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You are here: Home / Archives for Articles

Articles

Find all articles across all article series listed in reverse chronological order.

by James Reyes-Picknell Leave a Comment

Gremlins today

Gremlins today

“Gremlins today” is a series of short articles on problems that plague industrial operations the world over.

Originally, Gremlins were fictitious mischievous trouble makers who caused Royal Air Force aircraft breakdowns during World War II. Author Roald Dahl published a book about them in 1943, based on his own experience as an RAF pilot. Pilots in the RAF used to carry lucky Gremlins to ward off their effects. Dahl worked with Disney to publish a cartoon book based on them, but it never made it into a movie at the time. Never-the-less, it did loosely inspire the 1984 movie, “Gremlins,” by Steven Spielberg.

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Joe Anderson Leave a Comment

The Power of Vision in Leadership and Organizational Success

The Power of Vision in Leadership and Organizational Success

All Things Rise and Fall on Vision—or the Lack Thereof 

In leadership, vision is everything. It’s the guiding star that directs decision-making, inspires action, and shapes the future of an organization. Whether in business, maintenance, or any other field, a clear and compelling vision can determine the trajectory of success or failure. Without it, even the most well-intentioned efforts can flounder. The power of vision in leadership and organizational success cannot be overstated. In essence, all things rise and fall on vision—or the lack thereof. 

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Fred Schenkelberg Leave a Comment

3 Types of MTBF Stories

The MTBF Stories You Tell Can Cause Change

Stories communicate well. We have been telling stories long before the invention of writing or the internet. The MTBF stories we tell communicate our ideas, suggestions, and recommendations.

There are differences between good and poor stories. How you tell a story matters as well as the subject of the story. Now, MTBF stories may not be the most thrilling or entertaining, yet there are stories on MTBF topics that matter.

Let’s explore using the power of story to cause those around us to better understand and avoid the use of MTBF. [Read more…]

Filed Under: Articles, NoMTBF

by Semion Gengrinovich Leave a Comment

ALT: An in Depth Description

ALT: An in Depth Description

Accelerated Life Testing (ALT) is a method used in reliability engineering to assess the lifespan and performance of a product under accelerated stress conditions. The goal is to uncover potential faults and failures in a shorter time frame than would be possible under normal operating conditions. ALT is particularly useful when the product’s expected lifespan is long, and waiting for failures to occur naturally is not feasible.

In the context of Design Verification (DV), ALT can help shorten the testing time by inducing failures more quickly than under normal conditions. This allows engineers to identify and address potential issues earlier in the product development process, thereby improving the product’s reliability and reducing the time to market.

For example, consider an aluminum part used in automotive applications. The primary stressor for this part would be cyclic mechanical loading, which can cause fatigue over time. An ALT would subject the part to this stress at an accelerated rate, causing it to fail more quickly than it would under normal conditions. By analyzing the part’s response to the test, engineers can predict its lifespan and maintenance intervals under normal service parameters.

Aluminum 6061 is a widely used alloy in the automotive sector due to its excellent strength-to-weight ratio, corrosion resistance, and weldability, making it suitable for various applications including frame components, wheels, and suspension parts.

Yield Strength and Stress Levels

The yield tensile strength of 6061 aluminum alloy is 276 MPa (40,000 psi) please see (Fig. 1)

Based on this, we define three stress levels for the ALT:

  1. First Stress Level (90% of Yield Strength): This level is set at 90% of the yield strength, which calculates to 248.4 MPa.
  2. Second Stress Level (80% of Yield Strength): This level is set at 80% of the yield strength, which calculates to 220.8 MPa.
  3. Third Stress Level (70-75% of Yield Strength): For a range, we consider the average, setting this level at 72.5% of the yield strength, which calculates to 200.1 MPa.
Fig.1 Stress-Strain, Aluminium 6061

For every stress level 3 samples was failed, fitting the Weibull distribution and choosing different Reliability and confidence level, (pay attention axes are in Logarithmic scale, see Fig. 2):

Fig.2 Stress Amplitude vs. time to failure.

The blue step function (see Fig.3) appears to represent the stress amplitude levels and the corresponding number of cycles at each level that the part is expected to experience throughout its life. The steps in the function indicate changes in stress amplitude, with each horizontal segment corresponding to a period where the stress amplitude remains constant.

Visually, the blue step function does not intersect or cross the black solid line labeled as R99.9 C99.9. This suggests that the stress levels and the number of cycles at each level are within the bounds of the R99.9 C99.9 reliability and confidence level.

In other words, the part is expected to withstand the stress levels represented by the blue line without reaching the failure criteria associated with the R99.9 C99.9 line.

