In this session, we will delve into essential strategies for gaining clarity in the midst of reactive maintenance challenges.
[Read more…]Learning to See 3 Tips for Taking Control of a Reactive Situation
on Maintenance Reliability
A listing in reverse chronological order of these article series:
- Usman Mustafa Syed — Aasan Asset Management series
- Arun Gowtham — AI & Predictive Maintenance series
- Miguel Pengel — Asset Management in the Mining Industry series
- Bryan Christiansen — CMMS and Reliability series
- James Reyes-Picknell — Conscious Asset series
- Alex Williams — EAM & CMMS series
- Nancy Regan — Everday RCM series
- Karl Burnett — History of Maintenance Management series
- Mike Sondalini — Life Cycle Asset Management series
- James Kovacevic — Maintenance and Reliability series
- Mike Sondalini — Maintenance Management series
- Mike Sondalini — Plant Maintenance series
- Andrew Kelleher — Process Plant Reliability Engineering series
- George Williams and Joe Anderson — The ReliabilityXperience series
- Doug Plucknette — RCM Blitz series
- Robert Kalwarowsky — Rob's Reliability Project series
- Gina Tabasso — The Intelligent Transformer Blog series
- Tor Idhammar — The People Side of Maintenance series
- André-Michel Ferrari — The Reliability Mindset series
How to Avoid RCM Failure
Key Lesson for Success in Reliability Centered Maintenance
Why Do Reliability Centered Maintenance (RCM) Analyses Fail?
Hi everyone, I’m Nancy Regan, and in today’s video, I’m coming to you from the ancient ruins of Chichen Itza in Mexico! Standing in front of the “ball game” court, I’m reminded of one of the biggest reasons why Reliability Centered Maintenance (RCM) analyses often fail.
Just like trying to learn everything about this historic site in a few minutes, many organizations attempt to implement RCM after reading a book or taking a quick course, without truly understanding the process. In this video, I explain why having a deep understanding of RCM is crucial to carrying out a successful analysis—and how going into too little or too much detail can cause problems.
[Read more…]Linking Reliability Concepts and Safety Performance
Definition of Reliability
The concept of Reliability is often misused, misunderstood, and misinterpreted. Reliability in its academic root, is defined as the probability that a system will perform its intended function in a specified mission time and within specific process conditions. So, it is in essence a probability.
The time variable is crucial in calculating the reliability of a system. Reliability is the Probability of Success. And 1 minus the Probability of Failure.
$$ \displaystyle \large R\left(t\right) = 1 – F\left(t\right) \:\:\:\: (where \: F = Failure \: Probability) $$
[Read more…]Big Difference in Consequence Reduction Strategy and Chance Reduction Strategy
The vital difference between using consequence or chance reduction strategies if you want operational excellence results, is consequence reduction requires repairs and maintenance, whereas chance reduction removes repairs and maintenance.
In reading “Enterprise Asset Management Success the Plant Wellness Way for CEOs and Senior Executives” I was interested in your table on page 15 that showed risk based inspection and condition based monitoring techniques as consequence reduction strategies.
My understanding is that both RBI and CBM are specifically designed to prevent failure through reducing the likelihood of failure i.e. by detecting failure before it happens within timescales that allow mitigation action to be taken. In the API 581 RBI standard, consequence is treated as a constant over time so the methodology specifically targets risk reduction through more effective inspection or design changes. [Read more…]
How Defining Functions Shapes Your Reliability Strategy
Understanding RCM
Hi everyone, I’m Nancy Regan, and in today’s video, I’m breaking down what makes Reliability Centered Maintenance truly “Centered.” Using a real-life example from my own vehicle—where my fan only works on level four, causing all sorts of noise issues—I explain how defining the function of an asset is the key to understanding its reliability needs.
I walk through how writing Functions is the foundation of the RCM process, ensuring assets are maintained to meet the specific needs of their operating context. From there, I explain how this noisy fan failure creates non-operational consequences in my case, and why, in this situation, it’s okay to run this particular Failure Mode to failure. What does the “Centered” in Reliability Centered Maintenance mean? Watch to find out!
[Read more…]Fundamentals of Vibration Measurement and Analysis Explained
Thanks to Peter Brown for this article.
1. Introduction:
The advent of the microprocessor has enormously advanced the process of vibration data acquisition and analysis in recent years. Measurement tasks that took hours only two decades ago can now be completed in minutes and better decisions made because of better data presentation.
However, the basic processes of measurement and analysis have remained essentially unchanged, just like the machines from which the vibration is measured. The results of the measurement and data analysis need to be compared with known standards or guidelines and decisions made as to whether the machine is acceptable for service or maintenance should be planned. Increasingly these processes are being handled electronically but we are still a long way from replacing the fundamental knowledge and experience of the vibration analyst.
In this article we will review the basic principles of vibration measurement and analysis in order to lay the foundation for capable fault diagnosis to be considered later.
[Read more…]Will you Accept a “No Brainer” Opportunity?
