A longer video that provides an in-depth introduction to RCM basics and the RCM process.
[Read more…]Reliability: Where does RCM fit in?
on Maintenance Reliability
A listing in reverse chronological order of these article series:
- Usman Mustafa Syed — Aasan Asset Management series
- Arun Gowtham — AI & Predictive Maintenance series
- Miguel Pengel — Asset Management in the Mining Industry series
- Bryan Christiansen — CMMS and Reliability series
- James Reyes-Picknell — Conscious Asset series
- Alex Williams — EAM & CMMS series
- Nancy Regan — Everday RCM series
- Karl Burnett — History of Maintenance Management series
- Mike Sondalini — Life Cycle Asset Management series
- James Kovacevic — Maintenance and Reliability series
- Mike Sondalini — Maintenance Management series
- Mike Sondalini — Plant Maintenance series
- Andrew Kelleher — Process Plant Reliability Engineering series
- George Williams and Joe Anderson — The ReliabilityXperience series
- Doug Plucknette — RCM Blitz series
- Robert Kalwarowsky — Rob's Reliability Project series
- Gina Tabasso — The Intelligent Transformer Blog series
- Tor Idhammar — The People Side of Maintenance series
- André-Michel Ferrari — The Reliability Mindset series
Do You Contract Your Maintenance – Yes or No?
Guest post By Arnold (Arnie) F. Newland, CMRP
I have led internal maintenance teams towards world class reliability, I have outsourced specialized maintenance functions (predictive technologies) and I have worked with companies outsourcing all maintenance.
Maintenance outsourcing continues to grow with 65% of large companies outsourcing some maintenance..but perhaps for the wrong reasons.
Maintenance and Reliability Best Practices: Preventive Maintenance
Parametric versus Non-Parametric Life Estimations – Sacrificing Reality for Elegance
A parametric Life Analysis involves “forcing” or “imposing” a distribution’s parameters on a data set in order to obtain the “best fit”. However, it can lead to errors in results. The non-parametric estimation suggests that there are other approaches though not necessarily the easiest or “most elegant” ones. In the field of reliability engineering, we tend to like something so much that we use them in every “sauce”. A classic example is the Weibull Distribution. It has become so popular that Life Analysis is also known as a “Weibull Analysis”. As a reminder, the Weibull distribution is only one parametric distribution amongst a myriad of others, invented by Walodi Weibull in 1937. Dr Bob Abernathy’s New Weibull Handbook1 quotes: “the Weibull distribution provides reasonably accurate failure and failure forecasts……”. Thus, parametric distributions are good enough but not perfect to make a decision.
[Read more…]Show All The Total Losses of Breakdowns
A good way to change mindsets and behaviors toward preventing forced outages and stoppages is to show everyone in the operation the total business losses of breakdowns.
It is incredible what the total business losses of breakdowns can rise too. Plant and equipment breakdowns are ultimately due to having wrong thinking and doing wrong practices. In this response to an FAQ, I advise to tell your people the true costs of breakdowns. Let them share the pain and loss suffered by the business and start them thinking of better ways to care for their operating assets.
[Read more…]Are RCM Principles Complex?
Eighteen years ago, at a small restaurant in Bath, England, a former head of the Royal Navy’s RCM program said something very poignant to me. It answers this question.
[Read more…]Getting results – Change Can be a Rocky Road
To get different results of any kind, we need to make changes. As human beings we are very good at change, but not so good at “being changed”. If we want it, it will happen. If we don’t want it, we will resist.
Physical asset performance is a result of having a robust and reliable design to begin with, the right maintenance executed the right way, and operation within the assets’ performance limits. In an existing operation, the design is fixed already. Maintenance and operations however, are not, and can often be improved, usually with considerable effort. That effort however, can be well worth it.
[Read more…]The Effect of Managers and Supervisors on Organizational Success
Abstract: Do the reliability math on organizational structure design, and in a militaristic silo configuration you’ll see that managers have a huge influence on their departments performance. But what is most surprising is that supervisors in silo groups have more than double their manager’s impact on their group’s success. Managers making poor and wrong choices will cause serious trouble. But supervisors who get decisions wrong cause catastrophe.
[Read more…]Defining Inventory Min-Max Levels
A better approach using RAM models
Traditional spare parts or inventory calculation methods involving Min-Max levels lack rigor, especially for critical equipment. Reliability, Availability and Maintainability (RAM) models provide a better approach to this calculation.
[Read more…]Case Study Pipeline Proactive Failure Prevention Analysis
The request in the box below was received by email.
[Read more…]I am contacting you to make you aware of Request, RFP# 68250, “Breakthrough Technologies for Pipeline Leak Detection.”
We invite proposals for breakthrough technologies for pipeline leak prevention, detection, and remediation. We have identified you as a party with the potential expertise to respond to this request.
At What Point in an Asset’s Lifecycle Should RCM be Applied?
To maximize the benefits, RCM should be applied as early in the lifecycle as possible, beginning with the design stage. But, most RCM analyses are done on legacy assets – in other words – on assets that are already fielded. And many are initiated decades after the system was fielded – especially in the case of government and military equipment.
CMMS and HACCP Compliance: How CMMS Strengthens HACCP Compliance?
In the food industry, safeguarding consumers through meticulous food safety practices reigns supreme. Hazard Analysis and Critical Control Points (HACCP) serve as a cornerstone for food manufacturers, outlining a systematic approach to identify, eliminate, or minimize potential hazards throughout production. Preventive maintenance plays a vital role in mitigating risks associated with equipment failure, contamination, and other unforeseen circumstances. This article explores how a Computerized Maintenance Management System (CMMS) empowers food manufacturers to achieve HACCP compliance and cultivate a safe production environment. [Read more…]
Introduction of Machinery and its Management: 1906-1910 Regulations and Steam Manual
Hull Inspections – Condition-Based Maintenance
By the 1906 revision of the Regulations, there were many more technical changes to manage. Most ships now had iron or steel hulls, which changed the mechanism of how a hull would fail. Galvanic corrosion and methods to prevent it were well understood. The chapter covering “Preservation, Repairs, and Docking” required zincs, the sacrificial anodes to be placed near the screws to prevent galvanic corrosion.
[Read more…]What is Reliability Centered Maintenance?
RCM is one of the most powerful maintenance and reliability improvement processes out there. The name Reliability Centered Maintenance lends itself to a process that’s used to develop proactive maintenance for an asset – and it is. But RCM can be used to formulate scores of solutions that reach far beyond maintenance.
[Read more…]Beware of the Mean Time Between Failure Calculation Trap
An MTBF calculation is often done to generate an indicator of plant and equipment reliability. An MTBF value is the average time between failures. There are serious dangers with the use of MTBF that need to be addressed when you do an MTBF calculation.
Take a look at the diagram below representing a period in the life of an imaginary production line. What is the MTBF formula to use for the period of interest to represent the production line’s reliability over that time? [Read more…]
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