According to Miner’s rule, the cumulative damage is calculated by summing the ratios of the number of cycles experienced at each stress level to the number of cycles to failure at that stress level. Since the blue line does not cross the black line, it implies that the cumulative damage DD is less than 1, meaning the part is not expected to fail within the life cycle represented by the blue line, given the reliability and confidence level of R99.9 C99.9.

Fig. 3 Stress amplitude vs cycle to failure, and the stress amplitude usage stress (blue line)

The ability to predict failures and estimate product lifespan through ALT enables companies to enhance product design, improve quality, and ensure reliability before market release. It also facilitates the identification of potential failure modes and the development of maintenance schedules, which are crucial for safety-critical components.

Furthermore, ALT can be tailored to specific reliability and confidence level targets, such as R99.9 C99.9, allowing engineers to validate that products meet stringent reliability standards.

By leveraging the insights gained from ALT, companies can achieve a competitive edge by reducing time-to-market and minimizing the risk of costly recalls or customer dissatisfaction due to product failures.

The process of conducting an ALT typically involves the following steps:

Define the test objectives: This could be to identify failure modes, estimate the part’s life expectancy, or verify design margins.

Select the stressors: These are the types of stresses the part will experience in service. For an aluminum part, the primary stressor would be cyclic mechanical loading.

Develop the test plan: This involves designing the test to apply the selected stressors in a controlled and measurable way.

Conduct the test: The test is run according to the plan, and the part is monitored for signs of fatigue. The test continues until the part fails or reaches a predetermined number of cycles.

Analyze the data: The results are used to estimate the part’s life under normal conditions. This can involve statistical analysis and modeling.

In conclusion, ALT is a valuable tool in reliability engineering and DV, allowing for the prediction of product lifespan and the identification of potential issues in a shorter time frame than under normal conditions. This can lead to improved product reliability, reduced testing time, and faster time to market.

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Greg Hutchins Leave a Comment

Project Email Economics

Project Email Economics

Economics concerns itself with the determination of the most logical and effective use of resources to meet private and social goals for some form of benefit.  While primarily concerned with industry and business, its concepts of opportunity cost, supply and demand, present value, and mutual interdependence economics is also applicable to email; one of our most utilised forms of communication but, possibly, the most hated.

From its rudimentary beginnings in 1972, and despite an announcement in 2007 that email was dead and similar pronouncements by agencies such as WSJ and Forbes, email thrives.  It’s essential to businesses and this year, 2022, it’s anticipated that humans (and machines) will send 126.7 trillion emails, that’s ~15,800 per person.  For some humans, email is their raison d’etre so they may demonstrate their importance by how often they are cc’d or to whom they forward messages.  For others their perpetually full inbox, a permanent millstone round their neck, can be a symbol of futility and hopelessness as responses are demanded in time frames that can’t be supplied.

How often do we receive an email that’s also sent to a multitude of others?  How often do we question whether to respond, not respond, or even to take notice?  And how often do we question whether the email has any relevance to us, or even others.  Emails, like talk can be cheap.  When things are cheap they have little value which is of little or no benefit…and that’s simple economics.

Opportunity Cost

Opportunity cost, economically, is the cost of a decision measured by the next best alternative given up or, in other terms, the benefits you lose by choosing one alternative over another one.  From a communications perspective this “best alternative” is taken to be an email above other media such as a letter, memorandum, ‘phone call, or even a meeting.

Email can be an extremely efficient way of communicating, indeed as an opportunity in today’s marketing it’s almost indispensable.  It’s cheap, quick, simple, almost instantaneously accessible (or retrievable), paperless, and allows for mass sending thereby keeping everybody ‘in the loop’.  For many, and possibly most importantly, it’s ‘in writing’ and provides for future evidence if things go wrong.  However, its effectiveness compared with other media can be questionable as summarised below:

table of email alternative including benefits lost or gained by using email instead.

Emails, despite being pushed to us are often disregarded.  If they are unclear or poorly drafted and require clarifications, or are issued to al and sundry they may be ignored.  Alternatives are available but even though the supply of emails is never-ending, for many of us, the demand is not reciprocated.

Supply & Demand

In economics the price, or value of something is determined by supply and demand.  This price, the equilibrium price, is the value at which the quantity that consumers want to purchase equals the quantity that suppliers want to sell.  This applies to many types of communication such as books, cable TV, newspapers, but with email there’s a twist.

An email itself has little, if any, intrinsic value.  The content of an email to a ‘consumer’ may have value, there will have been some costs associated with its supply, and value may be attached to any response.  Emails can be forwarded to a consumer who may receive the same email multiple times, even without the original supplier’s knowledge or even consent, supply can certainly exceed demand for some.  Oversupply can also cut chains of command as well as spans of control and overload can cause confusion.

