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Home » Articles

Articles

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

by Chris Weir Leave a Comment

Human Factors in Reliability Centred Maintenance

Human Factors in Reliability Centred Maintenance

In Part 2 of Beyond the Numbers, I explored how human reliability principles can be integrated into traditional reliability artefacts such as Reliability Block Diagrams (RBDs), Fault Tree Analysis (FTA) and Failure Modes, Effects and Criticality Analysis (FMECA). Those tools help us understand how systems fail and how different failure paths interact.

But reliability engineering does not end with failure analysis.

In practice, the outputs of FMECA flow directly into the Reliability Centred Maintenance (RCM) process, where failure modes are translated into maintenance strategies such as inspections, condition monitoring, restorations or replacements.

If assumptions about human performance are simplified during reliability analysis, those assumptions do not disappear. They are carried forward, and often amplified, when maintenance requirements are defined.

Maintenance is where reliability modelling becomes an operational commitment.

[Read more…]

Filed Under: Articles, Beyond the Numbers, on Product Reliability

by Chris Weir Leave a Comment

The Benefits of Reliability Engineering

The Benefits of Reliability Engineering

Many people associate reliability engineering with metrics, and while they can be helpful when used correctly, they are not the primary benefit of reliability engineering. The real value lies in the thinking and decisions that shape those numbers.

[Read more…]

Filed Under: Articles, CRE Preparation Notes, Reliability Bites

by Semion Gengrinovich Leave a Comment

The Ford Brake Fiasco

The Ford Brake Fiasco

In the automotive industry, safety is paramount. Yet, even giants like Ford Motor Company can stumble when it comes to addressing critical safety concerns. The recent saga of Ford’s brake system issues serves as a stark reminder of the importance of corporate responsibility and the potential consequences of overlooking serious defects.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by nomtbf Leave a Comment

Considering WIIFT When Reporting Reliability

Considering WIIFT When Reporting Reliability

WIIFT is “what’s in it for them”. Similar to what’s in it for me, yet the focus is your consideration of what value are you providing your audience.

As a reliability engineer you collection, analyze and report reliability measures. You report reliability estimates or results. Do you know how your audience is going to use this information?

Consider WIIFT when reporting reliability. [Read more…]

Filed Under: Articles, NoMTBF Tagged With: Metrics

by James Reyes-Picknell Leave a Comment

Data Driven, or Data Enabled?

Data Driven, or Data Enabled?

We hear about data driven decisions and it’s become somewhat of a mantra for IT departments, managers and even executives. But they’ve got it wrong! Data shouldn’t drive anything – it can’t. But it can be a powerful enabler if we want. A subtle shift in language can lead to big gains in performance!

[Read more…]

Filed Under: Articles, Conscious Asset, on Maintenance Reliability

by Mike Sondalini Leave a Comment

Total Cost of Downtime

Total Cost of Downtime

The total cost of downtime extends across the business. In the worst cases, it impacts the entire organisation and customers.

From the moment of failure to the restart of production, no saleable product is made. Instead, money is spent on repairs, with continued fixed costs, and any potential profits that could have been made from saleable products is lost. The graph below illustrates what happens to production time and costs when operations stop due to equipment breakdown (t1). The time and costs required to repair the equipment to operational levels (t2) is unknown at the start of the breakdown.

During this time (t1 to t2) resources and money are needed to return the equipment to operation. Additional costs due to loss of production and therefore potential profit losses are also incurred in this time.

[Read more…]

Filed Under: Articles, Life Cycle Asset Management, on Maintenance Reliability

by Greg Hutchins Leave a Comment

AI Eats Jobs!

AI Eats Jobs!

I think we should be very careful about artificial intelligence. If I had to guess at what our biggest existential threat is, it’s probably that. So we need to be very careful.
Elon Musk – Entrepreneur

Artificial intelligence (AI) and robots conjure images of killer robots like the Terminator movie.

[Read more…]

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

by Nancy Regan Leave a Comment

Failure Effects in RCM: Why They Matter and How to Write Them

Failure Effects in RCM: Why They Matter and How to Write Them

In this video, filmed at the historic La Popa Monastery in Cartagena, Colombia, I dive into the importance of Failure Effects in the Reliability Centered Maintenance (RCM) process. Failure Effects might seem like just one step in the RCM journey, but they’re essential for understanding the impact of Failure Modes — and that’s what makes them so special.

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Joe Anderson Leave a Comment

CMMS in Maintenance

CMMS in Maintenance

The Importance of CMMS in Maintenance: A Game Changer for Reliability and Efficiency 

In today’s fast-paced industrial and manufacturing environments, maintenance teams are under constant pressure to keep assets running efficiently while minimizing downtime and controlling costs. A Computerized Maintenance Management System (CMMS) has become an essential tool for achieving these goals. More than just a digital record-keeping system, a CMMS provides a structured and data-driven approach to asset management, work order tracking, preventive maintenance scheduling, and overall maintenance optimization. 

[Read more…]

Filed Under: Articles, on Maintenance Reliability, ReliabilityXperience

by Chris Weir Leave a Comment

What do we Really Mean by “Reliability”?

What do we Really Mean by “Reliability”?

