in which something might fail.
Failures are any errors or defects, especially ones that affect the customer and can be potential or actual. They typically include the component, the damage or problem with it and the cause of it
“Effects analysis” refers to studying the consequences of those failures.
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Imagine being able to predict the next time a failure will occur for a piece of equipment without a huge amount of work. Wouldn’t it be nice to know the approximate point in time that a failure will occur on a critical piece of equipment? It is possible, but I am not talking about using MTBF, as it is not a good measure (if you need to understand why, please visit http://www.NoMTBF.com). What I am talking about is a Crow-AMSAA analysis. [Read more…]
Does the age of equipment increase the probability of failure?
That was the conventional wisdom until Nowlan & Heap discovered that components have six different types of failure patterns:
This means only 11% of failures are age related… 89% are not age related – so why do PM Programs still rely on time-based maintenance (Replacements, Overhauls) they only address 11% of failures.
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Mean Time Between Failure or MTBF is almost universally recognized in maintenance, reliability, and asset management.
Why is that? And does it actually help an organization improve the reliability of their assets?
The answer is a resounding No.
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There are 3 primary types of maintenance strategies utilized:
The strategy utilized depends on heavily upon the nature of the failure.
Meaning does it wear out with age or is a random failure independent of time? Condition based maintenance is acceptable for the random failures, while Time based maintenance works for wearing out type failures.
Lastly, Run to Failure is acceptable when there are no significant consequences in the event of a failure.
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There are many different methodologies used to determine what maintenance should be done.
Once you include the variants, the number of methodologies can become overwhelming. By the end of the podcast, you should have an overview of each methodology and when to use them.
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When you think of maintenance, what do you think of?
This episode will dissect the difference between Maintenance, Reliability, and Asset Management.
By understanding the difference between Maintenance, Reliability and its relation to Asset Management, you can change and guide the perception of Maintenance and the value it brings to the organization.
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This podcast is for the maintenance professional who has limited time to research the information they need.
The Rooted In Reliability Podcast is designed to do the research for you, and you can learn as you commute to work.
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