Emails can be akin to ‘chatting’ and as the idiom goes “Talk is cheap” because it’s easier to talk about doing something than doing it. Economically speaking it’s because “supply exceeds demand”.  Pragmatically speaking there are more emails than we need.

We use email to obtain or share information.  It’s also used to put forward opinions, involve multiple parties through multiple copies, escalate matters of importance to the sender and, in corporate rat races, cover one’s rear as well.  These tend to diminish the value of emails, but their value lies when used for legitimate or professional reasons.

Present Value

From a monetary standpoint a dollar today is worth more than a dollar in the future.  When it comes to email, and when used to transmit information for making decisions, the timely issue and receipt is essential for decision making.  Late decisions, or an absence of optimal information can mean the difference between success or failure, profit or loss.

Emails can take time to send, time for assimilation or interpretation, and possibly time for clarification prior to responding.  As a means of garnering opinions email can be extremely effective but only if time constraints are imposed and respected.  Late information will miss deadlines so decisions will be suboptimal due to incomplete data and, just as future money has a lower value, so do late emails.

But the value of an email for some can be historical.  Sending a ‘late’ email may be understood as being late, but it gives the opportunity for some proponents to say, ‘I told you so’.  Emails are records so, if problems arise, they may be used in any subsequent witch-hunt to either preserve or ruin reputations.  Although an almost instantaneous form of communication this is only in transmission.  A late email may miss the present, but for some its real value and benefit may well be in the future if history is investigated.

Mutual Interdependence

Mutual interdependence exists between parties because a change in one party’s strategy will affect the way in which the other behaves.  Economically this is the affect of a change in one firm’s pricing strategy on the sales and profits of others.  Email communication, outside of mass marketing and mailing lists, is, for the most part, a two-way street and the parties react to communications accordingly.

Incentives are part of such interdependence and the issuing of and response to emails are no exception.  Some people thrive on issuing emails.  They express personal opinions or ask for them, they let people know what’s ‘going on’, escalate matters as they see fit, and are seen to be ‘being busy’.  However, for effective communication some feedback is required so any would-be respondent needs to be incentivized to provide the same.  This may be fulfilling a duty of a job description, being seen to be involved, or to seek recognition.  For some it’s an act of self-preservation to avoid a reprimand or admonishment, but it may also be for their job satisfaction.

But for some, they choose not to reply.  Emails rarely get lost in the post and, although some may end up as ‘junk’ why don’t people reply?  If mutual interdependence isn’t recognised, then all too often there can be unintended consequences.  Badly crafted emails, failing to convey a precise message and make it clear that a reply is required, or requiring a recipient to read reams of trailing mails, while giving a complete history, can deter a reply.  The inclusion of multiple recipients is also a deterrent.

Another unintended consequence of emails is the ease at which they may be forwarded to others.  Recipients can easily include others.  ‘Many hands make light work’ but ‘too many cooks spoil the broth’ and the supply of emails can quickly exceed any legitimate demand.  The possibility of a responses with real value diminishes.  With increasing numbers of communication channels, we will experience diminishing returns and the probability of responses with value is inversely proportional to the number of recipients.

Conclusions

Studies show that tens of billions of dollars are lost annually because of poor communications.  These losses affect national economies as well as businesses and are manifested in slowdowns, project delays, and lost opportunities due to poor or late decisions and disputes.  Email is a contributory factor.

Email can be a boon, but its misuse can easily reduce the value of communication.  It can disincentivise those whose mailbox is perpetually full, overload others who are unable to respond, and create communication channels that are not needed.

Email, like talk, appears cheap, but if there’s a dispute, its only cheap until you hire your lawyer…so make sure your email is the economically viable communication opportunity.

Bio:

Malcolm Peart is an UK Chartered Engineer & Chartered Geologist with over thirty-five years’ international experience in multicultural environments on large multidisciplinary infrastructure projects including rail, metro, hydro, airports, tunnels, roads and bridges. Skills include project management, contract administration & procurement, and design & construction management skills as Client, Consultant, and Contractor.

Filed Under: Articles, CERM® Risk Insights, on Risk & Safety

by Nancy Regan Leave a Comment

Is Your Equipment Aging?

Is Your Equipment Aging?

Time to Review Your Maintenance Tasks with RCM

If you’re managing equipment that’s 10, 20, or even 40 years old, it may be time to revisit some of the maintenance tasks you’ve put in place. In today’s video, I explain why it’s essential to periodically review your proactive maintenance tasks and other strategies as your equipment ages and how Reliability Centered Maintenance (RCM) principles can help.