When people hear the word reliability, it’s often interpreted as meaning “zero failures”. While that’s understandable, it’s not what reliability engineering is really about.

The Certified Reliability Engineer (CRE) Body of Knowledge, produced by the American Society for Quality, defines reliability as:

“The probability that an item will perform a required function without failure under stated conditions for a specified period of time”

Crucially, each part of this definition needs to be clearly understood and agreed from the outset, particularly between customers and suppliers. Many reliability problems arise not because the definition itself is wrong, but because these elements are interpreted differently.

[Read more…]

Filed Under: Articles, CRE Preparation Notes, Reliability Bites

by Carl S. Carlson Leave a Comment

FMEA Quality Objective 13: LINKAGE

None of us is a smart as all of us. – Ken Blanchard

FMEAs have great potential value to improve product designs and manufacturing processes. That value increases significantly when FMEA is properly linked and connected to other analyses.

How can FMEA be linked to other analyses to increase value?

1. Design FMEA can be linked to Process FMEA.

  • Causes in the DFMEA become inputs to identification of failure modes in the PFMEA.
  • Effects in the DFMEA become inputs to identification of product-related effects in the PFMEA.
  • DFMEA can recommend Special Product Characteristics that are input to PFMEA.
  • Product designs must be able to be manufactured and assembled, and this can be supported by the DFMEA team considering design improvements that help ensure the design can easily be manufactured without failures.

[Read more…]

Filed Under: Articles, Inside FMEA Tagged With: FMEA Quality Objectives

by JD Solomon Leave a Comment

Three Primary Ways Reliability Engineers Can Look at Asset Life

Three Primary Ways Reliability Engineers Can Look at Asset Life

How long will an asset last? It sounds straightforward, but anyone who has spent time in infrastructure planning knows it’s one of the most deceptively complex questions we face. Reliability engineers, accountants, and operations leaders may use the same terms for asset life, yet they’re often talking about entirely different things—different assumptions, different incentives, different definitions of “truth.”

When those perspectives stay siloed, organizations make decisions that look defensible on paper but fall apart in practice. When we reconcile them, we create clarity, strengthen our systems, and make investment choices that actually hold up in the real world.  Understanding asset life is truly about complexity and systems thinking.

[Read more…]

Filed Under: Articles, Communicating with FINESSE, on Systems Thinking Tagged With: accounting, asset life, Decision making, engineering, operations

by Semion Gengrinovich Leave a Comment

Boeing 737 MAX: A Reliability Perspective

Boeing 737 MAX: A Reliability Perspective

The tragic crashes of the Boeing 737 Max serve as a stark reminder of the critical role reliability plays in engineering design and practice. These incidents, which occurred in October 2018 and March 2019, resulted in the loss of 346 lives and sent shockwaves through the aviation industry. The crashes of Lion Air Flight 610 and Ethiopian Airlines Flight 302 were not mere accidents but the culmination of a series of engineering oversights, management decisions, and regulatory failures.

At the heart of these tragedies was a complex interplay of advanced technology and human factors. The Boeing 737 Max, designed to be more fuel-efficient than its predecessors, incorporated a new flight control system that would ultimately prove to be its Achilles’ heel. This system, known as the Maneuvering Characteristics Augmentation System (MCAS), was intended to compensate for the aerodynamic changes resulting from the aircraft’s larger, more fuel-efficient engines. However, the MCAS relied heavily on data from a single sensor, creating a single point of failure that would have catastrophic consequences.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Ray Harkins Leave a Comment

Defining TEEP, OOE, and OEE

Defining TEEP, OOE, and OEE

This article is adapted from Chapter 3 of my book titled Measuring Manufacturing Effectiveness.

The book is organized as a structured, multi-chapter exploration of how manufacturing organizations define, measure, and interpret “effectiveness.” Rather than focusing on isolated metrics or tools, it examines measurement as a system; one that shapes decisions, priorities, and behavior across operations, quality, reliability, and management.

Each chapter is written to stand on its own, while also contributing to a larger, integrated framework for understanding manufacturing performance.

Chapter 3 focuses on three of the most commonly used, and most frequently misunderstood, manufacturing effectiveness metrics:

  • Total Effective Equipment Performance (TEEP)
  • Overall Operations Effectiveness (OOE)
  • Overall Equipment Effectiveness (OEE)

Although these measures are often treated as variations of the same idea, they differ in important and meaningful ways. This chapter clarifies what each metric is designed to measure, the assumptions embedded in each definition, and the types of questions each metric is and is not capable of answering.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by nomtbf 10 Comments

What Makes the Best Reliability Engineer?

What Makes the Best Reliability Engineer?

Formal education (master’s or Ph.D) or design/manufacturing engineering experience?

Where do you look when hiring a new reliability engineer? Do you head to U of Maryland or other university reliability program to recruit the top talent? Or, do you promote/assign from within? Where do yo find the best reliability people? [Read more…]

Filed Under: Articles, NoMTBF

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Recent Articles

  • Human Factors in Reliability Centred Maintenance
  • The Benefits of Reliability Engineering
  • The Ford Brake Fiasco
  • Considering WIIFT When Reporting Reliability
  • Data Driven, or Data Enabled?

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