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The 5 Rights and Wrongs of OEE

The 5 Rights and Wrongs of OEE

When I started to develop the RCM Blitz™ methodology over twenty years ago, the one thing I knew that would help to ensure successful Reliability-Centered Maintenance analysis was to develop a way that would guarantee every implemented analysis would provide a return on investment. The answer to this was simple enough, if you’re looking to improve safety and reduce health, safety and environmental incidents we should focus on critical assets that are struggling to maintain their inherent designed reliability. The best way to identify the best candidates is by measuring the OEE (Overall Equipment Effectiveness) of your top critical assets. [Read more…]

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Review: What is the Reliability of the Reliability Function

Review: What is the Reliability of the Reliability Function

Jezdimir Knezevic of the MIRCE Akademy published a paper with the title above and I have a few comments.

In the article, Jezdimir suggests that the statistical approach to describing the world about us is fundamental flaws and not inherently useful for our use. He compares a mathematical/statistical approach to a scientific approach and finds the stats wanting.

Let’s take a critical look at the topic of this paper and conclusions. [Read more…]

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Budgets — What to Do and How to Use Them

Budgets — What to Do and How to Use Them

Budgets represent plans or expectations for the future! They are a means to plan, forecast, coordinate and control the activities needed to achieve the business’ objectives. The budget document contains the amount of money that has been allocated to achieve those goals and the timing of its spending. Budgets cover the planned use of men, materials, external resources and management effort that is expected to be sufficient to hit the targets. Once the budget is finalised it becomes a tool to feedback how the actual progress is going compared to what was expected. [Read more…]

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Risk Management: Delusion, Illusion, and Reality

Risk Management: Delusion, Illusion, and Reality

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

Can we really manage risk, or do we delude ourselves by going through the prescribed activities of ‘risk management’ giving the illusion that it’s happening?  Is risk management merely a hypocritical ritual and applying some science to fate through statistical mumbo-jumbo, decision trees, and quantitative analyses? [Read more…]

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Basics of Brainstorming

Basics of Brainstorming

Did you know that best idea to solve a problem is often not the first one?

We all have plenty of bad ideas, hunches, guesses, and flawed ideas. That is ok. We also have great ideas and elegant solutions, too. The trick is exploring all those ideas to find the best ones.

One technique to draw out and capture many ideas is called brainstorming. You most likely have heard of and used this tool already. Let’s review a few key elements that make for excellent brainstorming results. [Read more…]

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ISO 9001:2015 Certifications and the American Society for Quality

ISO 9001:2015 Certifications and the American Society for Quality

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

I am a Senior member of ASQ, a quality professional association. I have two ASQ certifications. One, the Manager of Quality and Organizational Excellence (MQ/OE), is the highest general certification ASQ offers.  The other is a Six Sigma Green Belt (SSGB).  Over the past year or so, I have become concerned about the viability of ASQ.  Some friends now liken ASQ to a Moose Lodges.  While some lodges are still around, they are pretty much relics of earlier generations. 

With the publication of the ISO 9001:2015 certification figures for 2017, the concern increased.  This article looks at this issue and what the ISO 9001:2015 figures say about the disruptive environment ASQ faces. [Read more…]

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Tracking Belts on Bucket Elevators and Short Belt Conveyors

Tracking Belts on Bucket Elevators and Short Belt Conveyors

Tracking belts on bucket elevators and short belt conveyors. Flexible, flat belts are used on bucket elevators and belt conveyors to carry loose, bulk product. The belt is stretched tight from head drum to tail drum and the friction generated on the turning head drum is used to drive the belt and carry the product. The belt must run true on the end pulleys (drums) and stay within the sides of the equipment structure. If the belt runs off the drums, buckets will be destroyed and belt edges frayed. In the worst cases the belt runs off the pulleys resulting in a breakdown repair. Proper and long- lived tracking of belts is critical for trouble-free operation. [Read more…]

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Benefits of Comparing Lean/Kaizen with Agile/Scrum

Benefits of Comparing Lean/Kaizen with Agile/Scrum

Our previous article covered the benefits of comparing the DMAIC problem solving thought process with project management.  The key takeaway was DMAIC can be more effectively executed using “measure & plan” phase.

Now let’s compare and contrast agile/scrum with lean/kaizen.  While agile is primarily used in software development, there are many valid comparisons.  By making this comparison, those familiar with kaizen will improve their understanding of agile and vice-versa.  Also we’ll cover key success factors that are applicable to both.

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Dust Bag Selection for Bag-Houses

Dust Bag Selection for Bag-Houses

Bag house dust bag selection. The dust bags within a bag house must handle the process conditions they experience. The choice of bag materials is usually based on the cheapest fabric that will handle the conditions for a minimum of 3 to 5 years’ operation. The selection of the bag materials requires a good understanding of the process temperature, moisture content, chemical reactions with the bag fibre, dust loading effects and behaviour of the dust bags in operation. [Read more…]

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Benefits of Comparing DMAIC with Project Management

Benefits of Comparing DMAIC with Project Management

Our previous article covered the benefits of comparing waterfall with agile, emphasizing the benefit of planning the agile process and product backlog content.  In this article we’ll compare the Define, Measure, Analyze, Improve and Control (DMAIC) thought process, with a project management thought process.

DMAIC is a problem-solving thought process applies critical thinking to ensure robust problem solving.  (See our previous article on the subject here.)  DMAIC is not necessarily a process by which projects are managed, however.  Recall the high-level project management process as follows:

[Read more…]

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The Rover Says Good Bye! :(

The Rover Says Good Bye! :(

The Mars Rover is an incredible reliability story.  And as you may know they have decided to permanently shut it off. A friend recently sent me this email when he saw an article on it.

Hey Adam,

The Opportunity rover was supposed to last 90 days, and instead lasted 15 years.

Is that due to remarkable engineering, or was the machine really supposed to last that long and the scientists blew their calculations as to its “lifespan”?

Mark,

My response:

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