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Hemant Urdhwareshe Leave a Comment

SPC-1: Statistical Process Control Chart Selection, and Application Example on Excel

SPC-1: Statistical Process Control Chart Selection, and Application Example on Excel

Dear friends, Institute of Quality and Reliability (IQR) is happy to release this first video in our series on statistical process control charts. In the video, Hemant Urdhwareshe, Director of IQR and Fellow of ASQ explains criteria for selection of control charts, and has illustrated how to plot X-bar and Range chart using Microsoft Excel with an application example. Hemant has also explained briefly the interpretation rules to detect special causes. The video is little long but request viewers to watch it till end for best viewing experience.

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Semion Gengrinovich Leave a Comment

Importance of Failure Repeatability

Importance of Failure Repeatability

The importance of failure repeatability lies in its role in understanding and improving systems, processes, and products. Failure repeatability refers to the consistency with which a system or device can reproduce an outcome under unchanged conditions. In the context of product design engineering and testing, being able to consistently replicate a failure means that the underlying cause can be more accurately identified and addressed.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Fred Schenkelberg Leave a Comment

Different Data Same Decision

Different Data Same Decision

Different Data Same Decision

Let say you have some time to failure data on your equipment. A common action is to calculate the MTBF. All well and good until you expect to make a meaningful decision based on the calculation.

Using just the mean of the data, the MTBF value is likely to provide you with a less-than-useful bit of information. Thus, your decision will be rather random or worthless.

Let’s explore just how this simple calculation of perfectly good data can mislead your decision-making. [Read more…]

Filed Under: Articles, NoMTBF

by James Reyes-Picknell Leave a Comment

Trouble with maintenance planning?

Trouble with maintenance planning?

Are you having trouble producing good quality maintenance job plans?
Is your “standard job” plan library nearly empty?
Is your planned work running below 65% (bottom quartile)?
Note: scheduling without a plan, isn’t planned, and failing to plan is planning to fail!

With maintenance costs burning up to 30% or more of your operating costs (depending on industry) there can be a big benefit from reducing those costs. Every dollar saved goes straight to the bottom line, and upwards of 20% (sometimes more) can be achieved by doing a good job at maintenance work management. But many companies don’t even come close. At the heart of their problem is their approach to maintenance planning. Not the planners! They do their best but are often untrained and unfamiliar with good practice in planning.

However, even if your planner are well trained, they can be easily side-tracked by parts chasing, purchasing, schedule shuffling and even standing in for supervisors!

Artificial Intelligence (AI) has now come to planning!

If you are a planner, don’t worry. It won’t take your job, but it will help you become a superstar planner!

We all know that maintenance plans are critical to efficient work execution and keeping a lid on costs. Planners create those plans and then go on to schedule the work when it best suits the organization.

Creating maintenance job plans requires a great deal of knowledge and insight into parts, tools, trade skills, lifting apparatus, and so on. Only a planner on site has access to it all, because only he can actually see where the work will be performed. However, creating job plans is a lot of work. The average fully trained planner who is actually dedicated to planning (not scheduling), can produce maybe 4 or 5 good plans in a week. With hundreds or even thousands of jobs to plan, he can be planning for his whole career. Using old Work Orders as a sort of template helps, but planner productivity can still be low.

Introducing artificial intelligence to generate draft job plans quickly, gives the planner a huge boost in productivity – how about 40 good plans in a week, instead of 4 or 5? Combined with proper use of your CMMS / EAM’s capability to save standard job plans, your operation can rapidly move away from low single digit % planned work to reach benchmark levels > 95%. That can boost worker (trades) productivity from 30% (typical) to nearly double that. Considering the skilled trades shortages and trouble hiring them that everyone is experiencing these days, that’s a huge spin off benefit!

Conscious Asset has teamed with Perspect Analytics and Cato AI Solutions to create AIJobPlanner(tm). This cloud based tool takes seconds (up to a couple of minutes for very complicated jobs) to generate draft maintenance job plans that include: tasks / activities complete with sequencing, timing, resources (parts, special tools, materials, trades) all that are needed to complete the job. It automatically searches the web and our library for technical manuals and other information relevant to the equipment you specify. Our advanced tool will also accept input of your  site specific information such as technical manuals, Bills of Materials, etc. The tool produces a very comprehensive DRAFT job plan in seconds.

Caution: These DRAFT plans are very complete, but they still need review and possibly editing by a real planner. That effort to review and edit takes minutes, not the hours it usually takes to create a new plan from scratch.

