Articles

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

Quality, Reliability & Useful Life

The Impact of Precision Installation & Maintenance

Over the last several years I have been working on and off with customers to among other things build a maintenance strategy for their equipment that will insure the designed reliability of their assets.

A while back I was asked by one of these customers to come in perform several RCM (Reliability Centered Maintenance) analyses on some new equipment that was struggling to deliver the expected/promised production rates. As the team worked its way through the process of identifying failure modes I continued to ask the following questions: [Read more…]

by James Kovacevic Leave a Comment

Building a Reliability Culture

Laying The Groundwork for a Successful Change.

It turns out that you have been deploying the right reliability tools and maintenance practices, but the organization’s culture was preventing or hampering the results. This is a common scene played out in many organizations, but there is hope. The culture change will be a long road, as cultures are not changed overnight. [Read more…]

by Mike Sondalini Leave a Comment

Electric Motor Current Protection Saves Your Plant.

What you will learn from this article.

Electric motor power current draw reflects the motor’s working load.
The electric current through a power cable can be measured using the strength of the magnetic field created around the cable.
Under-current detection protects against loss of load situations.
Over-current detection protects against over-load situations.

[Read more…]

by Greg Hutchins Leave a Comment

Enterprise Risk management is Not a Standalone

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

Enterprise Risk management is Not a Standalone

When Enterprise Risk Management (ERM) is advocated, it often seems like it is the end all and be all. However, this is not true. It is a methodology which assists management in identifying the risk that can prevent an organization from accomplishing it desired goals. As such, it should be viewed as another management tool in a range of tools. Perhaps the best presentation of this idea, for local government, is from the city of Oshawa Canada. This piece discusses how it has integrated ERM into it continuous improvement process. [Read more…]

by Robert Allen Leave a Comment

The Definition of Done

In my previous article, we reviewed the project approval committee, and emphasized approval to start projects and/or approve projects in-process.

With any type of project oversight, presentations or project schedules are often reviewed.

For a more lean project management approach it would help to consider reviewing the actual deliverables, including a mutual understanding of the “definition of done”.

“Definition of done” is the agreed-upon evidence of completion of a process, activity or milestone and usually includes a project deliverable. Some examples of deliverables might include the project plan, project schedule, documents (requirements document, plans, and reports), analysis, and designs (drawings). Other considerations can be built-into “definition of done” including compliance, acceptance/sign-off, exceptions and best practices.

[Read more…]

by Dennis Craggs Leave a Comment

Sample Sizes – Surveys

Introduction

How many responses are needed for a survey? This question requires specifying the desired confidence and the accuracy of the survey results.

The Bernoulli Trial

A Bernoulli trial is an event that has two possible outcomes. Consider the case where the only possible outcomes are success or failure. Let the probability of a success is p and the probability of failure equals q. The probabilities of all possible events must equal 1, so q = 1-p. These relationships are expressed mathematically as

[Read more…]

by Adam Bahret 2 Comments

Strategy

Some leaders mistake “customer focus” to mean they have to serve all of the customers needs or respond to every request from the field. There are multiple needs I have for a vehicle. Because of this I have more than one vehicle. Many manufacturers have tried to make a car or truck that does everything. It often just ends up being a vehicle that is great at nothing. (See Pontiac Aztek)

Know your target. Make goals, make compromises. Don’t commit to high reliability without making sacrifices. Something has to move either it be schedule or new technology development. There are no worse words than a leader saying “…and it must be highly reliable” without discussing the cost of pursuing that reliability goal. Know up front if you are willing to trade reliability for growth of technology or time to market.

[Read more…]

by James Kovacevic Leave a Comment

Red Alert: Your Culture Is Hurting Your Reliability Efforts

The Warning Signs That You Need a Culture Change

Imagine working within (or maybe you don’t need to imagine it) an organization in which everything is completely reactive. You arrive early to try and organize the work for the day, yet only to find out someone else is there doing it. [Read more…]

by Greg Hutchins Leave a Comment

Why Most ERM Systems Don’t Work

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

So why don’t most Enterprise Risk Management system work? Simply, they don’t “manage” risk, they just record it. Manage is a verb not a noun. It is activity not an item. Making a list might be adequate for those who want to check off regulatory compliance, but it’s does not produce a ROI. [Read more…]

by Mike Sondalini 3 Comments

Reliability Centered Maintenance — What is it?

What you will learn from this article.

Meanings of ‘loss of function’, ‘failure modes’ and ‘failure patterns’.
RCM provides a way to select the best maintenance strategy for new plant and equipment.
PM Optimisation, a shorter version of RCM, is used on existing plant and equipment with sufficient known failure history.
The RCM process and procedure is introduced.
How to put RCM outcomes into workplace practice.

[Read more…]

by Ash Norton Leave a Comment

Priority Setting for Engineers

Setting Priorities – What is your water?

Last year, I had the opportunity to hear Kat Cole, Group President of FOCUS Brands at the time, speak on leadership and the power of setting priorities. Cole shared with us her experiences on a service trip in Africa, in hopes of helping nearby villages with humanitarian efforts, and what it taught her about setting priorities. In this article, I will recount her experience and provide step-by-step guidance for how you can apply it to your work as an engineer.

Sound good? Good – let’s get to it! [Read more…]

by Adam Bahret Leave a Comment

Margin Call

Stress Margin is an interesting topic because our gut reaction is “more is better.” But more isn’t better. The key is figuring out “How much and where?” this is where the attention should be paid.

Too much stress margin can end the project the same way making material too thick will turn a plane into nothing more than a crappy diner with too much security. It’s the correct margin that is needed. How do we select the correct margin?

[Read more…]

by Carl S. Carlson 2 Comments

Understanding FMEA Detection Risk – Part 2

Can you find this common error in detection ranking in the intermediate problem in this article? In the advanced problem, the topic of an in-service detection scale will challenge the most experienced readers.

[Read more…]

by Doug Plucknette Leave a Comment

Defining Precision Maintenance

Ask 10 people to tell you what Precision Maintenance means. While some will use a few of the same words or give a few similar examples of what they think Precision Maintenance is you are going to get 10 different answers.

While few would argue the importance of Precision Maintenance, I find it interesting that in the world that offers Certifications in Asset Management and Equipment Reliability (CRE, CRL, CMRP) you won’t find an agreed-on definition of what Precision Maintenance means. [Read more…]

by James Kovacevic Leave a Comment

Learning from A Failure

Why Failing Can Be Good and What You Can Take Away from It.

Regardless of how good a maintenance & reliability program is set up and managed, there will be failures. This is partly due to the maintenance program itself, where the focus is on the consequences of the failures, not the failures itself. This approach allows most organizations to manage large facilities will a minimum of staff and cost.

But what should happen when something does fail? Should we just carry on as usual since we avoided the consequences? Absolutely not. When a failure occurs, we need to learn from it and improve the maintenance & reliability program. Yet, many organizations address failures by implementing a PM routine. This is not the right approach. Remember only 11% of failures are age-related. Adding these PM routines to the program will cause a collapse of the program from too much work, not to mention the maintenance induced failures that result from it.

So what should happen? The failure should be analyzed and actions implemented to reduce the chance of the failure occurring again.
[Read more…]