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by Mike Sondalini Leave a Comment

Process Logic Controller (PLC) Basics

Process Logic Controller (PLC) Basics

What readers will learn from this article.

  • Overview of how a programmable logic controller (PLC) operates.
  • Communication methods used to connect the PLC to equipment.
  • Dangerous practices that will lead to trouble if not corrected.

A process logic controller is a computer designed for monitoring and controlling equipment. The personal computer that many people have at home is designed to accept signals from the keyboard or mouse and use instructions (software) to display the resulting effects on a screen (monitor). A PLC accepts signals (inputs) from sensors located throughout a piece of equipment or process plant. It then follows the instructions (program) within its memory and sends out commands (output) to operate equipment. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance Tagged With: process

by Mike Sondalini 1 Comment

Sealing Threaded Pipe Connections

Sealing Threaded Pipe Connections

Threaded connections on process chemicals and utilities piping can be difficult to seal. Leaks from threads in steam and compressed air service are common. This article looks at pipe thread design and the proper sealing of threads.  [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance Tagged With: process

by James Reyes-Picknell Leave a Comment

Process Optimization

Process Optimization

Welcome to the final blog in my 10-part series called “Uptime Insights”, where we explore a journey of excellence in maintenance.

To stay on top, managers must implement strategies that keep operations performing at high levels. In these articles, I will show you how to achieve excellence in maintenance – a critical business process in any capital intensive industry.

Uptime Insights Part Ten:

Process Optimization

Whenever you are following a set of steps to achieve some goal you are following a process.

Your people do their jobs through day to day implementation of those processes in order to deliver results.  If the processes are ill-conceived or inefficient things move slowly and results are more expensive to obtain than they need to be.

Well designed, efficient processes that integrate with other related business processes keep things running smoothly, costs down and help to keep people motivated. [Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability Tagged With: process

by Fred Schenkelberg 1 Comment

Uncovering Hidden Field Failure Problems

Uncovering Hidden Field Failure Problems

A reliable product does not fail often. Customers expect to a level of reliability performance and failures that occur too early dash their expectation.

The design and development team work to create a robust product. To meet the customer’s reliability expectations. The team may use a range of tools to detect any reliability problem prior to launch.

Yet, customers do uncover problems that surprise us. This may be a problem with how we identify and resolve risks, yet it could also be the development process didn’t look close enough to find the issues. Or, worse, we saw the issue and ignored it. [Read more…]

Filed Under: Articles, Musings on Reliability and Maintenance Topics, on Product Reliability Tagged With: process

by Fred Schenkelberg 1 Comment

5 Steps to Create a Reliability Plan

5 Steps to Create a Reliability Plan

A specific reliability plan may include any number of specific tasks. To build an effective plan you need the knowledge of the individual tools and techniques, plus how they may fit together to create an overall plan to achieve your goals.

Reliability Goals

Of course, this starts with establishing complete reliability goals that include function, environment characterization, probability of success (reliability) and duration.

I recommend setting specific goals for setup/installation (early life), the warranty period and the expected customer use period. [Read more…]

Filed Under: Articles, Musings on Reliability and Maintenance Topics, on Product Reliability Tagged With: process

by Fred Schenkelberg 1 Comment

3 Supply Chain Caused Failures

3 Supply Chain Caused Failures

Some days are better than others. We sometimes run into failure when working to create a new product. With a little investigation we suspect the components are not working as expected.
We’ll call the vendor and ask for an explanation. If this is normal production and variability of performance, our product will suffer an higher than expected failure rate. The vendor will assure us with:

  1. It must have been damaged during assembly or use by us.
  2. It was a very rare manufacturing mistake and won’t happen again.
  3. We haven’t seen this before and you’re the first to report such an issue.
  4. We know about this issue and it’s been resolved in our process.
  5. Must have been an ESD (electrostatic discharge) event.

Not helpful. [Read more…]

Filed Under: Articles, Musings on Reliability and Maintenance Topics, on Product Reliability Tagged With: process

by Fred Schenkelberg Leave a Comment

Minimize Supply Chain Failure Causes

Minimize Supply Chain Failure Causes

What happens when a product you produce fails? You customer may call and return the product. They may expect you to provide a replacement or refund.
Does it matter if the failure was due to a capacitor or motor that you didn’t design, just purchased?

No.

Does it matter if a supplier’s supplier made an error that directly lead to the failure?

No.

You customer experienced a failure and since the purchase was from you, you are expected to make it right.

[Read more…]

Filed Under: Articles, Musings on Reliability and Maintenance Topics, on Product Reliability Tagged With: process

by Fred Schenkelberg Leave a Comment

Reliability Engineering is More Than Tools

Reliability Engineering is More Than Tools

Reliability engineering is a blend of disciplines from material science to asset management. We use problem-solving, design, maintenance, and statistical tools on a regular basis, yet that is not the only thing we do.

Having met a few engineers that define their role as a reliability engineer as conducting HALT or FMEA only, strikes me as to what most believe we do, or should do, as a reliability engineer. It is true that someone may specialize by choice or chance on one tool, yet even then is that all they do?

I don’t think so.

[Read more…]

Filed Under: Articles, Musings on Reliability and Maintenance Topics, on Product Reliability Tagged With: process

by Fred Schenkelberg Leave a Comment

3 Ideas to Overcome Organizational Inertia

3 Ideas to Overcome Organizational Inertia

It seems the forces of nature are working against our ideas.

I recall being frustrated as a child playing in the sandbox. I wanted to create a ramp of sand to race my cars down. No matter how much I pushed and patted the dry sand succumbed to some unseen force and did not hold the desired shape.

In business, we sometimes experience the same frustration. It’s not gravity.

Instead, we are facing organizational inertia.

[Read more…]

Filed Under: Articles, Musings on Reliability and Maintenance Topics, on Product Reliability Tagged With: process

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