The “no brainer” opportunity
Imagine, 6 operational locations with a combined maintenance spend of $438 million and acceptable but mediocre performance. Production outputs ranged from 70% to 94% of nameplate values.
- The cost savings potential is $97 million.
- Improvement to nameplate levels adds upwards of $768 million in revenues.
- The spend to achieve that over 3 to 5 years was only $30 million.
That’s faster than the current mine permitting processes. Revenue was equivalent to adding a new mine at about 3% of the typical capital investment. Yes, this was a real customer in the mining industry with operations throughout North America.
[Read more…]The Importance of Proper Job Plans in CMMS and EAM Systems
By Paul Crocker CMRP CAMA, VIB1
In today’s industrial environment, the efficiency and reliability of maintenance operations are crucial. This is where Computerized Maintenance Management Systems (CMMS) and Enterprise Asset Management (EAM) systems come into play. These systems are designed to manage the maintenance function by tracking maintenance work, parts used, failure codes, and more.
[Read more…]Condition Based Maintenance vs. Preventive Maintenance Tasks
Finding the Best with RCM
Hi everyone, I’m Nancy Regan, coming to you from the Watermelon Festival in Russellville, Alabama! In today’s video, I talk about how Reliability Centered Maintenance (RCM) can help you find the “sweet spot” when choosing proactive maintenance tasks for your equipment.
Just like every watermelon has a sweet spot, RCM helps you pinpoint the best maintenance task for each Failure Mode. Using a simple example like “oil degrades due to normal use,” I explain how RCM guides you to decide between different options, such as Scheduled Replacements or Condition Based Maintenance. By answering the RCM questions, you can figure out which task is the most cost-effective or reduces the risk of failure to an acceptable level.
[Read more…]5 Decisions Reliability Analysis Can Help With
Introduction to Reliability or Life Analysis
Reliability Analysis or Life Analysis is a process where asset records are used to build a statistical model for the asset. The model will in turn provide information of its future performance. It becomes an indispensable tool for asset managers in terms of making life cycle decisions with regards to the asset preservation and eventually replacement. Let alone the safety of employees. Typically, though not necessarily always, those records are obtained from the Computer Maintenance Management System (CMMS).
The basis of the model is a statistical distribution. An example of the process is illustrated in Diagram 1 where a number of “n” centrifugal pumps are run on a test bench until they fail. Each time interval to failure is recorded and once all the failure records are collected, a normalized frequency graph can be constructed. This frequency graph helps define the statistical distribution that best represents the life cycle of a typical component in the population. Using specific mathematical transformations applied to the distribution, the probability of failure after a defined mission time can be derived. And much more information as we will discover in this article.
[Read more…]Maintenance Management Strategy by Physics of Failure Factors Analysis
The Physics of Failure Factors Analysis for selecting maintenance strategy is a one-person exercise that identifies all ways a component can physically fail. Equally important to its simplicity is its ability to select the most effective life cycle strategies for maximising reliability. Another powerful business advantage is the failure-addressing solutions arrived at are universal solutions that apply to every other identical component, whatever equipment it is in. Do a Physics of Failure Factors Analysis for one part and you do it for all identical parts for the life of your operation. It is a highly accurate and cost-effective maintenance strategy selection methodology.
[Read more…]A Big Mistake Organizations Make with Reliability Centered Maintenance
Hi everyone, I’m Nancy Regan, coming to you from The Watermelon Festival in Russellville, Alabama! In today’s video, I share one of the most common mistakes organizations make when it comes to Reliability Centered Maintenance (RCM)—and why this often leads to failed analyses.
Using a simple analogy of growing watermelons, I explain how RCM can go wrong when the right people aren’t involved. Just like watermelons need the right conditions to grow, RCM needs experienced facilitators and equipment experts to ensure the process succeeds.
[Read more…]What is the Connection between Equipment Risk and Equipment Reliability?
When it comes to Risk we have simplified it so much that we have failed Einstein’s advice, “Everything should be made as simple as possible, but not simpler.” It has been made too simple and missed the connection between risk and reliability.
Equipment risk has a direct impact on equipment reliability. What risks you allow your production plant and equipment to suffer will negatively impact its reliability. About 6 months ago I was playing about with the risk equation and a mathematical connection between risk and reliability revealed itself.
[Read more…]“Our World,” a Book for your Children
Here’s one you probably don’t expect from me. A children’s book! “Our World” is intended to spark curiosity In children about the world around them. It asks questions like, where does the water in my shower come from, how does the electricity in my light bulb get there, and many more. It uses everyday childhood experiences to spark questions.
[Read more…]Overcoming Challenges in Implementing a CMMS or EAM System
by Paul Crocker, CMRP, CAMA2, VIB1
Implementing a CMMS (Computerized Maintenance Management System) or EAM (Enterprise Asset Management) system can be a complex process fraught with challenges. However, organizations can effectively navigate these hurdles with the right strategies and tools.
[Read more…]
