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Home » Articles

Articles

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

by Kerina Epperly Leave a Comment

Unlocking Plastic Deformation

Unlocking Plastic Deformation

Failure Fingerprint: Plastic Deformation in Bearings

(Also known as “Brinelling,” “False Brinelling,” or “Plastic Flow” depending on cause and appearance)


Abstract: Unlike fatigue cracks or abrasive wear, plastic deformation represents a threshold failure where the material’s yield strength is exceeded, leading to permanent dimensional change. In high-precision components like bearings, even microscopic plastic flow the “failure fingerprint” can trigger catastrophic system vibration or total seizure. This article explores identifying markers of Brinelling, torsional yielding, and metallurgical slip.


[Read more…]

Filed Under: Articles, on Maintenance Reliability, The Reliability Crime Lab

by JD Solomon Leave a Comment

Why Reliability Engineers Should Embrace Monte Carlo Analysis

Why Reliability Engineers Should Embrace Monte Carlo Analysis

Monte Carlo analysis, or Monte Carlo simulation, is a technique for forecasting that accounts for uncertainty and variability. As an analytical tool, Monte Carlo analysis forces the project development process to incorporate wider thinking and minimize biases. As a communication tool, Monte Carlo analysis is powerful in showing the probabilities and possibilities and identifying the input parameters that impact a specific project context.

Monte Carlo analysis is now more convenient and affordable than at any point in its 70-year history. The technique provides huge additive value for large and complex projects and capital-intensive programs.

[Read more…]

Filed Under: Articles, Communicating with FINESSE, on Systems Thinking Tagged With: FINESSE fishbone diagram, Monte Carlo Analysis, Reliability techniques, risk, Uncertainty

by Fred Schenkelberg Leave a Comment

MTBF Search Result Sadness

MTBF Search Result Sadness

I was preparing to write this article and wondered how many search hits would appear for MTBF? So, opened Google and did an MTBF search. It is a common if misunderstood, acronym.

Beyond the 5,200,000 Google search results, it was the first page results that got me thinking. Keep in mind that Google often serves up a combination of what it thinks you are seeking and which sites have been useful for others.

Let’s break down what you find when you do an MTBF search. [Read more…]

Filed Under: Articles, NoMTBF

by Ray Harkins Leave a Comment

Manufacturing Time as a System

Manufacturing Time as a System

Measuring Manufacturing Effectiveness – Chapter 2: Manufacturing Time as a System

Over the past several years, I’ve been discovering a structured framework for understanding and improving how manufacturing organizations define, measure, and interpret “effectiveness.”

Not efficiency. Not productivity in isolation. Not isolated KPIs. But manufacturing effectiveness as a system that integrates operations, quality, reliability, capacity, flow, decision-making, and management behavior into a coherent measurement model. It may sound like a lofty goal. But please stay with me.

This article is drawn from Chapter 2 of my book, Measuring Manufacturing Effectiveness, which focuses on understanding time as a resource that is systematically reduced by cumulative and irreversible losses, at the end of which remains the time needed to manufacture good parts.

[Read more…]

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

by Semion Gengrinovich Leave a Comment

Test Failure During Validation – Is it Disaster or Blessing?

Test Failure During Validation – Is it Disaster or Blessing?

In the automotive industry, particularly when dealing with electromechanical components, the validation process is a critical phase that ensures the safety, reliability, and performance of products before they reach the market. However, there is a growing trend among companies to avoid failures during this process, often leading to panic when they occur. This article explores why encountering failures during validation should be seen as a blessing rather than a disaster.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Greg Hutchins Leave a Comment

How to Create a Positive Risk Culture

How to Create a Positive Risk Culture

There are several risk management solutions that organisations can implement to strengthen their organisational culture to create a positive ‘risk culture’ outcome.

These organisational practices include:

  1. Create an accountable organisation.
  2. Implement the appropriate organisational design.
  3. Create awareness of the strategic benefits of risk management.
  4. Create an effective risk governance structure.
  5. Create an effective risk function.
  6. Hire the right personality to head the risk function.
  7. Create a just and psychologically safe culture.
  8. Formalise informal risk communications.
  9. Create clear escalation and reporting pathways and trigger points.
  10. Simplify risk management tools, activities, and processes.

[Read more…]

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

by Mike Sondalini Leave a Comment

Developing a Planned Maintenance Strategy based on Criticality

Developing a Planned Maintenance Strategy based on Criticality

Use Equipment Criticality to Match Planned Maintenance Strategy to the Operational Risks

Planned maintenance has the purpose of rejuvenating equipment before parts start failing. Use maintenance strategy based on continual renewal to reduce operating equipment risk of failure so that you have your plant and equipment in good condition and thus free of age and stress related defects waiting for the chance to fail.

[Read more…]

Filed Under: Articles, Maintenance Management, on Maintenance Reliability

by Michael Keer Leave a Comment

Hardware Product Realization in the Age of AI

Hardware Product Realization in the Age of AI

Chapter 6: Applying Agile Hardware Techniques, Changing the Normalized “Old Ways” Part 2

In the previous chapter the first part of a practical look at how to apply agile methodologies to your hardware development process was explored.

This chapter completes a look at how to apply agile methodologies to your hardware development process.

As illustrated in the diagram at the beginning of this blog, companies that follow an agile hardware product realization process plan to invest more resources early in the process and, as a result, are able to realize extra profits over the product’s lifecycle. Compare the two lines showing the investment and profit profile of a standard (old ways) development process (from the diagram shown in the previous blog post) with that of those organizations who invest strategically early in the process.