Click here: aijobplanner.net To see the tool, a demo that loads automatically, to sign up for a free trial, or as a Beta Tester.

We are accepting up to 100 Beta Testers and have some special offers to make it more enticing for you to try the tool. Use the link above or the QR code below to go to the Beta Test site and sign up. Click on the “sign up free” button at the upper right of the screen. To get the special offers, we only ask that you try it, and give us your feedback.

The special offers are:

  • For the first 20 testers: free basic subscription for 1 or 2 users for first year. $720 savings.
  • For testers 21 to 100: 50% off basic subscription for 1 or 2 users for first year: $360 savings.
  • For all 100 testers: If you want more than the “basic” subscription, we will also give a substantial discount on Premium or Enterprise subscriptions. Since these require multiple user setup, just ask us if this option is of interest to you and we’ll set you up.

If you like the tool, here are our subscription plans:

  • Free – for a single user to give it a test ride (limit of 10 plans)
  • Basic – for a smaller scale operation, with 1 or 2 people planning maintenance work, with a limit of 500 plans per month. Available with credit card payment: $60/month.
  • Premium – for a larger site, with up to 10 people planning, and unlimited plans. Can create up to 50 custom templates and up to about 100,000 pages of your own technical documentation for the AI to use in creating your plans. Can pay with credit card or use PO. $500/month.
  • Enterprise – for very large sites, or multiple sites, with more than 10 people planning and unlimited plans. Can create up to 1000 custom templates and up to about 5,000,000 pages of your own technical documentation for the AI to use in creating your plans. We can also include the ability to search your existing Work Orders (additional cost). Requires a quotation, PO and custom set up.

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Greg Hutchins Leave a Comment

Company Acceptance of Hybrid PM is High Risk

Company Acceptance of Hybrid PM is High Risk

Guest Post by John Ayers (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

A Hybrid Methodology combining the speed and flexibility of Agile and the structure of Waterfall is feasible and practical. I base my opinion on the research I have done. I recently presented a Webinar to Project Management Institute (PMI) members on how to merge Agile and Waterfall to achieve a Hybrid methodology. The focus of this paper is to address the greatest risk to a company in implementing the new methodology i.e., acceptance of it. I addressed how to accomplish the merger to achieve a Hybrid method in a paper I wrote and posted on LinkedIn in May

[Read more…]

Filed Under: Articles, CERM® Risk Insights, on Risk & Safety

by Ramesh Gulati Leave a Comment

Are You Ready for a Reliability Journey

Are You Ready for a Reliability Journey

Assets are crucial in the production of goods and services. These assets must have minimal to no failures. However, assets tend to fail frequently, and reliability improvement projects do not always provide the expected results. This has been documented in numerous case studies.

This webinar will explore the reasons why assets continue to fail and why reliability projects do not always yield the desired outcomes. What steps can we take to ensure a successful reliability journey

In this insightful webinar, discover how we can equip our workforce with the necessary tools and techniques to decrease failures and increase reliability, ultimately maximizing the return from our assets.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Nancy Regan Leave a Comment

Who Is Responsible for Reliability?

Who Is Responsible for Reliability?

Building a Culture That Lasts

Hi everyone, I’m Nancy Regan, coming to you from beautiful Key Largo, Florida! ☀️ In today’s video, I’m discussing who’s responsible for reliability in an organization. Just like the intricate root systems of mangroves, every part of your organization plays a role in creating a strong and effective Reliability Culture.

From operators and maintainers to engineers and management, everyone must be involved to achieve the reliability you need from your equipment. Watch the full video to learn why building an effective Reliability Culture is essential and learn how to do it!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Hemant Urdhwareshe Leave a Comment

Fractional Factorial Design with Center Point: Design and Analysis

Fractional Factorial Design with Center Point: Design and Analysis

Dear friends, we are happy to release this video on fractional factorial design. In this video, Hemant Urdhwareshe has illustrated how to create a five-factor resolution-V design in Minitab (version 17) with an example of a virtual catapult (thanks to sigmazone.com)

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Semion Gengrinovich Leave a Comment

Degradation test and Diagnostics

Degradation test and Diagnostics

Degradation testing for electromechanical components such as pumps, valves, and sensors involves a series of steps to identify wear and tear that could lead to system failure. The goal is to detect these signs of degradation early enough to replace the part and prevent system failure.

For pumps, degradation can be monitored by sensors. A study on gear pumps used an accelerated life test (ALT) to monitor the degradation state. The volumetric efficiency of the pumps was measured over time, and the wear clearances were recorded. As the wear gap increased, the flow rate gradually decreased, indicating wear degradation.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

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