[Read more…]

Filed Under: AI, Articles, on Product Reliability, on Tools & Techniques, The Hardware Product Develoment Lifecycle

by Nancy Regan Leave a Comment

Are You Writing Failure Modes All Wrong? Learn the Truth

Are You Writing Failure Modes All Wrong? Learn the Truth

In this video, we’re testing our knowledge of how to write Failure Modes correctly — a crucial step in the Reliability Centered Maintenance (RCM) process. As my mentor John Moubray taught, we manage physical assets at the Failure Mode level, so it’s essential to get them right. I’ll walk you through a few examples to show what separates a properly written Failure Mode from a Failure Effect.

Learn how to identify specific Failure Modes that will help you get on the “right road” to creating safe and effective proactive maintenance tasks, intervals, and Default Strategies. Let’s dive in and see how well we know Failure Modes!

[Read more…]

Filed Under: Articles, Everyday RCM, on Maintenance Reliability

by Kerina Epperly Leave a Comment

Decoding Early Thermal Stress in Rotating Equipment

Decoding Early Thermal Stress in Rotating Equipment

Visual Inspections That Reveal Early Thermal Stress Damage

Thermal stress in components leads to premature failure. In the high-stakes world of industrial maintenance, the most dangerous failures are those that develop in silence. Thermally induced shaft damage typically does not announce itself with a sudden snap; rather, it matures through a progression of temperature gradients, mechanical constraints, and repeated thermal cycling. By the time cracks or permanent deformation become visible to the untrained eye, the window for low-cost intervention has usually closed.

Visual inspection and thermal imaging are both excellent non-destructive testing (NDT) techniques that detect impending failures early. In this article, we will discuss what to look for, what it means, and potential counter measures.


“Training site personnel to look for early indicators of thermal stress damage on shafts, couplings, and bearings is the single most effective way to prevent premature breakdown.”


[Read more…]

Filed Under: Articles, on Maintenance Reliability, The Reliability Crime Lab

by André-Michel Ferrari Leave a Comment

Multipopulation or Mixed Weibulls Overview

Multipopulation or Mixed Weibulls Overview

The Weibull distribution is a highly popular workhorse in Reliability Engineering. Sometimes a little too popular.  Its shape parameter (β) provides valuable information on the life characteristics of assets. In practice, a single Weibull distribution often fails to represent field or fleet data because the observed failures are not generated by only one homogeneous population. Instead, the data is frequently a blend of multiple underlying subpopulations. Relating to different designs, suppliers, duty cycles, environments, maintenance histories, etc. This is where multipopulation (mixture) Weibull models become valuable. They explicitly model heterogeneity rather than forcing one curve to “average out” incompatible behaviors. It is therefore incorrect to assume the population of failure times comes from a single Weibull distribution characterized by shape parameter 𝛽 and scale parameter 𝜂.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, The Reliability Mindset

by JD Solomon Leave a Comment

Why Reliability Engineers Should Beware of Monte Carlo Analysis

Why Reliability Engineers Should Beware of Monte Carlo Analysis

Monte Carlo analysis has key limitations that make it a major concern for reliability programs. This is not to say that reliability engineers should not embrace Monte Carlo analysis – in fact, they should. Monte Carlo analysis is one of the key techniques for managing uncertainty. This article discusses four contradictions that every organization should be aware of (and beware) when applying to reliability programs and managing uncertainty. A balanced approach that combines qualitative and quantitative techniques is recommended.




[Read more…]

Filed Under: Articles, Communicating with FINESSE, on Systems Thinking, Uncategorized

by Fred Schenkelberg Leave a Comment

4 Questions to Ask When Confronted with MTBF

4 Questions to Ask When Confronted with MTBF

MTBF comes up a bit too often. When it does I have found rolling my eyes and arguing against using MTBF is not very effective.

So, what should a knowing reliability professional do instead?

Let’s explore four questions that you can ask that may help others find the value in no longer talking about MTBF. [Read more…]

Filed Under: Articles, NoMTBF

by Semion Gengrinovich Leave a Comment

Historical Data

Historical Data

Historical failure data is a goldmine of information for reliability engineers. It provides a window into the life cycle of products, revealing patterns and trends that can inform future designs and manufacturing processes. By analyzing this data, we can:

1. Identify common failure modes

2. Detect early life failures indicating quality or production issues

3. Determine the onset of wear-out stages

4. Predict time-to-failure for similar products

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Greg Hutchins Leave a Comment

Project: Intelligent Disobedience — Uncommon Sense

Project: Intelligent Disobedience — Uncommon Sense

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




Seeing eye dogs, or guide dogs, are so well trained that they know right from wrong.  Even though their ‘master’ gives an order the trained canine won’t obey unless it’s safe; and that’s what we call intelligent disobedience.  The dog is praised for exhibiting such behaviour.  However, in corporate and project management circles, and despite the need for human intelligence enhanced through training, qualifications and experience, such behaviour is often branded as just plain disobedient.




Many organisations have some set of rules and regulations which govern expected norms of behaviour.  They form part of an organisation’s culture and such ‘expectations’ become some form of ethical standard.  Great…when there is ‘business as usual’.  But in a crisis standard operating procedures tend not to apply.  These situations, as well as people, can become heated and with heat can come fire and the tell-tale smoke that things aren’t quite right.




[Read more…]

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

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Recent Articles

  • Unlocking Plastic Deformation
  • Why Reliability Engineers Should Embrace Monte Carlo Analysis
  • MTBF Search Result Sadness
  • Manufacturing Time as a System
  • Test Failure During Validation – Is it Disaster or Blessing?

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